CARGO DECK CRANE

VOLUME 1
INSTRUCTION / MAINTENANCE

TYPE

CBW 40 / 29,5 ST

ORDER − NO.

162 001 − 040

Subject to alteration!
1st Edition: 14.07.2000 /ab
2nd Edition: 29.08.2000 /ab Mod. no. 11 989

LIEBHERR−WERK−NENZING GMBH, P.O.Box 10, A−6710 Nenzing / Austria / Europe

Phone (05525) 606−0, Telex 052141 lwn a, Telefax (05525) 606−200
 FOREWORD

This DOCUMENTATION has been prepared to allow the safe operation of the LIEB

HERR crane while utilizing the crane’s full range of operating possibilities. In addition,
the manual emphasizes the daily routine maintenance and informs the operator of the
operating principles of important assemblies and systems.

VOLUME 1 − INSTRUCTION / MAINTENANCE MANUAL

VOLUME 2 − TECHNICAL INFORMATION

VOLUME 3 − SPARE PARTS LIST

The DOCUMENTATION is prepared for extended service−, repair− and maintenance

work as well as ordering spare parts. This manual shall be used by trained Service−per

sonnel only.

This LIEBHERR crane shall be operated and serviced by from LIEBHERR−WERK NEN

ZING trained or authorized personnel only.

The procedures described in the DOCUMENTATION and general safety precautions

shall be observed at all times.

NON−OBSERVANCE OF THESE RULES CAN RESULT

IN PERSONAL INJURY AND STRUCTURAL DAMAGE.
Special attention shall be given to the safety devices built−in to the crane. They shall
be tested at regular intervals for good condition and proper operation. Crane operation
is prohibited if the safety devices are not working properly.

"S A F E T Y A L W A Y S C O M E S F I R S T"
must be the way of thinking and behaviour before, during and after crane operation.

If you receive any further information for the crane, such as technical modifications or
changes concerning operation, maintenance, or spare parts − please attach them to
provided volumes.
 PREFACE

INDEX − VOLUME 1

1. PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

1.1. TO THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

1.2. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.3. CRANE APPLICATION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.4. CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
1.5. STANDARD HAND SIGNALS FOR CONTROLLING CRANE
OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
1.6. GENERAL HINTS AND ADVISE FOR CRANE OPERATION . . . . . . . . . . 1.10
1.7. EXPLANATION OF SAFETY SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
1.8. LIEBHERR WORLD−WIDE SERVICE ORGANIZATION . . . . . . . . . . . . . . 1.19

2. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

2.1. ARRANGEMENT OF CRANES ON SHIP . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

2.2. ARRANGEMENT OF THE MAIN PARTS OF THE CRANE . . . . . . . . . . . . 2.4
2.3. TECHNICAL DESCRIPTION OF THE LIEBHERR DECK CRANE . . . . . . 2.9
2.4. LAYOUT OF THE OPERATOR’S CABIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
2.5. CONTROLS ON THE SWITCH CABINET X1 . . . . . . . . . . . . . . . . . . . . . . . 2.19
2.6. PREPARATIONS FOR CRANE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 2.20
2.7. ADDITIONAL CRANE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

3. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.2. SPECIAL SAFETY REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.3. MAINTENANCE OF HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.4. PRESSURE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
3.5. LIEBHERR CONDITION MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
3.6. GEARBOXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
3.7. MULTIPLE DISC BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
3.8. INSTRUCTIONS FOR USE OF CRANE ROPES . . . . . . . . . . . . . . . . . . . . 3.26
3.9. REPLACEMENT OF ROPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
3.10. ROPE PULLEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
3.11. ROLLER SLEWING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
3.12. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
3.13. MAINTENANCE INSTRUCTIONS FOR SLIP RING UNIT . . . . . . . . . . . . . 3.39
3.14. LUBRICATION AND GREASING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . 3.40
3.15. MAINTENANCE LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
3.16. SERVICE SPARE−PARTS AND STANDARD TOOLS . . . . . . . . . . . . . . . . 3.59

TABLE OF LUBRICANTS

−1.1− 979/2
PREFACE
979/2

979/2 −1.2−
 PREFACE

INDEX

1. PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

1.1. TO THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

1.2. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

1.2.1. CRANE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.2.2. SPARE PARTS / REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.2.3. PRESERVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.2.4. WELDING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

1.3. CRANE APPLICATION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

1.3.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.3.2. APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.3.3. USE OF THE CARGO DECK CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

