Operating Manual

Operating manual

EN

Type:

FCC-CBG 45(45)/32 LITRONIC Serial number:

165 124

ORIGINAL

001 - .0.2011 / lwnrai0 rai0

LOAD DIAGRAMM

Artikelcode/Item Code:

950968314 002

Ausgabe/Edition:

LIEBHERR CBG 45(45)/32 LOAD DIAGRAMM

50 12.0

45 40 9.0 35 30 ] t [ L 25 W S

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

20 15 10 5 0 0.0

5.0 6.0

10.0

15.0

20.0

25.0

30.0

25.0

30.0

32.0

35.0

Radius [m]

MAX. CRANE INCLINATION ±3° 50 45 40 35

GRAB SERVICE

30

] t [ L 25 W S

HOOK SERVICE (OVERRIDE SWITCH)

20 15 10 5 0 0.0

5.0

6.0

10.0

15.0

20.0

32.0

35.0

Radius [m]

MAX. CRANE INCLINATION ±1°

IT MUST BE GUARANTEED THAT NO SIGNIFICANT RELATIVE MOVEMENTS BETWEEN CRANE BARGE AND THE TRANSPORT VESSELS CAN OCCUR ! Dieses Dokument darf ohne unsere Genehmigung weder kopiert, noch vervielfältigt werden. This document shall not be copied or transferred to others without our consent.

Item Code: Revision:

950968314 2

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 works with the machine.



is instructed to carry out work on the on the machine.

Work with Work with or on the machine includes: 

Commissioning, operation, including the changing of slinging tackle



Maintenance, servicing, inspection and repair, dealing with supplies and auxiliary materials

The operation manual and the relevant load chart belong with the machine and must therefore be ready to hand in every cabin. Compliance with the operation manual by maintenance personnel: 

increases reliability 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 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 in the case of load charts).



Always replace the the CDROM by a new version, version, e.g. from revision revision documents.



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

Storage of documentation  

CBG_HD / V001

Always keep the operation operation manual manual ready ready to hand in the cabin. The spare parts catalogue and technical information must be available to maintenance and service personnel if required.

1

Structure and content of the documentation: The operation The operation manual contains: manual contains: 

“Product description



“Safety



"Operating elements"



“Operation



“Maintenance

The technical information contains: information contains: 

General diagrams



Hydraulic diagrams



Electrical diagrams

The documentation accompanying the product contains documentation regarding any:  

Attachments, e.g. cable drums, drums, air conditioning conditioning systems, etc. Rigging material, e.g. rotators, spreaders, grabs, etc.

The spare parts catalogue provides catalogue provides information about:  

All the spare parts parts used in the machine machine Spare part procurement

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

All images in this this operation manual manual are symbolic symbolic and may may differ from the delivery 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 Reader 7.0

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

2

CBG_HD / V001

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 delivery state 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 or serious 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 if it is not avoided. 


VORSICHT Denotes a dangerous situation which could result in minor or moderate injury if it is not avoided. 


ACHTUNG Denotes a dangerous situation which could result in material damage if it is not avoided. 


HINWEIS Denotes useful tips and hints. 

CBG_HD / V001

Refers to the current action and demonstrates how to perform tasks in a straightforward manner.

3

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 regional regulations.

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 the purposes 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 GmbH P.O. Box 10 Dr. Hans Liebherr Strasse 1 6710 Nenzing AUSTRIA / EUROPE Telephone: Fax: email: website:

4

+43 50809 410 +43 50809 41500 [email protected] www.liebherr.com

CBG_HD / V001

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

1.6

1.7

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

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

1.6.1

Construction conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

1.6.2

Environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.1

2.

31

Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

2.1

Technical condition of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

2.2

Areas of responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34

2.3

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

Requirements to personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

2.3.1

Machine operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

2.3.2

Rigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

2.3.3

Banksman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37

CBG_HD / V001

5

2.3.4

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

2.8

2.10

3.

Meaning of the safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9

41

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

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

Hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66

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

66

2.10.2 Special hand signals for rigging operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69

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

72

Inspection elements and operating elements . . . . . . . . .

77

3.1

Control station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78

3.2

Control lever left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80

3.3

3.2.1

Directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80

3.2.2

Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81

Control lever right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.1

6

Maintenance personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83

Directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CBG_HD / V001

83

3.3.2

3.4

Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

127

Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

128

4. 4.1

4.1.1

4.2

4.3

Inspections before daily commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . .

128

129

4.2.1

Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

129

4.2.2

Check hydraulic oil tank shutoff valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

130

Daily commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1

4.4

Entering the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CBG_HD / V001

131 131

133 7

4.4.1

4.5

4.6

Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9

136

4.5.2

Operating cabin lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

137

4.5.3

Operating crane lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

137

4.5.4

Operating helicopter warning light* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

137


4.11

4.12

4.13

4.14

4.15 8

Operating the air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PA amplifier* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating the PA amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windscreen wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

138 138

139 139

140

4.8.1

Operating windscreen wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

140

4.8.2

Operating the windscreen wash system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

141

Warning horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9.1

4.10

136

Operating searchlights* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.1

4.8

133

4.5.1

4.6.1

4.7

Adjusting the operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the warning horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

142 142

Central lubrication system* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

143

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

143

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

143

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

143

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

Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

145

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

145

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

146

Hoisting gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

147

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

147

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

148

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

Hook operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

152

CBG_HD / V001

4.16

4.17

4.18

4.19

4.20

4.21

4.22

4.23

4.24

4.25

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

153

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

154

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

155

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

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

Open Sea* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

171

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

171

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

171

Slack rope safety device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

172

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

172

Heavy lift operation* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173

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

173

Rope length metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

174

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

174

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

Specialised lifting* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

177

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

177

Winch synchronisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

178

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

179

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

180

Litronic test system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

182

CBG_HD / V001

9

4.26

4.27

4.28

4.29

4.30

5.

182

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

184

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

194

Abseiling device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

195

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

195

Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197

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

197

Interruption of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198

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

198

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

199

Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200

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

200

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

201

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213

5.1

Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214

5.2

Lubricants and consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

222

5.3

5.4 10

4.25.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

234

5.3.1

Checking the gearbox oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

234

5.3.2

Topping up the gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

235

Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

236

CBG_HD / V001

5.4.1

5.5

5.6

5.7

5.8

5.9

Distributor gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.11

5.12

5.13

5.14

237

238

5.5.1

Check gearbox oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

239

5.5.2

Topping up gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

240

5.5.3

Draining gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

241

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

Hoisting gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

248

5.7.1


249

5.7.2


250

5.7.3


251

Luffing mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

252

5.8.1


253

5.8.2


254

5.8.3


255

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.1

5.10

Lubricate ball bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

256 256

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

Fuelling system* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

265

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

266

Hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

267

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

267

Pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

269

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

270

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

270

Hydraulic cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

271

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

271

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

271

CBG_HD / V001

11

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

Limit switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

275

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

275

Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

276

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

276

Fire extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

277

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

277

Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

278

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

278

Lowering device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

279

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

279

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

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

Rope drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

299

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

299

5.17

5.18

5.19

5.20

5.21

5.22

5.23

5.24

12

CBG_HD / V001

5.25

5.26

5.27

5.28

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

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


308

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

308

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 / V001

13

14

CBG_HD / V001

1

1

Product description

1.

Product description This chapter provides information on 

The capabilities of the machine.



The equipment and additional equipment of the machine.



CBG_HD / V001

Assembly of the main components.



Main technical data.



Importance and arrangement of safety devices on the machine.

15

Product description

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

16

CBG_HD / V001

Product description

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.

CBG_HD / V001

17

Product description

1.3

Appropriate use Possible applications are determined by the supplied equipment. Use machine exclusively to carry out the operations listed and described in this operation 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 observed.



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 specified fuels and lubricants.

Special operations must be discussed with the manufacturer before they are carried out, and must be documented by both parties. Any application for the machine that is different from or more complex than those 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 to the machine arising from inappropriate use!

18

CBG_HD / V001

Product description

1.4

Inappropriate use Inappropriate use corresponds to misuse that can be foreseen if proceeding in a 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:

CBG_HD / V001



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 the operating company.



if the machine is commissioned without the requisite training and knowledge 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 operational safety 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 operation mode.



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.

19

Product description

1.5 1.5.1

Technical description Complete machine

Figure 2 Main components

20

1

Boom

2

Cabin

3

Slewing column

4

Counterweight

5

Base column

CBG_HD / V001

Product description

1.5.2

Slewing column  front view

Figure 3 Slewing column  front view

CBG_HD / V001

1

Wind speed sensor

2

Slewing ring bearing

21

Product description

1.5.3

Slewing column  rear view

Figure 4 Slewing column  rear view

22

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

CBG_HD / V001

Product description

1.5.4

Machinery room

Figure 5 Machinery room

CBG_HD / V001

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

23

Product description

1.5.5

Hydraulic oil tank

Figure 6 Hydraulic oil tank

24

1

Air breather

2

Oil level sensor

3

Return filter

4

Inspection hatch

5

Shutoff valve

6

Sight glass for checking oil level

CBG_HD / V001

Product description

1.5.6

Hand pump with tank

Figure 7 Hand pump with tank

CBG_HD / V001

1

Tank

2

Dip stick and oil inlet

3

Air breather

4

Hand lever

5

Pressure gauge

6

Pressure connection

25

Product description

1.5.7

Hand pump without tank

Figure 8 Hand pump without tank

26

1

Restrictor valve

2

Hand lever

3

Measuring connection

4

Pressure connection

5

Suction connection

6

Pump cylinder

CBG_HD / V001

Product description

1.5.8

Central lubrication system

Figure 9 Central lubrication system

CBG_HD / V001

1

Supply container

2

Overpressure valve

3

Pump outlet

4

Filling nipple

5

Interim lubrication button

6

Control unit

27

Product description

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

28

CBG_HD / V001

Product description

1.5.10 Boom

Figure 11 Boom

CBG_HD / V001

1

Rope pulley

2

Hoisting rope

3

Luffing pulley

4

Luffing rope

5

Boom pivot bearing

6

Load pickup equipment

7

Searchlight

29

Product description

1.6

1.6.1

Technical data

Construction conditions

Classification, certifying authority

1.6.2

LRS (Lloyds Register of Shipping)

Environmental conditions

Ambient temperature

-25°C to +45°C

Design temperature

-10°C

Relative humidity

93 %

Max. heel without load

3°

Max. trim without load

3°

Max. wind speed when machine is in use

20m/sec (0,245kN/m²)

Max. wind speed when machine is in parked position

63m/sec

Max. wind speed when machine is in storm parked position

63m/sec

30

CBG_HD / V001

Product description

1.7

Safety equipment The safety equipment includes: 

Emergency stop



Fire extinguisher (may be supplied by customer)



1.7.1

Acoustic signal transmitters

Emergency stop Emergency stop Emergency stops located:

CBG_HD / V001



by switch cabinetX1



by engine



in cab



by access ladder



in base column



by winches

31

Product description

32

CBG_HD / V001

2

2

Safety

2.

Safety This chapter provides information on

2.1



warns user about other risks.



provides information about dangers arising during appropriate use.



provides information about how to avoid dangers.