1.4. CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

1.5. STANDARD HAND SIGNALS FOR CONTROLLING CRANE

OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

1.6. GENERAL HINTS AND ADVISE FOR CRANE OPERATION . . . . . . . . . . 1.10

1.6.1. GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

1.7. EXPLANATION OF SAFETY SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15

1.7.1. PROHIBITION SIGNS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
1.7.2. WARNING SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
1.7.3. MANDATORY SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
1.7.4. RESCUE SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17

1.8. LIEBHERR WORLD−WIDE SERVICE ORGANIZATION . . . . . . . . . . . . . . 1.19

−1.3− 979/2
PREFACE

979/2 −1.4−
 PREFACE

1. PREFACE

1.1. TO THE OWNER

Any questions concerning to the care and upkeep of this crane which have not been covered in this book
should be directed to your nearest LIEBHERR SERVICE STATION.
LIEBHERR reserves the right to make alterations or modifications to this equipment at any time, which in
their opinion may improve the performance or efficiency of the crane.

DANGER","WARNING", "ATTENTION", "IMPORTANT" and "NOTES" are used throughout this manual
to emphasize critical instructions. In this manual these special instructions are used as follows:

DANGER !
Denotes an extreme intrinsic hazard, which could result in a high pro
ability of death or serious injury, if proper precautions are not taken.

WARNING !
Denotes a hazard, which could result in injury or death, if proper pre
cautions are not taken.

ATTENTION !
Denotes a reminder of safety pratices or directs attention to unsafe
practices, if proper precautions are not taken.

. IMPORTANT !
Denotes IMPORTANT operation and maintenance procedures, which could result in damage or
destruction of the machine or in any of its components, if not observed.

. NOTE !
NOTE describes operation and maintenance procedures, which should be followed to keep your
CRANE operational and insure long machine life and to facilitate certain procedures.

The safety rules included in this manual represents a minimum set of standards for safe crane operation.
Every operator should be familar with and follow these rules at all times. Written rules, however, cannot cover
all situations which might occur on the job.

−1.5− 979/2
PREFACE

1.2. GENERAL INFORMATION

1.2.1. CRANE SERIAL NUMBER

For easy identification each crane is marked with a serial number. This serial number is punched into a plate
fixed to the base frame of the slewing column.
All correspondence with Liebherr or one of our branch offices should include the respective serial number
of the crane.

1.2.2. SPARE PARTS / REPAIRS

In case crane components or service products have to be replaced, resp. added, only original equipment
from the manufacturer and service products which are identical (design and function ) to the original ex

changed parts resp. products must be used.
If spare parts or service products other than those authorized by the original equipment manufacturer,
LIEBHERR cannot be hold responsible for any malfunction or damage to persons or property.
Repairs or modifications on the crane software package are only allowed to be made by service engineers
from LIEBHERR or LIEBHERR authorized personnel.

1.2.3. PRESERVATION

The crane has to be preserved if not in operation for more than 3 months.
Preservation instructions are obtainable through our service department.

1.2.4. WELDING OPERATIONS

Welding operations on the crane to be executed by qualified welders only with approved welding material
and welding procedures, fully in accordance with the requirements of the relevant classification society.

1.3. CRANE APPLICATION AND OPERATION

1.3.1. GENERAL

This is probably the most important area relative to safety since it involves the greatest frequency of expo

sure to danger. The operator should be of sound mind and body and be able to understand and apply estab

lished operating rules. He should be able to exercise good judgment in dealing with the many situations
which cannot be anticipated and covered herein.
Since the manufacturer has no direct control over the crane application and operation, the user is fully
responsible for good safety practice.

1.3.2. APPLICATION

In general, established operating safety rules should be observed when performing operating functions.
Operating safety rules are found in codes of the following organization:
−DOE (Department of Energy)
−ILO (International Labour Organization)
and in the Occupational Safety and Health Act, as well as in Local or National Codes.
It is obvious that written rules cannot cover all situations that might be encountered on the job. To meet such
unexpected situations the operator must be able to supplement the rules mentioned above with his own
ones based on good judgment.

979/2 −1.6−
 PREFACE
1.3.3. USE OF THE CARGO DECK CRANE

Intended Operation
The LIEBHERR CARGO DECK CRANE is designed only for crane operation and only lifting appliances which
have been approved by the crane manufacturer are to be used. The crane may only be used for loads which
lie within the limits of the appropriate load curve.
It is to be assumed that the exterior conditions for the working range of the crane do meet the working re

quirements, so that the technical details stated in the section ‘Technical Data‘ regarding angles, inclines,
etc. can be maintained without risk.
When working, the crane is designed for hook operation. This also applies when the corresponding hoist
accessories used by the customer meet the regulations of the crane type. In case of any doubts, this should
be explicitly clarified.

DANGER !
Observe without fail the capacities for the individual operating situations.
You will find these in the Technical Data as well as in the capacity charts in
the Operation Manual.

Use of professional personnel

Operation, service, maintenance and repairs may only be carried out by specially trained personnel. It must
be ensured that the trained personnel who are engaged do not only dispose of the corresponding special

ized knowledge, but in addition also know and use all questions relating to safety and prevention of accident
regulations.

Environmental Conditions
For the safe operation of the crane it is absolutely necessary to ensure that the environmental conditions,
under which the machine will be operating, are according to regulations.

Other Foreseeable Misuses like

−offlead/Sidelead or dragging loads
−transporting of people or personnel
−operating loads outwith the prescribed limits
are strictly forbidden !

−1.7− 979/2
PREFACE

1.4. CONVERSION TABLE

Conversion factors for SI units : The current edition of the rules are in dual units presented with the MKS
units first followed by the U.S. Customary units in parentheses. A third system of units now being used in

ternationally is the system Internation d’Unites (SI). For the convenience of the purchasers of this book who
use SI units, the following conversion table has been included. This table only provides conversion factors
for those U.S. Customary units and MKS units that differ from SI units, that are used in the rules and guides
of the American Bureau of Shipping. Proper use of significant figures and rounding−off techniques should
be given due consideration when using the conversion table.

Quantity U.S. Customary Multiply by To obtain SI units

or MKS Unit

Area ft2 9.290 304 (10−2)* m2

in2 6.451 600 (102)* mm2

Bending, Torque lb−in 1.129 848 (10−1) Nm

kg−m 9.806 650* Nm

Density lb/in3 2.767 990 (104) kg/m 3

Electrical ft−lb 1.355 818 J

in−lb 1.129 848 (10−1) J
kcal 4.186 800 (103)* J
kg−m 9.806 650* J

Force lb 4.448 222 N

ton (long) 9.964 017 (103) N
kg 9.806 650* N
ton (metric) 9.806 650 (103)* N

Length fathom 1.828 800 m

ft 3.048 (10−1)* m
in 2.540 (101)* mm

Mass lb 4.535 924 (10−1) kg

ton (long) 1.016 047 (103) kg
ton (metric) 1.000 (103) kg

Plan angle degree p/180 rad

Power hp 7.456 999 (102) W

hp (metric) 7.354 99 (102) W

Pressure, Stress psi 6.894 757 (103) N/m2 (or Pa)

6.894 757 (10−3) N/mm2
6894 757 (10−2) bar (or 105N/m2)
ton (long) in2 1.544 426 (107) N/m2 (or Pa)
1.544 426 (101) N/mm2
kg/cm 2 9.806 650 (104)* N/m2 (or Pa)
9.806 650 (10−1) bar (or 103 N/m2)
kg/mm 2 9.806 650 (106)* N/m2 (or Pa)

Temperature °F (°F − 32) / 1.8* °C

Velocity knot (kn) 0.514 444 m/sec.
Volume ft3 2.831 685(10−2) m3
gallon (liquid) 3.785 412 (10−3) m3
3.785 412 I
in3 1.638 706 (104) mm3

* Exact value ABS January 1980

979/2 −1.8−
 PREFACE

1.5. STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS

HOIST LOWER USE MAIN HOIST

USE WHIP LINE RAISE JIB LOWER JIB

MOVE SLOWLY RAISE JIB AND LOWER JIB AND

LOWER THE LOAD RAISE THE LOAD

SWING STOP EMERGENCY STOP

TRAVEL STOP ALL

MOVEMENTS

−1.9− 979/2
PREFACE

1.6. GENERAL HINTS AND ADVISE FOR CRANE OPERATION

This machine is used primarily for hoisting, lowering and positioning of loads. To operate with maximum
safety certain procedures must be followed.
One capacity chart label (load diagram) is supplied with this crane. It is placed in the driver’s cabin. The load
diagram shows the max. permissible load which is allowed to be lifted in correspondence to the actual ra

dius. The actual load and radius for main− or whip hoist are indicated on two displays in the cabin.
The following is a suggested procedure for making a typical lift:
a) Determine the weight to be lifted. Be sure to add the weight of hookblock, slings, spreader bars,
chains and any other gear used. The weight should be marked on the load − if not, consult someone
who knows it. Do not attempt lifting any load of unknown weight.

b) Consult the machine capacity chart for the maximum radius (min. jib angle) to safely handle the load.
The following facts about the capacity chart should be noted at all times:

1) The capacities listed in the chart are based on strength of materials. Exceeding these capacities
will overload the machine and could result in attachment or rope failure, or damage to machine.
2) All capacities are for 360ø rotation.

c) Raise the jib from jib rest and position hook over load.

d) Lower the hook block directly over the load. If the jib angle is lower than the capacity chart listing
for the weight involved the load must be positioned closer to machine or broken down into smaller
packages.