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

CBG_HD / V001



Machine in perfect condition



Unauthorised conversion or modification not permitted



Regular maintenance



Operational safety devices

33

Sicherheit

2.2 2.2.1

Areas of responsibility Manufacturer The manufacturer:

2.2.2



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 worldwide maintenance and repair service.



runs a training centre and provides training for the owner's operating and maintenance personnel as a service.

Owner The owner:

34



ensures that the machine is operated and maintained by qualified personnel only.



checks that all individuals who come into contact with the machine are fully qualified, and authorises them to work.



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



provides all necessary protective equipment to individuals working with or near the machine.



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 any faults that may affect safety.



performs inspections on the machine based on national regulations in addition to the inspections stipulated by Liebherr.



informs the manufacturer of any accident involving the machine leading to serious injury or major 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 consulting the manufacturer.



uses only original Liebherr spare parts.

CBG_HD / V001

Safety

2.2.3

Machine operator The machine operator:

2.2.4



have read and understood the operation manual.



operates the machine for the purposes intended, within the limit values specified in the load chart and in accordance with the setup and the operation 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.







Rigger The rigger:

2.2.5



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.




Banksman The banksman:

2.2.6



conveys signals from the rigger to the machine operator.



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




Maintenance personnel Maintenance personnel:

CBG_HD / V001



maintain the machine to ensure that it remains in a safe and reliable condition.



have read and understood the operation manual.






perform all specified maintenance work.







35

Sicherheit

2.3 2.3.1

Requirements to personnel Machine operator The machine operator:

2.3.2



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.

Rigger The rigger:

36






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



is authorised to rig loads.






is capable of accurately estimating 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.







CBG_HD / V001

Safety

2.3.3

Banksman The banksman:

2.3.4






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.







Maintenance personnel Maintenance personnel:

CBG_HD / V001






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.







37

Sicherheit

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 personnel is 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

38

CBG_HD / V001

Safety

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 the danger 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. Operating any 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 effects must not hinder access to the cab or the operation of the machine.

CBG_HD / V001



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.

39

Sicherheit

2.6

Danger zone The danger zone is the area surrounding the machine, in which people can possibly 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!

40



Ensure that there are no persons in the danger zone.



Leave the danger zone.

CBG_HD / V001

Safety

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!

2.7.1



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



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

Meaning of the safety signs The safety signs are divided into three main groups of different shapes and colours:

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

CBG_HD / V001

41

Sicherheit

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 of potential injury and/or danger to life.

Danger area

Danger from electrical voltage

Danger from suspended load

Heeling hazard

Heeling hazard

42

CBG_HD / V001

Safety

Heeling hazard

Danger from hot surfaces

Slip hazard

Fall hazard

Stumble hazard

Crushing hazard

Crushing hazard

CBG_HD / V001

43

Sicherheit

Crushing hazard

Rolling over hazard

Danger from ropes

Danger  electromagnetic waves

Danger from pressure reservoir

Danger from batteries

44

CBG_HD / V001

Safety

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 in jury.

General mandatory sign

Wear helmet

CBG_HD / V001

45

Sicherheit

Wear ear protection

Wear face protection

Wear hand protection

Wear foot protection

Use safety harness

46

CBG_HD / V001

Safety

2.8 2.8.1

Hazards Mechanical action WARNUNG Mechanical actions due to moving machinery! When operating the machine, numerous danger areas and situations can caus 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 sliding elements.

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 CBG_HD / V001

47

Sicherheit

2.8.2

Electrical energy WARNUNG Electrical energy in live machine parts! 



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 of electrocution.

ERSTE HILFE

 Protection/personal safety 









Recovery position







 Additional first aid

HINWEIS  Always

seek medical attention after electrical accidents. It is possible that symptoms of an irregular heartbeat may be experienced some time after the accident.

48

CBG_HD / V001

Safety

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. 



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 of the body.



Replace damaged hydraulic components immediately with original Liebherr spare parts.

Examples of hydraulic energy: Tissue damage from leaks.

Sepsis from hydraulic oil entering bloodstream.










Recovery position








CBG_HD / V001



Gently cover injured area(s) with a sterile antibacterial dressing .



Rinse eyes with pure drinking water.

49

Sicherheit

2.8.4

Burns VORSICHT Contact with hot surfaces and consumables! High surface and equipment temperatures can lead to burns or scalding. 


HINWEIS Observe the following safety notes:  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 the drive system.










Recovery position








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): 

50

Gently cover injured area with a sterile antibacterial dressing. CBG_HD / V001

Safety

2.8.5

Chemical burns VORSICHT Contact with corrosive consumables! Acids and bases cause chemical burns to skin and tissue, and blindness if the come in contact with the eye. Acids and bases will damage clothing. 



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










Recovery position








CBG_HD / V001



Removing clothing from injured body parts.



Rinse injured areas with drinking water.



Gently cover the area with a sterile antibacterial dressing.

51

Sicherheit

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. 



o not transport any flammable fluids with the machine except in fireproof containers.



Only store small amounts of fuel or highly flammable or selfigniting material.



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



Clean the machine with nonflammable fluids.



Do not store cleaning cloths in machinery room and remove flammable residues, 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 to the 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 discharging batteries. Vaporised fuel in combination with electrostatic discharge between machine and fueling unit.

52

CBG_HD / V001

Safety










Recovery position








CBG_HD / V001



(For further information see: 2.8.3 Firefighting)



(For further information see: 2.7.4 Burns)

53

Sicherheit

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. 



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, contact with hazardous gases is a possibility. The refrigerant from the air conditioning system circuit displaces the oxygen in the air.

ERSTE HILFE










Recovery position








54

CBG_HD / V001

Safety

2.8.8

Electromagnetic influence WARNUNG Electromagnetic influence when the machine is deployed near transmitting stations, radar stations or directional radio systems! Malfunctions or failure of electronic implants (pacemakers). Malfunction or failure of the control system. 



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.

CBG_HD / V001

55

Sicherheit

2.8.9

Exposure to wind DANGER Exposure to wind! Noncompliance with maximum permitted wind speed while operating machine increases risk of accident! 



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



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



Operators to find out weather forecast and current wind velocity at site where machine is to be operated before starting work. If excessive wind speeds are expected within next few hours, do not start machine and take precautions 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 load capacity 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:

56



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.

CBG_HD / V001

Safety

If no anemometer is fitted to boom head, use table below to estimate roughly how 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

Wave height (m)

0

Calm

0

0

1

Light air

2

0,1

Small flakylooking ripples without white crests.

2

Light breeze

5

0,2

Small, short waves. Glassy, nonbreaking crests.

3

Gentle breeze

9

0,6

Small, short waves. Crests begin to break. Mostly transparent foam. Occasional small, white foam heads.

4

Moderate breeze

13

1

Small, longer waves. Many have white crests.

5

Fresh breeze

19

2

Moderate longer waves. Widespread white crests. Isolated froth.

6

Strong breeze

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 edges begin to froth. Foam covers the surface in pronounced streaks in the wind direction.

9

Severe gale

44

7

High waves. Thick strips of foam in the wind direction. Wave crests roll 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 lies on the surface in thick white streaks in the wind direction. Sea is white from foam. Strong intermittent 'rolling' of the sea. Visibility affected by froth.

11

Violent storm

60

11,5

Exceptionally high waves (small and mediumsized ships are momentarily hidden from view behind the waves). Sea is completely white from foam, which streaks in the wind direction. Edges of the wave 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.

CBG_HD / V001

Mirrorsmooth sea.

57

Sicherheit

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.


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 is no longer possible to work at maximum permitted lifting capacity.

58

CBG_HD / V001

Safety

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 local welding spots on supports, especially on the swing ring. 



Before a thunderstorm, place boom in parked position.



uring a thunderstorm, always keep away from large freestanding metal parts (e.g. the machine).



Earth machines whose steel structure does not have direct contact to ground.



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.










Recovery position







 Additional first aid 

CBG_HD / V001

(For further information see: 2.8.1 How to respond in the event of a current transfer)

59

Sicherheit

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. 



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 protection regulations for the disposal of fuels or waste.



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

Examples of environmental hazards: Leakages Refilling consumables incorrectly

60

CBG_HD / V001

Safety

2.9 2.9.1

How to respond in dangerous situations 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 that symptoms of an irregular heartbeat may be experienced some time after the accident.

CBG_HD / V001

61

Sicherheit

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 the

fire (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.

62

CBG_HD / V001

Safety

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.

CBG_HD / V001

63

Sicherheit

Incorrect

Correct

Fight the fire with the wind behind you.

Extinguish the fire from the front to the back and from the bottom to the top.

But: Extinguish dropping and liquid fires from the top to the bottom.

Do not use extinguishers in succession but use several extinguishers at the same time.

Make sure that the fire does not reignite  always extinguish glowing embers with water.

64

CBG_HD / V001

Safety

Incorrect

Correct

Do not put fire extinguishers back in place after use  refill them.

CBG_HD / V001

65

Sicherheit

2.10 Hand signals Hand signals: 

are used for communication purposes when there is visual contact between 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 signals are to be used.

The following overview comprises: 

Hand signals in accordance with BGV A8 (Germany)



Hand signals in accordance with ASME/ANSI B30.5 (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 

66

Do not continue movement. Stretch out both arms to the side horizontally. Palms of the hands face forward.

CBG_HD / V001

Safety

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 slow circling motion.

Lower, Down 

Hold the right arm down. Palm of the hand faces inwards and makes a slow circling motion.

Slowly 

Stretch out right arm horizontally. Palm of the hand faces down and is moved slowly up and down.

Depart 

CBG_HD / V001

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

67

Sicherheit

Approach 

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

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) 

68

Lightly bend in the left arm while holding it out horizontally and move to and fro to the side.

CBG_HD / V001

Safety

Indicate distance reduction 

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

2.10.2 Special hand signals for rigging operations

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 

CBG_HD / V001

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

69

Sicherheit

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 hand and rotate.

Lower boom and lift load 

70

Bend the right arm. Thumb points downwards. Bend the left arm. The index finger points upwards. Hold the left hand under the right hand and rotate.

CBG_HD / V001

Safety

Swing rotary platform to the right 

Bend the left arm and hold it up. The thumb points outwards in the direction of rotation. Stretch out the right arm downwards. The index finger points 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 finger points downwards. The hand makes small, circular movements.

Open grab 

Stretch out right arm horizontally. Hold the hand downwards with fingers halfopen.

Close grab 

CBG_HD / V001

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

71

Sicherheit

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. Hand makes small, circular movements.

Use main winch 

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

Use auxiliary winch 

72

Bend the right arm and hold it upwards. Tap the underside of the elbow with the left hand. Then give further hand signals.

CBG_HD / V001

Safety

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 

CBG_HD / V001

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.

73

Sicherheit

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 be lowered.

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 

74

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

CBG_HD / V001

Safety

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 circular motions (forwards or backwards).

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

CBG_HD / V001

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).

75

Sicherheit

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 to your chest.

Extend boom (machines with telescopic arm) 

76

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

CBG_HD / V001

3

3

Control and operating elements

3.

Control and operating elements This section

CBG_HD / V001



provides information on the configuration of the control and operating elements.



provides information on the designation of the respective element.