. IMPORTANT !
Do not attempt to drag the load closer to machine with the attachment.

e) Secure the load to hookblock. The following points should be noted when picking a load:

1) The jib head must be positioned directly above the load and within the maximum chart radius.
The attachment is designed to lift and should never be used to drag a load sideways, inward or out

ward.
2) Never exceed the capacities listed on either capacity chart.
3) When lifting loads near max. machine− or rope capacity, care must be taken to avoid sudden
loading and unloading of the hoist line. Ease into the load.

f) Hoist the load to the desired height. Raise or lower the attachment to position the load for lowering.
Be careful when jib down or swinging with the load, outswing caused by centrifugal force will in

crease the load radius resulting in a decreased load capacity. When lowering the jib, with load, do
not exceed the maximum radius listed in the capacity chart for the weight being handled.

. NOTE ! THINK SAFETY :

You, the operator are in charge of an important piece of equipment. It is very important that you
know what it can do. It is also very important that you know what it should not do. No set of instruc

tions can anticipate all of the situations you will come across. The rules given here cover general
usage and some of more specific cases. If conditions arise not covered by these rules, consult
the manufacturer. The cost of a phone call may save someone’s life.

. IMPORTANT !

Only operators trained by the manufacturer authorized personnel are allowed to operate the
crane.

979/2 −1.10−
 PREFACE
1.6.1. GENERAL SAFETY RULES

1) Read this operators manual and heed it. The manual contains valuable information.

2) Whenever an operator leaves the crane for any reason, the following must be done:
a) Lower the load to firm supporting surface.
b) Shut down engine.
c) Never depend upon the winch brake to suspend a load, unless the operator is at the controls and
ready to handle the load. Brake slippage, vandals, mechanical malfunctions could cause the load
to drop if left in the air unattended.

3) The operator must not eat, read, or otherwise given his attention while operating the crane. Remem

ber, operating is a full time job.

4) Don’t allow crane loads to pass over people, or endanger their safety. Remove all loose objects. All
non−operating personnel should leave the immediate area when the crane is operating.

5) Be sure your work area is clear. Make sure you have proper clearance for crane, jib and load. Don’t
swing, hoist or lower the load, raise or lower jib without first making sure no one is in the way. If your
vision is obscured, locate a signal man so you can see him and he can see all areas you can’t. Follow
his signals. Be sure you and the signal man understand each others signals.

6) Inspect the crane daily. Don’t operate a damaged or poorly maintained crane. Pay particular atten

tion to the attachment and wire ropes. If a component is worn or damaged, replace it before operat

ing. Remember, parts are cheaper than people. OSHA (Occupational Safety and Health Act) regula

tions state "a through inspection of all ropes shall be made once a month and a full, written, dated
and signed report of rope condition kept on file where readily available". Replace any worn or dam

aged rope. Pay particular attention to jib hoist ropes and pendants. Check end connections (pins,
sockets, wedges, etc.) for wear and damage.

7) Don’t let the load hit the jib. Don’t let the jib rest or hit against other objects. A damaged or dented
jib may result, which will weaken the jib. If the damage is severe the jib may collapse. If a lattice or
diagonal bracing member is broken or cracked, replace it. If bent, straighten it. Important detailed
information on jib repair is available from you distributor. Some of the steel used in jib is a special
type which can be ruined by improper repair procedures. If a chord is bent or damaged, even a small
amount, don’t use it. don’t try to repair it. Chords are so vital to the strength of the jib that it is not
practical to attempt repairs.

If the jib is struck or damaged by anything − stop. The loading on a jib increases as the jib is lowered;
a damaged jib or jib suspension system may collapse during lowering. Use a helper crane to assist
in lowering a damaged jib.

8) Be sure the jib hoist pawl is always engaged except when lowering the jib. Don’t relay on the jib hoist
winch brake alone to hold the jib. Wear and other factors may affect the ability of the brake to hold
the jib.

9) Never get on or off the crane in motion. Use both hands when climbing onto the crane. A ladder is
provided − use it.

10) Keep your crane clean, in good repair and in proper adjustment, oil or grease on the decks may
cause falls. Improper adjustments can lead to crane damage, load dropping or other malfunctions.

11) Keep a dry chemical or carbon dioxide fire extinguisher in the cab or immediate vicinity of the crane
at all times. Instruct all operating and maintenance personnel in the use of the extinguisher. Check
periodically to make sure it is charged properly and is in work order.

12) Never tamper with safety devices. Keep them in good repair and proper adjusted. They were put
on the machine for your protection.

13) Don’t smoke when fueling or fuel−up the crane near an open flame. Keep the nozzle in contact with
the filler neck to prevent static electric sparks. Shut down the engine when fueling.

14) Before performing repairs or adjustments, bring jib into parking position and place load hook on
deck. Post a warning sign in cab so no one will try to start the engine.

−1.11− 979/2
PREFACE
15) Always replace protective guards and panels before operating machine. Never wear loose clothing
which may be caught in machinery. Always wear hard hats, safety glasses, steel toe shoes and any
other safety equipment required by local or job regulations.

16) Always shut the crane engine down before "servicing" any part of the hydraulic system.

17) Keep fingers, feet and clothing away from sheaves, drums and ropes unless the crane is shut down
and everyone knows what you are doing. Never place a hand on lines when climbing to top of the
crane. A sudden movement may pull them into the drum or sheaves.

18) Use extreme caution when removing radiator caps, drain plugs, grease fittings, hydraulic pressure
caps, etc. They may blow off and hit you or you may be burned by hot oil, water or steam.

19) Always wear safety glasses when drilling, grinding or hammering on metal. You may get chips in
your eye.

20) The operator, supervisor or person in charge must see to the following:

a) Loads must be well secured before lifting. Be sure that the rigging can’t slip off or pull away from
the load or get out of position on the load. Be sure load is rigged so it won’t fall over.

b) Chains and slings must be of adequate size, in good condition and not twisted around each other.
A test certificate must exist for each item of lifting equipment.

c) The load must not catch on an obstruction when lifting or swinging. Be sure load, fall lines or any
other part of machine doesn’t snag or strike any obstruction.

d) Avoid sudden starts and stops. Lift carefully, swing gently, lower and set loads carefully. Jerking
the load, swinging the crane roughly and lowering the load rapidly will put shock loadings and pos

sible side loadings on the jib. rough treatment can also break a machine. Unnecessary abuse lables
the operator as a beginner. Be a professional.

e) Never wrap the hoist line around the load. Never use discharged, worn or damaged rope for
slings. It may break and drop the load.

21) The hoist line must be vertical when starting to lift, if not the load will swing in, out or sideways when
lifted from the ground.

When picking a heavy load, the crane will lean toward the jib. This is caused by elasticity of the crane
and the jib. The lean will increase operating radius so the load will swing outward when it clears the
ground. This outswing is dangerous to anything in the path of the load and because of the increase
in the load radius may overload the crane. To overcome this outswing, jib up as the load is lifted so
fall lines remain vertical. When setting the load on the ground, lower the jib after load touches down
to avoid hook block swing when it is unhooked from load or the jib contacting the jib backstops.

22) One workman should be designated a signal man, and the operator should obey signals from him
only. A signal to stop should be obeyed no matter who gives it. See hand signals chart earlier in this
section.

23) Know your load. Don’t try to guess or estimate the load. Use a scale weight or certified weight, a
hook scale or load indicating system. Remember − the weight you are lifting includes the weight
of any lifting slings or gear, the hook block and any overhaul weights. The total weight must never
exceed the rated capacity of the machine, as listed on the capacity chart, for the position, jib length,
load radius, no. of lines and conditions of operation being used. Remember − capacity chart ratings
are based on ideal conditions:

a) Calm wind
b) No side loads or outswing of load
c) Good visibility
d) Machinery in perfect condition and equipped as when leaving the factory.

When such conditions cannot be attained, loads being handled must be reduced to compensate.
The amount loads are reduced depends upon how good or how poor the actual operating condi

tions are. It is a matter of judgement and experience. Some factors which may require reduction of

979/2 −1.12−
 PREFACE
loads below listed ratings are:

a) wind
b) Hazardous surroundings
c) Inexperienced personnel
d) Poor visibility
e) Fragile loads
f) Machine in poor condition

When in doubt, don’t take a chance. Reduce ratings more than you think you need to.

Avoid working the crane in high winds. If you must work in a wind, reduce capacities considerably
below those shown on the capacity chart. Wind blowing against the load and the jib produces a side
load on the jib and reduces its capacity.

When lifting large loads such as building panels in a wind, the movement of the load may pose a
danger to workmen or building structures. Out swing of load will increase load radius and may over

load the machine. This could lead to jib failure or machine damage.