77


3.1

Control station

Figure 13 Control station

78

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


Ignition

1

Ignition off

2

Ignition on

Bypass

1

Bypass off

2

Bypass on

Winch service mode

CBG_HD / V001

1

Holding winch

2

Normal operation

3

Closing winch

79


3.2

Control lever left

3.2.1 Directions

Figure 14 Control lever left

A

B

C

D

80

Preselection

Function



Raise boom

Preselection

Function



Lower boom

Preselection

Function



Swing to right

Preselection

Function



Swing to left

CBG_HD / V001


3.2.2 Buttons

Figure 15 Control lever left

1

2

3

4

5

CBG_HD / V001

Preselection

Function





Preselection

Function





Preselection

Function





Preselection

Function





Preselection

Function



Warning horn

81


6

7

8

9

82

Preselection

Function

Fourrope grab operation

Grab bulk cargo

Preselection

Function





Preselection

Function



Bypass sector

Preselection

Function



Control enable

CBG_HD / V001


3.3

Control lever right

3.3.1 Directions

Figure 16 Control lever right

A

B

C

D

CBG_HD / V001

Preselection

Function



Raise load

Preselection

Function



Lower load

Preselection

Function


Open grab

Preselection

Function


Close grab

83


3.3.2 Buttons

Figure 17 Control lever right

1

2

3

4

5

84

Preselection

Function


Raise grab

Preselection

Function


Lower grab

Preselection

Function





Preselection

Function





Preselection

Function



PA amplifier on

CBG_HD / V001


6

7

8

9

CBG_HD / V001

Preselection

Function





Preselection

Function





Preselection

Function





Preselection

Function



Control enable

85


3.4 3.4

Cont Contro roll pan panel el oper operat atin ing g ele eleme ment nts s Signal lights

Signal lights

Buttons

Buttons with signal lights 

LED on:  Function active



LED off:  Function inactive

Buttons with signal lights 





1

Buttons with signal lights 1 

Light Emitting Diode (LED)





86

CBG_HD / V001


Switch

Key switch

1

Key switch

2 

3

1

Key

2

Light Emitting Diode (LED)

3

Button





HINWEIS 

CBG_HD / V001

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

87


3.4. 3.4.1 1 Cont Contro roll pane panell X25 X25

Figure 18 Control panel X25

88

CBG_HD / V001


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 / V001

89


3.4. 3.4.2 2 Cont Contro roll pane panell X26 X26

Figure 19 Control panel X26

90

CBG_HD / V001


Engine on / off

Hook operation


Winch service operation mode

Bypass lower luffing gear limit switch

Bypass slack rope protector

Heavy lift operation

CBG_HD / V001

91


Special load operation

92

CBG_HD / V001


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 / V001

93


Roof window wash system

94

CBG_HD / V001


3.5

Air conditioning*

2 1

Figure 21 Air conditioning main switch

CBG_HD / V001

1

Main switch off

2

Main switch on

95


2

1

Figure 22 Air conditioning system control unit

96

1

Temperature

2

Fan speed

CBG_HD / V001


3.6 3.6.1

Litronic monitor Monitor overview

1

2

3

Figure 23 Monitor overview

3.6.2

1

Status indicator

2

Status display

3

Function key symbols

Status indicator The different status displays appear in the upper part of the monitor as symbols. Overload

Fourrope grab open

Fourrope grab closed

CBG_HD / V001

97


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

98

CBG_HD / V001


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 / V001

99


3.6.4

Home screen

0.6 HEEL/TRIM °

Figure 24 Home screen

0.6 HEEL/TRIM °

Current Heel / Trim

Engine status

Load taring

Rope taring

100

CBG_HD / V001


Time

Current load on the holding winch

Current load on the closing winch

Sector indicator

CBG_HD / V001

101


1

2

3 4 5 6

7 8 9 10

16

102

15

14 13 12

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

11

CBG_HD / V001


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 / V001

103


Power supply on (green)

Power supply off (red)

Engine speed

Current consumption

104

CBG_HD / V001


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 / V001

105


3.6.7

Settings screen

Figure 27 Settings screen

Max. heel / trim and wind

Select load chart

Select harbour area

Select open sea

106

CBG_HD / V001


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 / V001

107


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

108

CBG_HD / V001


3.6.8

Litronic test system screen

+



++



Figure 28 Litronic test system screen

Start test system

Keyboard

Increase volume +

Reduce volume 

CBG_HD / V001

109


Increase brightness +

Reduce brightness 

7

8

9

4

5

6

1

2

3

0

.

P

+

E

+/





+

ENTER

Figure 29 Keyboard Minimise

Numeric keypad 7

8

9

4

5

6

1

2

3

0

.

P

Negative numbers +/

110

CBG_HD / V001


Increase brightness +

Exponents E



Reduce volume

Reduce brightness 

+

Increase volume

Correction value screen

Crane screens

Litronic test system

Enter ENTER

Cursor back

Function key

Cursor forwards

CBG_HD / V001

111


3.6.9

Hydraulics screen

Figure 30 Hydraulics screen

Hydraulic oil temperature

Luffing gear pressure

112

CBG_HD / V001


Slewing gear pressure

Slewing gear pressure

Holding winch pressure

Closing winch pressure

CBG_HD / V001

113


3.6.10 Temperature screen

Figure 31 Temperature screen

Gearbox temperature

Luffing winch gearbox temperature

114

CBG_HD / V001


Holding winch gearbox temperature

Closing winch gearbox temperature

CBG_HD / V001

115


3.6.11

Sector limiting screen

Figure 32 Anticollision screen

Select sector

Delete selected sector

Select right sector point

116

CBG_HD / V001


Select left sector point

2

3

1

4

CBG_HD / V001

1

Inactive sector area

2

Active sector area

3

Current outreach

4

Current slewing angle

117


3.6.12 Data recorder screen

94.9

0

MB %

2

3

0 t

0 t

4 0 t

5

6

0 t

0 t

94.9

°

°

12 3 100

0

0.0

t

0.0

t

0.0

t

Figure 33 Data recorder screen

Data recorder Start

Data recorder Pause

Data recorder Stop

118

CBG_HD / V001


1

94.9

0

MB %

3

4

2

3

0 t

0 t

4 0 t

5

6

0 t

0 t

94.9

°

°

12 3 100

0

0.0

8

7

9

CBG_HD / V001

2

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

t

0.0 6

t

0.0

t

5

119


3.6.13 Error screen

Figure 34 Error screen

New error message

Confirmed error message (new display !!!)

1

120

2

3

1

Error number

2

Short error description

3

Identification of the responsible I/O module CBG_HD / V001


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 unbalanced output. If this input is used at the same time as the DIN input, both signals are transmitted.

DIN microphone input This input allows the use of dynamic microphones with balanced and unbalanced output. If this input is used at the same time as the XLR input, both signals are transmitted. Special connections to the plug allow music to be turned down manually (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 / V001

121


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 function is 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.

122

CBG_HD / V001


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

CBG_HD / V001

1

Auxiliary supply off

2

Auxiliary supply on

123


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

124

1

Main power supply on

2

Main power supply tripped

3

Main power supply off

4

Main power supply reset

CBG_HD / V001


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 / V001

125


126

CBG_HD / V001

4

4

Operation

4.

Operation This section

127



provides information on operating the machine.



provides information on the operation modes.



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

CBG_HD / V001

Operation

4.1 4.1.1

Access Entering the machine

Figure 39 Access CBG

WARNUNG Unauthorised entry of machine during operation! 

CBG_HD / V001

Enter machine exclusively when it is shut down.

128

Operation

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 the Liebherr service department.

Ensure that the following conditions are satisfied:  

The operation manual has been read and understood.



The operation manual is ready to hand in the cabin.



4.2.1

All maintenance and inspection work has been regularly carried out.

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

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.

  

CBG_HD / V001

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).

129

Operation

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.

130

CBG_HD / V001

Operation

4.3 4.3.1

Daily commissioning Starting engine Ensure that the following conditions are satisfied: 

Prestart checks have been carried out.



No one other than the machine operator is on the machine or within the danger 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".  Set Power unit 2 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 X25

lights up.

 Set Main power supply switch at switch cabinet X2 to position "Main power

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

supply on".

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

CBG_HD / V001

131

Operation

 Engine 1 main power supply on signal light on control panel X25 lights up

when 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.

132

CBG_HD / V001

Operation

4.4 4.4.1

Operator's seat 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.

CBG_HD / V001

133

Operation

Figure 43 Adjusting the backrest  Press lever upwards.  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.

134

CBG_HD / V001

Operation

Figure 45 Adjusting the height of the front of the seat  Press lever upwards.  Pressing down on and relieving the front seating area adjusts its height.

Figure 46 Adjusting the height of the rear of the seat  Press lever upwards.  To adjust the height of the rear of the seat, press on it then release the

pressure.

CBG_HD / V001

135

Operation

4.5 4.5.1

Lighting 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.

136

CBG_HD / V001

Operation

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 "Helicopter

warning light on" position.  Helicopter warning lights light up.

CBG_HD / V001

137

Operation

4.6

Air conditioning* WARNUNG Leaks in air conditioning coolant circuit in enclosed spaces! Suffocation. If there is a high refrigerant concentration in the air: 

4.6.1

Immediately leave the enclosed space (cabin).

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.

138

CBG_HD / V001

Operation

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

4.7.1

PA amplifier on

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 

CBG_HD / V001

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

139

Operation

4.8 4.8.1

Windscreen wiper Operating windscreen wiper

Figure 50 Windscreen wiper 1

Roof searchlight

2

Front windscreen wiper

 Press the Front windscreen wiper intermittent operation button on the wind-

screen wiper control panel.  Intermittent windscreen wiper is active (windscreen wiper wipes at de-

fined 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-

screen wiper control panel again  Windscreen wiper continuous operation is active.  Press the Front windscreen wiper intermittent operation button on the wind-

screen wiper control panel again  Windscreen wiper is deactivated.

140

CBG_HD / V001

Operation

 Press the Roof windscreen wiper intermittent operation button on the wind-

screen 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-

screen wiper control panel again  The interval period becomes shorter.  Press the Roof windscreen wiper intermittent operation button on the wind-

screen wiper control panel again  Windscreen wiper continuous operation is active.  Press the Roof windscreen wiper intermittent operation button on the wind-

screen wiper control panel again  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.

Ensure that the following conditions are satisfied:  

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 wiper

control panel.  Windscreen wiper running in intermittent mode.  Windscreen cleaning fluid is sprayed.

 Press the Roof windscreen wash system button on the windscreen wiper

control panel.  Windscreen wiper running in intermittent mode.  Windscreen cleaning fluid is sprayed.

CBG_HD / V001

141

Operation

4.9

Warning horn

Figure 51 Warning horn control lever functions 1

4.9.1

Warning horn

Using the warning horn  Press Warning horn button on lefthand control lever.  Warning horn sounds.

142

CBG_HD / V001

Operation

4.10 Central lubrication system* Lubrication of the swing ring bearing is performed automatically in accordance with 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 factory setting 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 factory setting 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.

CBG_HD / V001

143

Operation

4.11 Select operation mode 4.11.1 Select hook operation Ensure that the following conditions are satisfied: 

Control levers are in neutral position.

 Press hook operation buttonon control panel X26.  Signal light lights up when hook operation is selected.

4.11.2 Select winch service mode Ensure that the following conditions are satisfied: 


 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 are

operated.  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 Ensure that the following conditions are satisfied: 


 Press fourrope grab operation button on control panel X26.  Signal light lights up when fourrope grab operation is selected.

CBG_HD / V001

144

Operation

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! Structural breakdown.  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).  Move lefthand control lever back to neutral position.  Slewing gear brake engages, slewing column stops rotating.

CBG_HD / V001

145

Operation

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 status indicator on the Litronic monitor lights up.

146

CBG_HD / V001

Operation

4.13 Hoisting gear 4.13.1 Operating the hoisting gear DANGER Incorrect operation of hoisting gear! Structural breakdown.  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.  Move righthand control lever back to neutral position.  Load stops moving.

CBG_HD / V001

147

Operation

4.13 4.13.2 .2 Hois Hoisti ting ng gear gear stop stop The hoisting gear stops automatically automatically on reaching the limit switch and it is no longer possible to move in the respective direction.

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

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

148

CBG_HD / V001

Operation

4.14 4.14 Luff Luffin ing g gear 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 4.14.1 .1 Opera Operati ting ng luff luffin ing g gear gear DANGER Incorrect operation of luffing gear! Structural breakdown.  Accelerate

and and brake luffing luffing gear slowly slowly..

Figure 54 Luffing gear control lever functions

 Move lefthand control lever forwards.  Boom luffs out.  Move lefthand control lever back to neutral position.  Boom stops moving.  Move lefthand control lever backwards.  Boom luffs in.  Move lefthand control lever back to neutral position.  Boom stops moving.

CBG_HD / V001

149

Operation

4.14 4.14.2 .2 Luff Luffin ing g gear gear stop stop The luffing gear stops automatically on reaching the limit switch and it is no longer possible to move in the respective direction.

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

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

Figure 55 Boom positions

150

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 CBG_HD / V001

Operation

4.14.3 4.14.3 Bypass Bypass luffin luffing g gear gear limit limit switc switch h DANGER Incorrect operation of luffing gear! Structural breakdown.  Accelerate

and and brake luffing luffing gear slowly slowly..

switch button on control  Press and hold down Bypass lower luffing gear limit switch button panel X26.  Move lefthand control lever forwards.  Boom luffs out.  When 0° parked position is reached, move left control lever back to neutral

position. switch button on control panel  Release the Bypass lower luffing gear limit switch button X26.

CBG_HD / V001

151

Operation

4.15 4.15 Hook Hook oper operat atio ion n 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, ensure that additional authorised personnel are monitoring to prevent slack rope.

Figure 56 Fourrope grab

152

1

Closing ropes

2

Holding ropes

3

Nemag shackle

CBG_HD / V001

Operation

4.15 .15.1 Attac tach 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.  Move righthand control lever forwards.  Holding ropes are slackened.  Select closing winch service operation mode.  Move righthand control lever forwards.  Closing ropes are slackened.  Remove slung lifting device (e.g. fourrope grab).  Sling hook.  Remove securing ropes.

CBG_HD / V001

153

Operation

4.15.2 Adjust hook position

Figure 58 Raise hoisting gear control lever function

 Select holding winch service operation mode.  Move righthand control lever backwards.  Holding ropes become taut.  Select closing winch service operation mode.  Move righthand control lever backwards.  Closing ropes become taut.  Select service mode, normal mode.

 Press the Settings page button on the Litronic monitor.  Settings page opens.

 Move righthand control lever backwards.  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.

154

CBG_HD / V001

Operation

4.15.3 Operate hook

 Select hook operation mode.  Crane screen with hook is displayed on the main screen on the Litronic

monitor.

HINWEIS 

The selected operation mode is stored and automatically chosen the next time the machine is started.

Raise / lower hook DANGER Incorrect operation of hoisting gear! Structural breakdown.  Accelerate


Figure 59 Hoisting gear control lever functions  Move righthand control lever forwards.  Hook is lowered.  Move righthand control lever back to neutral position.  Hook stops moving.  Move righthand control lever backwards.  Hook is raised.  Move righthand control lever back to neutral position.  Hook stops moving. CBG_HD / V001

155

Operation

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 the manufacturer.



Obey the safety instructions and operating instructions of the fourrope grab manufacturer.



When changing lifting devices and when in winch service mode, ensure that 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 the fourrope grab is suitable for this machine.

Figure 60 Fourrope grab

156

1

Closing ropes

2

Holding ropes

3

Nemag shackle

CBG_HD / V001

Operation

4.16.1 Assemble fourrope grab  Rest the attached lifting device (e.g. hook) 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 61 Lower hoisting gear control lever function

 Select holding winch service operation mode.  Move righthand control lever forwards.  Holding ropes are slackened.  Select closing winch service operation mode.  Move righthand control lever forwards.  Closing ropes are slackened.  Remove slung lifting device (e.g. hook).

ACHTUNG Incorrect joining of ropes! Damage to ropes

CBG_HD / V001



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



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

157

Operation

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

 Select holding winch service operation mode.  Move righthand control lever backwards.  Holding ropes become taut.  Select closing winch service operation mode.  Move righthand control lever backwards.  Closing ropes become taut.  Select service mode, normal mode.


158

CBG_HD / V001

Operation

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 position.

 Move righthand control lever backwards.  Fourrope grab is raised.  Load on the ropes is equalised automatically.

 Press the Store opened fourrope grab button on the settings page for the

Litronic monitor.  Position of the open fourrope grab is stored.  Rope length difference with fourrope grab open is indicated.

 Select closing winch service operation mode.  Move righthand control lever backwards.  Fourrope grab closes.  Select service mode, normal mode.  Raise and lower the closed fourrope grab 2 times.  Load on the ropes is equalised automatically.

 Press the Store closed fourrope grab button on the settings page for the

Litronic monitor.  Position of the closed fourrope grab is stored.  Rope length difference with fourrope grab closed is indicated.

CBG_HD / V001

159

Operation

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 next time the machine is started.

Raise / lower fourrope grab DANGER Incorrect operation of hoisting gear! Structural breakdown.  Accelerate


Figure 63 Hoisting gear control lever functions

 Move righthand control lever forwards.  Fourrope grab is lowered.  Move righthand control lever back to neutral position.  Fourrope grab stops moving.  Move righthand control lever backwards.  Fourrope grab is raised.  Move righthand control lever back to neutral position.  Fourrope grab stops moving.

160

CBG_HD / V001

Operation

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 closes.  Fourrope grab closed status indicator on the Litronic monitor continues

to flash whilst fourrope grab is closed.  Fourrope grab closed status indicator on the Litronic monitor appears

illuminated constantly when fourrope grab is closed.  Move righthand control lever back to neutral position.  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 to

flash 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.  Move righthand control lever back to neutral position.  Fourrope grab stops moving

CBG_HD / V001

161

Operation

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 t he 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

162

1

Raise fourrope grab.

2

Lower fourrope grab

CBG_HD / V001

Operation

 Move righthand control lever to the left.  Fourrope grab closes.  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 is selected.

Figure 66 Bulk cargo mode control lever function 1

Grab bulk cargo

 Move righthand control lever to the left.  Fourrope grab closes.  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).

 Move righthand control lever backwards.  Fourrope grab is raised. CBG_HD / V001

163

Operation

4.17 Data recorder* The data recorder records all load cycles performed with the machine and stores the data on a memory card. However the minimum load must be approx.3 tonnes and theminimum 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.

164

CBG_HD / V001

Operation

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specifi-

cally.

 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 Litronic

monitor.  Small circle appears in the display.

CBG_HD / V001

165

Operation

4.17.3 Record load cycle

 Press the Start data recorder button on the data recorder screen on the

Litronic 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.

166

CBG_HD / V001

Operation

4.17.4 Selecting hatch cover With this function the relevant hatch cover is selected to be loaded or unloaded. 2

1

2

3

0 t

0 t

4 0 t

5

6

0 t

0 t

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 the

Litronic 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.

CBG_HD / V001

167

Operation

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


95.8



61.0


Structure of the file data.txt (example): date

time start

time stop

average load [t]

load in rope [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

...

168

date

Start date

time start

Time of load takeup

time stop

Time load set down

average load [t] (excl. lifting device)

Weight of the load when driving over trigger

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 [%] tage

Maximum utilization of the device as a percen-

CBG_HD / V001

Operation

4.17.6 Exchange data HINWEIS  A

flashcard slot on the computer is a prerequisite for reading the flashcard.



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. CBG_HD / V001

169

Operation

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.

170

CBG_HD / V001

Operation

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 Litronic

monitor.

 Harbour area status indicator appears on the Litronic monitor.  Load chart changes.

CBG_HD / V001

171

Operation

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 and rope 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.

172

CBG_HD / V001

Operation

4.20 Heavy lift operation* 4.20.1 Select heavy lift operation


monitor.

 Press the Heavy Load Hoist button on the settings page of the Litronic moni-

tor.  Crane screen with heavy load hook is displayed on the main screen on

the Litronic monitor.

CBG_HD / V001

173

Operation

4.21 Rope length metering Rope length metering: 

indicates the calculated rope length between boom head and hoisted load 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.

174

CBG_HD / V001

Operation

4.22 Sector limitation* The purpose of sector limitation is to avoid collisions with objects in the working area. 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.

CBG_HD / V001

175

Operation

 Position boom tip over left sector point.  Press the Select left sector point button on the anticollision screen on the

Litronic 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 the

Litronic 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 sector

boundary.

176

CBG_HD / V001

Operation

4.23 Specialised lifting* When specialised lifting is selected, the machine can be operated in a smaller working radius.

4.23.1 Select specialised lifting


monitor.

 Press the Specialised Lifting button on the settings page of the Litronic

monitor.  Specialised lifting is selected.

CBG_HD / V001

177

Operation

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 holding winch. 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 moni-

tor.

178

CBG_HD / V001

Operation

4.24.1 Synchronise winches automatically


 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.  Move righthand control lever back to neutral position.  Load stops moving.

 Select holding winch service operation mode or closing winch service opera-

tion mode.  Press the Synchronise winches button on the settings page of the Litronic

monitor.  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 sta-

tus indicator goes out.  Press the Synchronise winches button on the settings page of the Litronic

monitor.  Button Synchronise winches becomes white.  Winch synchronisation is inactive. CBG_HD / V001

179

Operation

HINWEIS  As

soon as the status indicator Winches not synchronised goes out, the raising 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 lifting device.


 Select holding winch service operation mode.  Move righthand control lever forwards.  Holding ropes are lowered.  Move righthand control lever backwards.  Holding ropes are raised.  Select closing winch service operation mode.  Move righthand control lever forwards.  Closing ropes are lowered.  Move righthand control lever backwards.  Closing ropes are raised.  Synchronise winches by eye.

180

CBG_HD / V001

Operation


 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 Litronic

monitor is initialised.

CBG_HD / V001

181

Operation

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 (if available). It is used to monitor inputs and outputs, flags, internal system variables and statuses. 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:

182



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

CBG_HD / V001

Operation

Figure 74 Litronic test system overview 1

Header: Name of the current screen

2

Main window: Displays information

3 4

Input bar: For display and correction of entered values, display of status messages and input prompts Menu bar: Function key symbols

The Litronic test system comprises a number of screen pages; the function key symbols 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 the number of repetitions (these appear in the input line) or by pressing the required function key symbol. These include, for instance PREVIOUS and NEXT .

CBG_HD / V001

183

Operation

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:

184



NEXT CAN LINE goes to the next CAN line.



PREVIOUS MODULE andNEXT MODULE toggle between the modules in the selected CAN line.



PREVIOUS and NEXT move the cursor up and down to highlight a channel in the selected module. The highlighted channel is displayed as an inverse I or O.