24) Don’t operate at radii and jib lengths where the capacity chart lists no capacity. Don’t use longer jib
or tip extensions than listed on the chart. Either of the above can cause jib and/or extension failure.

25) Keep the load lines as short as possible to prevent excessive swinging.

26) Watch out for centrifugal force when swinging a load. Swing gently. Centrifugal force tends to in

crease load radius. This increase in radius could overload the crane and cause crane damage.
When stopping the swing overswing of the load can side load the attachment.

27) Know the load radius. Don’t guess it. Determine radius by using the gauge in the driver’s cabin or
mechanical jib angle indicator, the jib length and the capacity chart or measure it with a steel tape.
Remember, radius is the horizontal distance from the centerline of rotation of the crane to the center
of gravity of the load is hanging free.

28) Know the jib length. Don’t guess it. Use of an incorrect jib length can cause an accident.

29) Use at least the number of parts of hoist line specified in the reeving plan to handle the load. Local
codes may require more parts of line than shown. Check code requirements and use them where
applicable.

Use special when handling loads on single part line with jib at a short radius. This is especially impor

tant when hoist line is off aux. winch. The jib may be whipped back over crane.

30) Test the winch brake by raising the load a few inches and holding. It should hold easily.

31) Don’t pull sideways on the jib, not even a little bit. Lift straight up on every load. Moving anything
by pulling sideways with the hoist line is liable to buckle the jib. It may also damage the swing mecha

nism.

32) Don’t alter any part of the machine. Additions to or changes in any part of the equipment can create
loadings which the crane was not designed for. Such changes may seriously affect the useable ca

pacities and make the entire capacity chart invalid. Such changes can dangerously overload or
weaken critical parts and may cause disastrous failure.

33) Don’t pick loads with main winch and aux. winch at the same time, even if total load weight is within
crane capacity

34) Don’t lift more than one separately rigged load at a time even if both loads combined don’t exceed
the cranes capacity. Your full attention cannot be given to both loads, creating a dangerous situation.

35) Use caution when jib up to minimum radius. Be prepared to stop jib travel. If the jib limit device mal

functions, the jib and backstops may be damaged or someone may be hurt.

36) When operating near minimum radius, be ready to jib down as you set the load down, to compen

sate for the tendency of the jib to move back against the backstops when the load released. This

−1.13− 979/2
PREFACE
action occurs because of elasticity in the jib hoist system. Severe bending in the jib can occur if it
is allowed to bear against the backstops too heavily.

37) Watch out for "two−blocking" (forcing the hook block into head machinery). This can result in rope
or sheave damage and possibly pull the attachment over the rear causing crane damage. If this ma

chine is equipped with an "anti−two block" device, make sure it is functioning properly before oper

ating the crane. Never fully depend on "so called" safety devices. Nothing replaces the good judge

ment and safety consciousness of the crane operator.

38) Block under the jib top section (front and rear) before disconnecting from extensions. Since the top
section is tapered, it will fall to the ground when unpinned. this could result in an accident.

39) When operating the crane equipped with any form of load indicating mechanism, overload warning
system or any automatic safety device, remember that such devices cannot replace the skill and
judgement of a good operator. Such devices cannot, for instance, tell when too few parts of line are
being used to hoist a load, or correct for the effects of wind, or warn that the device may be improp

erly adjusted, or correct for side pulls on the jib, or for many conditions which may occur and which
may create hazards. It requires all the skill, experience, judgement and safety consciousness that
a good operator can develop to attain a safe operation. Many safety devices can assist the operator
in performing his duties, but he should not depend on them to keep him out of trouble.

40) After a slack rope operation, make sure the rope is properly seated in sheaves and on drums before
continuing to operate. Use a stick or mallet to set the rope, not your hands.

41) Make sure machine is equipped with an adequate length of wire rope. Check wire rope length by
lowering hook block to water level and observing rope left on drum. Never allow less than 3 full wraps
of rope on any drum. If all the rope is run off a drum, the load will jerk, possibly causing damage to
rope, attachment or machine.

42) Make sure there is a latch on the hook, and that, it works properly. Without a latch, it is possible for
slings or chains to come off the hook and allow the load to fall.

43) When lifting submerged loads. Don’t pull sideways − or jib may collapse. If possible, rig the load
so it is lifted from one end. Don’t yank or jerk on the load. When a submerged load reaches the sur

face, don’t attempt to lift it out of the water all at once. It may be saturated with water and will weigh
many times what you expect. Allow it to drain as you raise the load slowly. Be patient, as draining
may take a long time. A load, when removed from the water, even when fully drained, will have a
greater effective weight than it will when submerged because of buoyancy.