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 of a 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 andNEXT to switch 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 to the second page.



BACK returns to the main menu.

CBG_HD / V001

Operation

MEMORY screen page This screen page is used to display the internal flags that are being used. Description of the function key symbols: 

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



PREVIOUS PAGE andNEXT PAGE toggle between the pages. Each page contains 16 flags from the selected section.



PREVIOUS andNEXT move between the flags. The highlighted flag appears as an inverse M.



Add the highlighted flag to the Select list using SELECT . If the flag is already 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, values can 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 oldest value is removed from the list. These Select lists can also be backed up on the memory card and reloaded from 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 entering the IEC address.



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

How to delete entries from the Select list:

CBG_HD / V001



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.

185

Operation

Description of the function key symbols: 

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. The highlighted entry is displayed as an inverse I, O or M.



NEXT PAGE moves to the next page of the Select list so that more values can be viewed.



IDENTIFY displays the inputs 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 then displayed. 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 appears from 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. The IEC address is entered in the input line using the corresponding function symbols 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 necessary using function key symbol TAKE & BACK to accept the address.

Description of the function key symbols:

186



Use M, I or Q to select the IEC type flag, input or output. The output is changed each time a key is pressed and appears in the input bar. A correction 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 is changed 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 the IEC address from the input line.

CBG_HD / V001

Operation

Select File Load screen page On this screen page a saved Select list can be loaded from the memory card. Description of the function key symbols: 

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 andCHARACTER UP modify the last character in the input line.



PREVIOUS andNEXT 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 way to 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. Description of the function key symbols:

CBG_HD / V001



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 andCHARACTER UP modify the last character in the input line.



PREVIOUS andNEXT move the cursor up and down in the list. When a file 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) and returns to the SELECT screen page.



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

187

Operation

CORRECTION screen page This screen page is used to display the correction values. Description of the function key symbols: 

NEXT SECTION moves between the 4 correction value sections: XBWD.



PREVIOUS PAGE andNEXT PAGE toggle between the pages. Each page contains 16 correction values from the selected section.



PREVIOUS andNEXT 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 file name can be selected from the menu that now appears. A standard file name (created from the current date) is suggested. This name can be changed.



Add the highlighted entry to the Select list using SELECT . If the entry is already selected, it will be removed from the list. The name of a correction value will be displayed inverse if it is selected.







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. Description of the function key symbols: 

188

ALL lists all saved messages (max. 15,000).



PREVIOUS START andNEXT START move between all messages saved at each startup.



PRIORITY MAXFILTER andPRIORITY MINFILTER list the saved messages filtered by priority.



GROUP FILTER lists the saved messages filtered by certain groups.



SINCE START lists exclusively the messages since the machine was started.



LANGUAGE enables a different language to be loaded for the messages. Messages that are not found in the selected language are displayed in English. This language change applies only to the MESSAGES screen page and not to the Litronic test system.



PREVIOUS andNEXT move between the messages.

CBG_HD / V001

Operation



SAVE TO CARD saves all messages (ALL or SINCE START) in a file. The file name can be selected from the menu that now appears. A standard file name (created from the current date) is suggested. This name can be changed.







Language Selection screen page The language in which the messages are displayed is selected on this screen page. Description of the function key symbols: 

PREVIOUS andNEXT 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:

CBG_HD / V001



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

189

Operation

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 in the input bar. Description of the function key symbols: 

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 connections on or off. This setting does not become active until the next time the machine is switched on.



V32/V110 switches on the V32 or V110 protocol for GSM modem connections. This setting does not become active until the next time the machine is switched on.



PREVIOUS andNEXT change between the interfaces; the default is Modem 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. Description of the function key symbols:

190



REMOVE CARD must be pressed before removing a memory card from the drive. Switching off the Litronic control system is another option. The system automatically recognises when a new card has been inserted.



DIR LIST displays the files and directories (but no subdirectories) on the current drive.



PREVIOUS DRIVE andNEXT DRIVE change between the individual drives available to the Litronic controller.



CHECK CARD checks the current drive for errors.




CBG_HD / V001

Operation

Time Functions screen page Date and time are displayed on this screen page. Description of the function key symbols: 

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 on this screen page. The supervisor level is necessary to change the time, for example. Description of the function key symbols: 

When the LEVEL CHANGE key is pressed, the value in the input line is taken 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 displayed on this screen page. Description of the function key symbols: 

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. Description of the function key symbols:

CBG_HD / V001



MODULE INFO changes to the CAN Configuration screen page.




191

Operation

Display Configuration screen page The display options for the INPUT/OUTPUT screen page are defined on this screen page. Description of the function key symbols: 

ALL MODULES is used to display all CAN modules ("used" and "not used") 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 and flag 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 system is switched back on. Description of the function key symbols: 

PREVIOUS andNEXT 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 FUNCTIONS screen page.

Sampling Trace screen page The Sampling Trace screen page is used for online tracing of data from previously 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. Description of the function key symbols:

192



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 automatically to status READY. This function symbol is only available if "Sampling Trace" is active.



LOAD FROM CARD loads a configuration from a saved "Sampling Trace" file. A menu appears from which the name of the file can be selected . CBG_HD / V001

Operation



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 can be selected.



SAVE TO SELECT takes variables that were used in the "Sampling Trace" and saves them in the Select list. Existing entries in the Select list are deleted.



LOAD FROM SELECT loads the currently selected variables into the "Sampling Trace" list.



PREVIOUS andNEXT 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 permitted limits.







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). Description of the function key symbols: 

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), the PDE (Process Data Acquisition) and the data logger. Description of the function key symbols:

CBG_HD / V001



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.




193

Operation

Clients screen page This screen page shows the status of the individual communication interfaces (clients). Description of the function key symbols: 

PREVIOUS andNEXT 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 the Litronic 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 the

Litronic monitor.  The Litronic test system main menu is displayed on the monitor.

194

CBG_HD / V001

Operation

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.

CBG_HD / V001

195

Operation

 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 

196

To stop or slow down, hold the running rope tightly and / or release brake lever.

CBG_HD / V001

Operation

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 and

turn to the right.

CBG_HD / V001

197

Operation

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 control

panel X26.  Move lefthand control lever forwards.  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.  Press Engine on / off button on control panel X20.

 Set Ignition key switch to "Ignition off" position.

CBG_HD / V001

198

Operation

4.28.2 Commissioning after work interruption







199

CBG_HD / V001

Operation

4.29 Decommissioning DANGER Unauthorised commissioning of machine! 

Secure machine against unauthorised commissioning when leaving it.

4.29.1 Lower boom to parked position  Lower boom down to lower luffing gear limit switch.

 Press and hold down Bypass lower luffing gear limit switch button on control

panel X26.  Move lefthand control lever forwards.  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.  Lower boom down to lower luffing gear limit switch.

CBG_HD / V001

200

Operation

4.29.2 Switch off engine  Press Engine on / off button on control panel X20.


 Set Power unit 1 main power supply switchat switch cabinet X2 to position

"Main power supply off".  Set Power unit 2 main power supply switchat switch cabinet X2 to position

"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!

201



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)

CBG_HD / V001

Operation

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 power unit, 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  Press Engine on / off button on control panel X20.





 Set ball valve DA to position "both power units active".

 Set ball valve DB to position "both power units active".

CBG_HD / V001

202

Operation

 Open ball valve HB1.  Open ball valve HB2.  Open ball valve HB3.  Open ball valve HB4.  Open ball valve EB1.  Open ball valve EB2.


"Main power supply on".  Set Power unit 2 main power supply switch at switch cabinet X2 to position








203

CBG_HD / V001

Operation

Operation with power unit 1  Press Engine on / off button on control panel X20.





 Set ball valve DA to position "power unit 1 active".

 Set ball valve DB to position "power unit 1 active".

 Open ball valve HB1.  Close ball valve HB2.  Open ball valve HB3.  Close ball valve HB4.  Open ball valve EB1.  Close ball valve EB2. CBG_HD / V001

204

Operation







205

CBG_HD / V001

Operation

Operation with power unit 2  Press Engine on / off button on control panel X20.





 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 HB1.  Open ball valve HB2.  Close ball valve HB3.  Open ball valve HB4.  Close ball valve EB1.  Open ball valve EB2. CBG_HD / V001

206

Operation







207

CBG_HD / V001

Operation

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 electric motor.

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:  Set valve H63A to emergency operation position.  Build up pressure using hand pump.

When the fourrope grab is fully open:  Set valve H63A to normal position.  Set valve H62A to normal position.  Set valve H62C to normal position.

CBG_HD / V001

208

Operation

4.30.4 Lower fourrope grab  Connect hand pump to the hoisting gear connection and by the tank  Set valve H62 to emergency operation position.  Set valve H62A to emergency operation position.  Set valve H62B to emergency operation position.  Set valve H62C to emergency operation position.  Simultaneously set valves H63 and H63A to emergency operation position.  Build up pressure using hand pump.  Multidisc brakes H61U andZ61U 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 H63A to normal position.  Set valve H62 to normal position.  Set valve H62A to normal position.  Set valve H62B to normal position.  Set valve H62C to normal position.

4.30.5 Lower hook (holding winch only)  Connect hand pump to the hoisting gear connection and by the tank  Set valve H62 to emergency operation position.  Set valve H62B to emergency operation position.  Set valve H63 to emergency operation position.  Build up pressure using hand pump.  Multidisc brake H61U releases.  Hook is lowered for as long as the hand pump is operated.

After completed emergency operation:  Set valve H63 to normal position.  Set valve H62 to normal position.  Set valve H62B to normal position.

209

CBG_HD / V001

Operation

4.30.6 Lower hook (holding winch and closing winch)  Connect hand pump to the hoisting gear connection and by the tank  Set valve H62 to emergency operation position.  Set valve H62A to emergency operation position.  Set valve H62B to emergency operation position.  Set valve H62C to emergency operation position.  Simultaneously set valves H63 and H63A to emergency operation position.  Build up pressure using hand pump.  Multidisc brakes H61U andZ61U release.  Hook is lowered for as long as the hand pump is operated.

After completed emergency operation:  Set valve H63 to normal position.  Set valve H63A to normal position.  Set valve H62 to normal position.  Set valve H62A to normal position.  Set valve H62B to normal position.  Set valve H62C to normal position.

CBG_HD / V001

210

Operation

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.  Build up pressure using hand pump.  Multidisc brakes D61U , D61V , D61W andD61X release.  Turn crane using additional equipment (e.g. chain hoist).

After completed emergency operation:  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.  Build up pressure using hand pump.  Multidisc brake E61V releases.  Slowly open restrictor valve E63.  Regulate lowering speed with restrictor valve E63.

After completed emergency operation:  Close restrictor valve E63.  Set valve E62 to normal position.

211

CBG_HD / V001

Operation

CBG_HD / V001

212

5

5

Maintenace

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, all exposed 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 shortened if necessary. Shortening of intervals largely depends on the operating conditions. ACHTUNG Insufficient lubrication! Damage to machine. 

CBG_HD / V001

The prescribed lubrication intervals as per the maintenance schedule must be observed.

213

Maintenance

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 knowledge and experience needed to carry out maintenance tasks.

Symbols without colour fill: 

Authorised and qualified personnel of LIEBHERR or its authorised dealers carry out these maintenance and inspection tasks.



Authorised and qualified personnel: Specially trained personnel with comprehensive and indepth knowledge of 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 indicated. HINWEIS 

The spare parts catalogue lists all spare parts need for carrying out maintenance 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:

214



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.

CBG_HD / V001

Maintenace

Maintenance/inspection according to operating hours

s r a y l e r y y a l h 2 3 t e y y r y y - l y n r l o f l a r e k m a e e v - h y e v y e e l i e 3 / / / / a w / h h h h d / h 0 0 0 0 / h 0 0 0 0 0 h 0 0 0 0 0 0 8 4 5 1 2 4 6

s l a v r e t n i l a i c e p S

WORK TO BE CARRIED OUT by trained maintenance personnel

by authorised 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 load on 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 (if fitted)

 

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 (if fitted)



Inspect the condition and attachment of the recoil polyamide plates (if fitted)

Electric motor 

Dependent on humidity and weather conditions, check that electric motor is 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 the electric motor)

Distribution gearbox (if fitted) CBG_HD / V001

215

Maintenance

Maintenance/inspectionaccording to operating hours

s r a y l e r y y l a h 2 3 s e t y l l y a n - r y y r y f r v l o l a e e r k m a e v v e t e y h y e n e l e 3 / / / / i i l a w / h h h h a i d / h 0 0 0 0 s c / h 0 0 0 0 0 r a e h 0 0 0 0 0 0 e p 8 4 5 1 2 4 6 y S



 oneoff task

 oneoff task



 when necessary

 when necessary

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) 

Check oil level



Renew filter elements of all hydraulic filters



Renew air breather on hydraulic oil tank

 







216



Bring system up to working speed and take oil sample 10 hours after every 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 2000 hours / every 2 years



If Liebherr Hydraulic 37 is being used, change hydraulic oil every 4000 hours / 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





Clean magnet and return filter (once per week during the first 250 hours) Check pressure settings and correct them if necessary





Every 10,000 hours / every 6 years  renew all external hoses

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

CBG_HD / V001

Maintenace


s r a y l e r y y l a h 2 3 t e y n y y r y - l y r f l o l a e r k m a e v e y e - h y e v e l i e 3 / / / / a w / h h h h d / h 0 0 0 0 / h 0 0 0 0 0 h 0 0 0 0 0 0 8 4 5 1 2 4 6




 oneoff task

 oneoff task



 when necessary

 when necessary

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 air breather

 

Check attachment of limit switch and coupling



Check limit switch is working correctly (if possible)



Inspect pin connection / threaded connection between winch and main structure 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 fixing point itself



Check condition and attachment of pressure rollers



Check condition and attachment of overspool safety device

Slewing gear Check oil level

 

Check air breather



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

 

CBG_HD / V001

Checking that holding brake is working

217

Maintenance






 oneoff task

 oneoff task



 when necessary

 when necessary

Slewing bearing 

Check every 250 hours that the slewing bearing is adequately lubricated and 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 correctly and 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 and slewing 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 and relubricate them if necessary

 

If the rope is replaced, replace the rope kicker on the winch (only on CBB 2980  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 

Check condition and lubrication of pulley bearings, and relubricate them if necessary

 

218

In order to even out wear on the rope, shorten the rope by 1/3 of the winch circumference (with multilayer spooling)

Renew all plastic pulleys every 8 years

CBG_HD / V001

Maintenace






 oneoff task

 oneoff task



 when necessary

 when necessary

Rigging Inspect hook for corrosion, wear and damage, and relubricate rope sheave 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 and damage



Inspect condition, lubrication and wear of cable drums, check that they are attached securely, relubricate and top them up if necessary



Inspect condition of hook garage, check it for wear and check that it is attached securely



Check that tandem and anticollision operation are working correctly



Boom Check the tightening torque of the boom flange connecting pins, inspect them 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

 

CBG_HD / V001

Relubricate all lubrication points every 250 hours

219

Maintenance






 oneoff task

 oneoff task



 when necessary

 when necessary

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 electric motor 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 or site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 seated securely 

Check threaded connections on the copper busbar at random to ensure that they are secure

 

220

Inspect carbon brush for wear every 1500 hours or at least once every 6 months

Clean metal particles from the insulation between the slip rings

CBG_HD / V001

Maintenace






 oneoff task

 oneoff task



 when necessary

 when necessary

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 original operation manual Check that all operating elements are working correctly



BORNACK KE10 St crane abseil rescue equipment

CBG_HD / V001



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 corrosion damage.



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.

221

Maintenance

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! 

5.2.1

Dispose of all hazardous materials, such as: waste oil, coolant, contaminated filter elements, etc., in accordance with national or regional regulations.

Lubrication chart

Figure 77 Lubrication chart CBG

222

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

CBG_HD / V001

Maintenace

Oil top up plan

Figure 78 Oil top up plan CBG

CBG_HD / V001

1

Hydraulic oil tank

2

Holding winch gearbox

3

Closing winch gearbox

4

Luffing winch gearbox

5

Slewing gearbox

6

Distributor gearbox

223

Maintenance

5.2.2

984363514 0

Item code

- Utility Requirements

LIEBHERR

Crane: Order:

Filling capacitytable Edition

FCC-CBG 45(45)/32 LITRONIC 162832 , 162851, 165046-047 Unit

Req./Unit

1. Winch(es): - Main Hoist Winch - Lu ng Winch - Auxili ary Hoist Winch

No.of Unit

Total

Type

21 l 10,5 l -

2 1 -

42 l 10,5 l -

Gear Oil Gear Oil -

2. Slewing Gear(s): - Slewing Gear(s) for sc - Slewing Gear(s) for main arm

23 l -

4 -

92 l -

Gear Oil -

3. Grease: - All sheaves, bearings - All other grease lines - slewing ring + greasing lines

1,4 kg 1,8 kg 37,5 kg

1 1 1

1,4 kg 1,8 kg 37,5 kg

Grease Grease Grease

4. Cabin: - Windscreen washer

5l

1

5l

Anti Freeze Mixture

5. Gearbox:

6,5l

1

6,5l

Gear Oil

1200 l 250 l

1 1

1200 l 250 l

Hydraulic Oil Hydraulic Oil

7. ElectricPower Consump tion: - according to drawing 993921714 - Power Supply Survey

-

-

-

-

8. DieselEngine: according to drawing - Power Supply Survey

-

-

-

-

6. Hydraulic System: - Hydraulic tank - Hydraulic line system

NOTE: F or oil type refer t o t he at tached l ist "RECOMMENDED OIL TYPES FORLIEBHERRSHIP- AND OFFSHORECRANES" 16.01.2008

Date

LWN

BargehrR.

Work

Prepared

accordingLIKVwork˜ow

Checked

Approved

No copying or duplication of this document without the permission of Liebherr. This document has been issued electroni cally and is valid wit hout signature.

Figure 79 Filling capacity table

224

CBG_HD / V001

Maintenace

5.2.3

Lubrication chart

No

Lubrication

Outside temperat-

Type ISO

.

points

ure

VG/SAE

yearround to 20°C

SAE 10W40

below 20°C with preheating yearround to 20°C 1.

Engine, oil bath air filter

SAE 10W40

Lubricants ACEA E4

ACEA E4/E6/E7 API CF4 / CG4 CH4 / CI4

SAE 5W30

below 30°C with preheating Mechan. gears and

Liebherr

Liebherr Motoroil 10W40

API CF

below 20°C with preheating yearround to 30°C

Specification

ACEA E4

Liebherr Motoroil 10W40 low ash required when using a soot particle filter Liebherr Motoroil 5W30

API CF

up to 20°C

SAE 85W90

API GL5

Liebherr Hypoid EP90

up to 40°C

SAE 75W90

API GL4; GL5, MT1

Liebherr Syntogear Plus 75W90

from 25°C to 50°C**

ISO VG3246

DIN 51 524 / T3

Liebherr Hydraulic 37

SAE 10W20

HVLP

2. winches 3.

Drive shafts

ATF* from 25°C to 50°C**

4.

1.DEXRON II D/E

ISO VG46 (3268)

DIN 51 524 / T3

SAE 10W20

HVLPD HC

Hydrostatic drive

biodegradable in ac-

unit, hydraulic

cordance with CEC

steering

L33A393 from 50°C to 30°C

ISO VG1546

DIN 51 524 / T3

SAE 0W20

HVLPD HC

Liebherr Hydraulic Plus

Liebherr Hydraulic Plus Arctic

biodegradable in accordance with CEC L33A393 from 25°C to 150°C

DIN 51 502

tion bearing, ball/

For lubrication system

KP 2 K30

rollerbearing

from 20°C to 150°C

Roller bearing, fric-

5.

Liebherr universal grease 9900

Lubricating KPF 2 N25 grease, lithium

swing rings, universal joints, other grease lubrication

CBG_HD / V001

from 60°C to 140°C For lubrication system

saponified

DIN 51 502

Liebherr universal grease Arctic

KPFHC 1N60


225

Maintenance

No

Lubrication

Outside temperat-

Type ISO

.

points

ure

VG/SAE

Specification

Liebherr Lubricants


DIN 51 502

For lubrication system

OGPF 2

Liebherr universal grease 9900

from 20°C to 150°C Open pinions and 6.

Lubrication and from 60°C to 140°C

open gears, ropes

OGPF 1


OGPF 00

Liebherr paste spray

preservation For lubrication system from 55°C to 140°C All areas

7.

Ropes

8.

Telescopic boom

Liebherr WRLube SC

from 40°C to 50°C All areas

Special regulation

DIN 51 502 KP 2 K30

down to 37°C 9.

DIN 51,757/4

Liebherr grease for telescopic components 9613 Plus Liebherr Antifreeze Mix

Coolant DIN 51 432/2

10.

Screenwash fluid

Rala Klirr

down to 80°C

* 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: 

226

Contact the Liebherr Lubricant Hotline (+49 (0) 7354/806060 or [email protected]).

CBG_HD / V001

Maintenace

Ordering data Engine oil 5l canister

20l canister

210l drum

1000l container


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


10 42 57 12

10 42 57 13

10 42 57 15

10 42 57 19

5l canister

20l canister

210l drum

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

5l canister

20l canister

210l drum

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

5kg tub

10kg tub

25kg tub

Gearbox oil 1000l container

Hydraulic oil 1000l container

Grease 400g cartridge Liebherr universal grease 9900

10 29 68 16

10 29 68 13

10 29 68 12


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-

86 13 036 08

ponents 9613 Plus

Coolant 5l canister

20l canister

210l drum

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

CBG_HD / V001

1000l container

10 35 90 77

227

Maintenance

Screenwash fluid 5l canister

20l canister

Screenwash 80°C

200l drum

1000l container

89 03 108 14

Oil concentrate

Liebherr special additive NL

5l canister

20l canister

10 51 53 00

10 51 57 52

200l drum

1000l container

Oil analysis kit Oil analysis kit: 88 56 018 14

228

CBG_HD / V001

Maintenace

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 oils may 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 with Liebherr. 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

CBG_HD / V001

Liebherr mineral oils with one another

Can be mixed in any ratio

Liebherr mineral oils with biodegradable Liebherr oils

Can be mixed in any ratio

Liebherr oils with thirdparty oils

To ensure that oil properties are not altered, do not mix to a proportion higher than 10%.

To ensure biodegradability, do not add more than 2% mineral oil (as per regulations in most European countries)

229

Maintenance

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 with the corresponding identification number (Id.no.).