979/2 −1.14−
 PREFACE

1.7. EXPLANATION OF SAFETY SIGNS

1.7.1. PROHIBITION SIGNS:

Fire, exposed flame and smoking prohibited Do not operate switch

No entrance for unauthorized personnel Prohibited for persons with pacemaker

1.7.2. WARNING SIGNS

Warning of hanging load Warning of electro−magnetic field

Warning of high voltage Danger of falling

−1.15− 979/2
PREFACE

Warning of danger through batteries Warning of danger through slipping

Danger through hot surface

1.7.3. MANDATORY SIGNS

Wear eye protection Wear safety gloves Wear safety protection

Wear safety helmet Wear safety boots Wear ear protection

979/2 −1.16−
 PREFACE

Follow information on the Switch off power supply Use safety device
component, in the in
structions for use and in
structions for operating
the vehicle

1.7.4. RESCUE SIGNS

First Aid
Fire extinguisher

Doctor

−1.17− 979/2
PREFACE

979/2 −1.18−
 PREFACE

1.8. LIEBHERR WORLD−WIDE SERVICE ORGANIZATION

Edition: 15.03.2000

− AUSTRIA −
LIEBHERR−WERK NENZING GMBH Tel. No. +43 5525 606−0
P.O. Box 10 Fax. No. +43 5525 606−20
Tschalenga 3 Tlx. No. 52549 LWNET A
A−6710 NENZING
Service manager ship crane:
Mr. Harald Fröhlich Tel. No. +43 5525 606−387
Fax. No. +43 5525 606−54
Tlx. No. 52549 LWNET A
E−mail: [email protected]
Service manager offshore crane:
Mr. Harald Mühlhauser Tel. No. +43 5525 606−308
Mr. Andreas Kopf Fax. No. +43 5525 606−625
Tlx. No. 52549 LWNET A
E−mail: [email protected]
E−mail: [email protected]
Service manager harbour mobile crane:
Mr. Günter Leonhartsberger Tel. No. +43 5525 606−242
Fax. No. +43 5525 606−622
Tlx. No. 52549 LWNET A
E−mail: [email protected]
LIEBHERR−SERVICE CONTRACTORS IN:

− GERMANY −
LIEBHERR−NENZING−SERVICE Tel. No. +49 40 76702 200
Am Neuländer Baggerteich 1 Fax. No. +49 40 7658779
D−21079 HAMBURG 90 Tlx. No. 213540 LHSKS D
Contact: Mr. G. Mellmann

− GREAT BRITAIN −
LIEBHERR−SUNDERLAND WORKS Tel. No. +44 191 567 9977
Ayres Quay Fax. No. +44 191 567 2723
Deptford Terrace Tlx. No. 53445 LIEBHSW G
SUNDERLAND SR4 6DD Contact: Mr. Uwe Kari
E−mail: [email protected]

− NETHERLANDS −
LIEBHERR NETHERLANDS BV Tel. No. +31 33 4500 277
Industrieterrein de Hoef Fax. No. +31 33 4500 292
Beeldschermweg 2 Tlx. No. 79144 LNE NL
3821 AH AMERSFOORT Contact: Mr. Chris Kats
E−mail: [email protected]

− NORWAY −
H.L.S. A/S Tel. No. +47 37 011025
Vikaveien 29 Fax. No. +47 37 010225
Postbox 61
N−4817 HIS Contact: Mr. Harek Leif Sandnes
E−mail: [email protected]

−1.19− 979/2
PREFACE
− ARGENTINIA −
INGENIERA DE EQUIPOS S.A. Tel. No. +54 11 4 8157784
I.D.E.S.A. Fax. No. +54 11 4 8157405
Chacabuco 145
4th Floor Office 46 Contact: Mr. L. Palacios
(1069) BUENOS AIRES E−mail: [email protected]