Store conservative agents in a cool, dry place. Must be stored at a temperature between 15°C and 20°C.

230

CBG_HD / V001

Maintenace

5.2.6

Oil diagnosis system HINWEIS 

Do not delay the first oil change of the unit in question, because increased contamination 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 oil and 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 Ensure that the following conditions are satisfied: 

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 the

container with wellmixed oil.

CBG_HD / V001

231

Maintenance

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

232

CBG_HD / V001

Maintenace

 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

CBG_HD / V001

233

Maintenance

5.3

Slewing gear

Figure 82 Slewing gear

5.3.1

1

Sight glass

2

Vent screw

3

Filler neck

4

Slewing pinion

Checking the gearbox oil level Ensure that the following conditions are satisfied: 

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.

234

CBG_HD / V001

Maintenace

5.3.2

Topping up the gearbox oil Ensure that the following conditions are satisfied: 







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.


CBG_HD / V001


235

Maintenance

5.4

Electric motor ACHTUNG Wrong grease! Damage to electric motor. 

Exclusively use lubricants in accordance with the lubricant information label 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

236

1

Electric motor

2

Grease nipple CBG_HD / V001

Maintenace

5.4.1

Lubricate ball be bearings Ensure that the following conditions are satisfied: 




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 for 1 to 2 hours.  Surplus grease is squeezed out of the ball bearings.  Close lubrication opening.

Entsorgung Avoid the risk risk of environmental environmental damage! damage! 

CBG_HD / V001

Dispose of all hazardous hazardous materials, such as: waste oil, coolant, contaminated filter elements, etc., in accordance with national or regional regulations.

237

Maintenance

5.5

Distributor gearbox VORSICHT Hot gearbox components and gearbox oil! Burns. 

Carry out maintenance and inspection work on distributor gearbox exclusively when diesel engine is switched off and has cooled down.




Figure 85 Distributor Distribut or gearbox viewed from above 3

Oil dipstick

4

Vent valve

Figure 86 Distributor Distribut or gearbox viewed from below

238

1

Drive for pump

2

Oil drain

3

Driven by engine CBG_HD / V001

Maintenace

5.5.1

Check gearbox oi oil le level Ensure that the following conditions are satisfied: 

Engine is turned off.



Machine is secured to prevent unauthorised operation.




VORSICHT Hot gearbox components and gearbox oil! 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:  Top up using the appropriate gearbox oil according to the lubrication chart.

If gearbox oil level is above MAX mark:  Drain the gearbox oil.


CBG_HD / V001


239

Maintenance

5.5.2

Topping ing up ge gearbox oi oil Ensure that the following conditions are satisfied: 













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.  Pull out oil dipstick and wipe with a clean, lintfree cloth.  Open vent valve.  Top up gearbox oil to MAX mark.  Insert oil dipstick as far as it will go.  Close vent valve.  Start machine and let it run at idle speed for 10 minutes.  Turn off machine and after 1 minute check gearbox oil and top up if ne-

cessary.

Entsorgung Avoid the risk of environmen environmental tal damage! damage! 

240


CBG_HD / V001

Maintenace

5.5.3

Draining gearbox oil Ensure that the following conditions are satisfied: 










A suitable and sufficiently large large collecting container container is to hand. hand.



An oil drain hose hose is to hand. hand.






 Open vent valve.  Place collecting container in position.  Open oil drain  Attach oil drain hose. hose.  Oil drains out.  Disconnect oil drain hose.  Close oil drain.


CBG_HD / V001


241

Maintenance

5.6 5.6.1

Slewing co connection Grease the to toothing Ensure that the following conditions are satisfied: 








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 rotary

connection 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.

242

CBG_HD / V001

Maintenace

5.6.2

Checking bearing lubrication Ensure that the following conditions are satisfied: 








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 fill

with suitable grease according to the lubricant table with a grease gun via the 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.

CBG_HD / V001

243

Maintenance

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 measuring points

244

1

Slewing column (rotating)

2

Slewing ring

3

Base column (nonrotating)

CBG_HD / V001

Maintenace

Figure 89 Slewing bearing tilt measurement, rollerbearing slewing ring measuring points

CBG_HD / V001

1

Slewing column (rotating)

2

Slewing ring

3

Base column (nonrotating)

245

Maintenance

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 at

that 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 cannot be 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 remains

constant.  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, boom radius, measuring instrument, load, jackup cylinder position).

246

CBG_HD / V001

Maintenace

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.

CBG_HD / V001

247

Maintenance

5.7

Hoisting gear

Figure 91 Hoist winch

248

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

CBG_HD / V001

Maintenace

5.7.1

Check gearbox oil level Ensure that the following conditions are satisfied: 








VORSICHT Hot winch components and hot gearbox oil! Burns and open wounds. 

Carry out maintenance and inspection work on winches exclusively when machine has been switched off and has cooled down.



Wear protective equipment.






Entsorgung Avoid the risk of environmental damage! 

CBG_HD / V001


249

Maintenance

5.7.2

Topping up gearbox oil Ensure that the following conditions are satisfied: 















 Clean the area around the oil dipstick and oil filler neck.  Pull out oil dipstick and wipe with a clean, lintfree cloth.  Open vent valve.  Top up gearbox oil to MAX mark.  Insert oil dipstick as far as it will go.  Close vent valve.  Start machine and let it run at idle speed for 10 minutes.  Move winch in both directions at low speed.  Turn off machine and after 1 minute check gearbox oil and top up if ne-

cessary.


250


CBG_HD / V001

Maintenace

5.7.3











A suitable and sufficiently large collecting container is to hand.



An oil drain hose is to hand.








 Open vent valve.  Place collecting container in position.  Remove protective cap from oil drain.  Attach oil drain hose.  Oil drains out.  Detach oil drain hose and replace protective cap.


CBG_HD / V001


251

Maintenance

5.8

Luffing mechanism

Figure 92 Luffing winch

252

1

Air breather

2

Oil dipstick, oil filler inlet

3

Oil drain

CBG_HD / V001

Maintenace

5.8.1

Check gearbox oil level Ensure that the following conditions are satisfied: 



















CBG_HD / V001


253

Maintenance

5.8.2

Topping up gearbox oil Ensure that the following conditions are satisfied: 















 Clean the area around the oil dipstick and oil filler neck.  Pull out oil dipstick and wipe with a clean, lintfree cloth.  Open vent valve.  Top up gearbox oil to MAX mark.  Insert oil dipstick as far as it will go.  Close vent valve.  Start machine and let it run at idle speed for 10 minutes.  Move winch in both directions at low speed.  Turn off machine and after 1 minute check gearbox oil and top up if ne-

cessary.


254


CBG_HD / V001

Maintenace

5.8.3






















 Open vent valve.  Place collecting container in position.  Remove protective cap from oil drain.  Attach oil drain hose.  Oil drains out.  Detach oil drain hose and replace protective cap.


CBG_HD / V001


255

Maintenance

5.9 5.9.1

Hydraulic system 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 out exclusively 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.

256

CBG_HD / V001

Maintenace

5.10 Hydraulic oil tank

Figure 93 Overview of hydraulic tank

CBG_HD / V001

1

Air extractor

2

Oil level sensor

3

Return filter

4

Inspection hatch

5

Sight glass for checking oil level

257

Maintenance

5.10.1 Checking the hydraulic oil level Ensure that the following conditions are satisfied: 

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 out exclusively 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.

258

CBG_HD / V001

Maintenace

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based hydraulic oil”, please contact Liebherr service department.

Ensure that the following conditions are satisfied: 







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 off and the temperature of the hydraulic oil is 40° or less.




ACHTUNG Hydraulic oil topped up incorrectly! Damage to the hydraulic system. 

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! Damage to the hydraulic system. 

Make sure the return filter is free of dirt and foreign bodies.

 Remove the cover from the filter housing. CBG_HD / V001

259

Maintenance

ACHTUNG Incorrect hydraulic oil. Damage to the hydraulic system. 

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.

260

CBG_HD / V001

Maintenace

5.10.4 Draining the hydraulic oil Ensure that the following conditions are satisfied: 







The gear oil is at normal operating temperature.












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. CBG_HD / V001

261

Maintenance

5.10.5 Cleaning magnetic rod in return filter Ensure that the following conditions are satisfied: 







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 off and 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! Damage to the hydraulic system. 

Make sure the return filter is free of dirt and foreign bodies.

 Remove the cover from the filter housing.

262

CBG_HD / V001

Maintenace

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 cor-

rectly. CBG_HD / V001

263

Maintenance



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.

264

CBG_HD / V001

Maintenace

5.1 5.11 Fuel Fuelli ling ng syst system em** ACHTUNG Incorrect use of fuelling system! Environmental damage. 

Operate fuelling system exclusively if the refueling process is monitored by 2 persons.

Figure 100 Fuelling system

CBG_HD / V001

1

Hydraulic oil tank

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

265

Maintenance

5.1 5.11.1 1.1 Fill Fill hydr hydrau auli lic c oil oil tan tank k  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.

266

CBG_HD / V001

Maintenace

5.12 5.12 Hydr Hydrau auli lic c oil fil filte ter r 5.12 5.12.1 .1 Repl Replac ace e pres pressu sure re filte filter r

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. CBG_HD / V001

267

Maintenance

 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 as

it will go.  Start the engine and leave it to idle.  Check hydraulic system for leaks.

If there is a leak in hydraulic system:  Contact Liebherr service department.

268

CBG_HD / V001

Maintenace

5.13 5.13 Pressu Pressure re accumu accumulat lator or

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 by trained maintenance personnel.



In case of uncertainty contact Liebherr after sales service.

VORSICHT Hot hydraulic oil escaping under high pressure. Burns and open wounds. 

Wait a few minutes until the pressure has fallen to 0 bar and the temperature of the hydraulic oil is no more than 40°C.




ACHTUNG Dirt and foreign bodies in hydraulic system. Damage to the hydraulic system. 

CBG_HD / V001

Make sure the hydraulic system is free of dirt and foreign bodies.

269

Maintenance

5.13 5.13.1 .1 Chec Check k pres pressu sure re acc accum umul ulat ator or Ensure that the following conditions are satisfied: 










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 the

target pressure indicated by the operating data of the pressure accumulator. If actual pressure is below target pressure:  Change the pressure accumulator.

5.13 5.13.2 .2 Chan Change ge pre press ssur ure e accum accumul ulat ator or Ensure that the following conditions are satisfied: 







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 accumu-

lator.  Thoroughly clean the outside of the pressure accumulator so that the mar-

kings and operating data are clearly visible.

270

CBG_HD / V001

Maintenace

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:  Contact Liebherr service department.

5.14.2 Preserving hydraulic cylinders Ensure that the following conditions are satisfied: 







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 adequate corrosion 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.

CBG_HD / V001

271

Maintenance

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/low temperatures, 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 and cracks, etc.).



Degradation of the outer layer (formation of cracks in the hose material, etc.).



Deformation in the pressurised and depressurised state, and at bends that do not correspond to the original state of the hydraulic hose or hose line (layer separation, bubble formation, etc.).



Leaks.



Damage or deformation of the hose fitting which reduces the strength of the 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 lines

must be renewed. HINWEIS If detaching the hydraulic connection causes oil to leak 

use the vacuum pump.


272


CBG_HD / V001

Maintenace

5.16 Electrical system 5.16.1 Replace fuses and lamps Ensure that the following conditions are satisfied: 







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 the slip 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 breathing mask).

 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.

CBG_HD / V001

273

Maintenance

5.16.3 Replacing of filter mat Ensure that the following conditions are satisfied: 







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 Ensure that the following conditions are satisfied: 







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 circuit

breaker.

274

CBG_HD / V001

Maintenace

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.  Contact Liebherr service department.

CBG_HD / V001

275

Maintenance

5.18 Emergency stop 5.18.1 Check the emergency stop to ensure it is working correctly 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:  Contact Liebherr service department.

276

CBG_HD / V001

Maintenace

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.

CBG_HD / V001

277

Maintenance

5.20 Personal protective equipment 5.20.1 Checking that personal protective equipment is in place, 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.

278

CBG_HD / V001

Maintenace

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.

CBG_HD / V001

279

Maintenance

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.

280

CBG_HD / V001

Maintenace

5.22.2 Check fill level of lubrication pump Ensure that the following conditions are satisfied: 







The grease gun from the Liebherr tool kit is present and filled with correct grease.

ACHTUNG Incorrect or impure grease! Damage to machine.  Avoid

contamination: fill supply container exclusively using grease gun via the 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 Ensure that the following conditions are satisfied: 





To ensure optimum lubrication, the following factoryset time intervals must not be 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. CBG_HD / V001

281

Maintenance

5.22.4 Check lubrication points Ensure that the following conditions are satisfied: 





 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.

282

CBG_HD / V001

Maintenace

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 of its service life and to remove it from service before it fails completely. The following points are important when determining the inspection intervals and 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 most commonly occurring types of rope wear. DANGER Incorrect maintenance of the ropes! Load breakaway.  All

the listed criteria must be checked at the prescribed maintenance intervals.



Check the rope in particular around the end attachment as it is subject to increased mechanical stresses at this point.

If any doubts on the operational safety of a rope exist: 

Lay down the rope or have the rope inspected by a qualified engineer.

Ensure that the following conditions are satisfied:

CBG_HD / V001







283

Maintenance

5.23.1 Checking the rope diameter As a result of natural wear that occurs during use, ropes gradually become thinner and must eventually be withdrawn from service. If the rope diameter has reduced over long sections 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. Ensure that the following conditions are satisfied: 







A caliper gauge with wide jaws is available.

Figure 106 Rope diameter: (left) correct measurement, (right) incorrect measurement

 Measure the rope diameter on two separate points at least one metre distant

from 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: 

284

Checking the rope drive.

CBG_HD / V001

Maintenace

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 the inner ones.

Figure 108 Loop formation Single wires or groups of wires emerge from the rope structure. The loops usually lie in a series of strands.

Figure 109 Necking The diameter of the rope is reduced over short lengths. Rope sections immediately before the end attachment must be checked for necking with particular care. Necking is often difficult to recognise at these points.

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 by turning on its axis.

CBG_HD / V001

285

Maintenance

Figure 111 Corkscrew The axis of the unloaded wire rope becomes helical. This prevents the rope drive from running smoothly. The resultant damage includes increased abrasion and wire breaks. The rope must be replaced if the deformation at the thinnest point 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.

286

CBG_HD / V001

Maintenace

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 distinction is made between atmospheric corrosion (produces "even" rusting) and local types of corrosion such as pitting (forms deep holes at points where the protective 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, the rope must be changed regardless of whether or not wire breaks have occurred.

 Check ropes for corrosion.


CBG_HD / V001

287

Maintenance

5.23.4 Check ropes for abrasion

Figure 114 Rope abrasion Abrasion reduces both the static breaking force of the rope due to reduction of the metallic crosssection and its fatigue limit due to wear notches. If the rope diameter has reduced by 10% or more relative to the nominal dimension, the rope must be changed regardless of whether or not wire breaks have occurred.

 Check ropes for abrasion.


288

CBG_HD / V001

Maintenace

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 of its 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 regardless of whether or not wire breaks have occurred.

HINWEIS 

Permitted operating temperatures for ropes and end attachments, refer to EN123853.

 Check ropes for significant heat damage.

If a rope displays signs of external heat damage, such as recrystallisation, melting. etc.:  Switch off the machine and, if possible, determine the cause of the damage.  Remove the rope and/or rope pair. CBG_HD / V001

289

Maintenance

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 the end of the service life c), 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 contact the manufacturer for more information. For Sealedesign wire ropes whose number of outer wires in strands does not exceed 19, the rope in table 1 should be classified two rows above the actual applicable row. Note: The wirebreak coefficients apply to steel grooves or plastic pulleys in combination with multiplelayer spooling (for the rope section that is subject to the greatest strain), but not to plastic pulleys in combination with singlelayer spooling. a) Filler

wires are not considered to be bearing wires. In the case of wire ropes with 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 c) A

rope diameter

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 for ropes that are used on or in systems in Groups M5 ć M8.

290

CBG_HD / V001

Maintenace

Twistfree ropes Rope category (see Annex E)

Number of bearing wires in the outer strands of the wire rope a) n

21

4 Nicks in ropes

Number of wire breaks at the end of the service life c), d)

6 D b)

30 D b)

2

4

2

4

2

4

to 100 22

3 Nicks in ropes 4 Nicks in ropes over 100

23

At least 10 outer braids

Note: The wirebreak coefficients apply to steel grooves or plastic pulleys in combination with multiplelayer spooling (for the rope section that is subject to the greatest strain), but not to plastic pulleys in combination with singlelayer spooling. a) Filler

wires are not considered to be bearing wires. In the case of wire ropes with 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 c) A

rope diameter

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 for ropes 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:

CBG_HD / V001



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 international regulations.

291

Maintenance

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 be higher 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:  Switch off the machine and, if possible, determine the cause of the damage.  Remove the rope and/or rope pair.

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.

292

CBG_HD / V001

Maintenace

5.23.8 Transporting ropes Ropes are very sensitive to external damage. WARNUNG Incorrect transport (loaded, unloaded)! Ropes may become damaged. 

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.

CBG_HD / V001

293

Maintenance

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! Ropes may become damaged. 

Wind ropes in accordance with the following instructions.

If the winding area of the rope is more in the upper rope layer when operating winches with multiplelayer spooling, the lower rope layer may become loose. This results in a slight ovalisation of the rope that changes the winding diameter across the width of the drum. This leads to gaps in the running rope layer, which impairs the spooling properties and increases rope wear. ACHTUNG Lower rope layer loosened! Risk of damage to the rope. 

Improve the the spooling properties and decrease wear: completely unwind the rope at regular intervals and then wind it up again under pretension (1 to 2% of the rope minimum breaking force).

A rope works most economically when its entire length is used. It is therefore recommended that an appropriate length of rope is used for lengthy operations. Ensure that the following conditions are satisfied: 


ACHTUNG Incorrect handling of the rope! Risk of damage to the rope. 

Do not brake the rope directly.



Do not pull the rope along the ground.

With multilayer winding: 

294

1. Pretension the rope layer with at least 10% of SWL (max.) whilst installing the rope.

CBG_HD / V001

Maintenace

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 kink formation.  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.:  Remove the rope.

CBG_HD / V001

295

Maintenance

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 applied (at least the weight of the rope).



If the old rope is used as the luffing rope, ensure that the new rope does not 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's instructions must be followed).

ACHTUNG Rope deflexion angle is too large (more than 4 °)! Risk of damage to the rope. 

Position the pulley as far away as possible and without any lateral deflection.








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 (the

rope 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 cor-

rectly 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 wire

rope is winding onto the winch drum correctly.

296

CBG_HD / V001

Maintenace

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.

CBG_HD / V001

297

Maintenance

5.23.12 Lubricate ropes Regular rope maintenance ensures safe operation of the crane and increases the service life of the rope. Ensure that the following conditions are satisfied: 


 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 winch

drums and the pulleys.  Apply grease with a brush. In special cases a highpressure lubricating de-

vice 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.

298



Wear protective clothing (especially protective gloves).



Use a brush for cleaning.

CBG_HD / V001

Maintenace

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 the end of its service life more quickly due to increased wear. The grooves of the winching drums and the pulleys are therefore checked for wear using test templates. Test templates are related to the nominal groove base diameter.

Checking winch drum groove base for wear Ensure that the following conditions are satisfied: 







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 groove diameter 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).

CBG_HD / V001

299

Maintenance

The diameter of the test template is not the same as the groove base of the winch 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

 Remove the rope.  Smooth the surface of the grooves.  Contact Liebherr service department.

300

CBG_HD / V001

Maintenace

5.25 Rope pulleys 5.25.1 Checking pulleys for ease of movement, signs of wear 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 test template. The rope grooves often exhibit an imprint corresponding to the negative imprint of the rope in question. The impressions of the individual strands in the rope grooves are normal and not undesirable, since these produce a greater rope support surface, which increases the service life of the rope. When the rope is changed, the ridges must be removed and any sharp edges on the surface of the pulley smoothed. Ensure that the following conditions are satisfied: 







A test template is available.

Figure 122 Checking steel pulleys for wear

CBG_HD / V001

1

Test template

2

Steel pulley

A

Maximum permissible wear on pulley

301

Maintenance

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.  Contact Liebherr service department.

Checking plastic pulleys for wear The rope grooves often exhibit an imprint corresponding to the negative imprint of the rope in question. The impressions of the individual strands in the rope grooves are normal and not undesirable, since these produce a greater rope support surface, which increases the service life of the rope. When the rope is changed, the ridges must be removed and any sharp edges on the surface of the pulley smoothed. Ensure that the following conditions are satisfied: 







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:  Replace the pulley.  Contact Liebherr service department.

302

CBG_HD / V001

Maintenace

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 must also be in good condition, without wobbles or any other damage.  Check pulleys for damage (nicks, wobbles, cracks, notches, etc.).

If the pulley is damaged:  Replace the pulley.  Contact Liebherr service department.

CBG_HD / V001

303

Maintenance

5.25.2 Lubricating pulley bearings Ensure that the following conditions are satisfied: 







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! Damage to the pulleys. 

Clean dirt, gum, etc. from the plastic pulleys.

ACHTUNG Unauthorised cleaning agent! Damage to the pulleys. 

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, nitric acid)



Concentrated organic acids (e.g. formic acid)



Concentrated bases (e.g. sodium, caustic potash solution or corrosive potassium 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 cleaning

agents.

304

CBG_HD / V001

Maintenace

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.  Contact Liebherr service department.

5.26.2 Checking that cabin door and door lock work properly 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.  Contact Liebherr service department.

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.  Contact Liebherr service department.

CBG_HD / V001

305

Maintenance

5.26.3 Changing the windscreen wipers Ensure that the following conditions are satisfied: 

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's instructions.

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.

306

CBG_HD / V001

Maintenace

5.26.4 Filling windscreen wiper system Ensure that the following conditions are satisfied: 

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 wipers

with a needle.

CBG_HD / V001

307

Maintenance

5.27 Air conditioning* 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 by authorised 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 are

clean and in good working order.

308

CBG_HD / V001

Maintenace

5.28 Machine care 5.28.1 Cleaning the machine Liebherr recommends that the external machine parts are cleaned regularly to maintain an even surface quality. This is strongly advised following work with highly corrosive materials. 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 Avoid the risk of environmental damage. 

CBG_HD / V001


309

Operating Manual

Recommend Documents