− AUSTRALIA −
MORROW EQUIPMENT CO. (AUST.) Tel. No. +61 2 9525 7741
A39 − 1 Endeavour Rd Fax. No. +61 2 9525 0278
P. O. Box 533
CARINGBAH NSW 2229 Contact: Mr. Bill Jones
AUSTRALIA
− BRASIL −
LIEBHERR−BRASIL Tel. No. +55 125 32 4233
GUINDASTES E OPERATRIZES LTDA. Fax. No. +55 125 32 4366
Rodovia Presidente Dutra Km 59 Tlx. No. 125 540 LBGM BR
Caixa postal 204
12500 GUARANTINGUETA S. P. Contact: Mr. Karl Riess
− CANADA −
KEY MARINE INDUSTRIES LTD. Tel. No. +001 604 251 4010
1407 E. Georgia Street Fax. No. +001 604 251 4020
VANCOUVER, B.C. Website: http://www.keymarine.com
V5L 2A9 Contact: Mr. Phil Houston
E−mail: [email protected]
− COSTA RICA −
SERVICIOS INTERCONTINENTALES S.A. Tel. No. +506 798 4387
LIEBHERR NENZING CRANE SERVICE Fax. No. +506 758 3800
Casa Amarilla
Frente Parquesito Asis Esna Contact: Mr. Peter Jordan
Apdo 187 PORT LIMON, C.R. E−mail: [email protected]
− CHILE −
H. TESSINI Ltda. Tel. No. +56 32 826243
Pacific Coast, Representationes & Fax. No. +56 32 826471
Technical Assistence
Avda. Almte. Gráu 2541 Contact: Mr. H. Tessini
Coop. Tte. Serrano
QUILPUE − VALPARAISO
− CHINA −
LIEBHERR (HKG) LIMITED Tel. No. +86 21 64152148
Shanghai Representative Office +86 21 64152149
Suite 709 Fax. No. +86 21 64736786
7/F. Jin Zhong Building
680 Zhao Jia Bang Road Contact: Mr. Andreas Ganahl
SHANGHAI, CHINA 200031 E−mail: [email protected]
− HONG KONG −
LIEBHERR (HKG) LIMITED Tel. No. +852 2889 3081
Unit 6, 14/F Fax.No. +852 2889 3156
Paramount Building Tlx. No. 68983 LHKG HX
12 Ka Yip Street
Chai Wan Contact: Mr. Rainer Schmied
HONG KONG E−mail: [email protected]

979/2 −1.20−
 PREFACE
− JAPAN −
MARINE ENTERPRISE CO., LTD. Tel. No. +81 78 3020171
1−1, 5−Chome Fax. No. +81 78 3020177
Minatoshima Nakamachi Tlx. No. 5622789 MARICO J
CHUO−KU, KOBE Contact: Mr. Shigeo Hirayama
− NEW ZEALAND −
MORROW EQUIPMENT CO. (NZ) Tel. No. +64 4 589 4924
Unit 13, Parkhead Court Fax. No. +64 4 589 3195
Western Hutt Road, Petone
P. O. Box 31−168 Contact: Mr. Bill Houlker
Lower Hutt
WELLINGTON
− SINGAPORE −
LIEBHERR−SINGAPORE PTE. LTD. Tel. No. +65 265 2305
No. 8 Pandan Avenue Fax. No. +65 261 6485
SINGAPORE 2260 Tlx. No. 35053 LSBSIN
Contact: Mr. Oliver Hepp
E−mail: [email protected]
− SOUTH AFRICA −
LIEBHERR−AFRICA PTY. LTD. Tel. No. +27 11 817 3873
Vlakfontein Road Fax. No. +27 11 817 3884
Fulcrum Ind. Township
P.O.Box 841 Contact: Mr. Chris Vorster
Springs / Transvaal 1560
− TAIWAN −
SWITCH MEANS INDUSTRIAL CO., LTD. Tel. No. +886 22 698 4558
Suite 6, 7/F. Sec. 1, Shin−Tai Wu Road Fax. No. +886 22 698 4556
Hsi−Chih Town, Taipei Hsien,
Taiwan, R.O.C. Contact: Mr. Kenny Kung
− USA − EAST COAST −
SCHILLER SERVICE CORP. Tel. No. +001 757 727 0894
1001 Thomas Street Fax. No. +001 757 727 6982
HAMPTON / VA 23669−3034
U.S.A. Contact: Mr. Ingo Schiller
E−mail: [email protected]
− USA − WEST COAST −
SCHILLER SERVICE CORP. Tel. No. +001 757 727 0894
Mr. A. Shahroodi Fax. No. +001 757 727 6982
2785 Pacific Coast Hwy #E 257
Torrance, CA. 90505−7060 Contact: Mr. Ingo Schiller
U.S.A E−mail: [email protected]
− UNITED ARAB EMIRATES −
LIEBHERR−CRANE−SERVICE Tel. No. +971−4 34 10 30
FRONTLINE SHIPREPAIRING LCC Fax. No. +971−4 34 10 46
162, Al Jadaf
P.O. Box 50053 Contact: Mr. K. Wittenberg
DUBAI
U.A.E.

−1.21− 979/2
PREFACE

979/2 −1.22−
 GENERAL DESCRIPTION

INDEX

2. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

2.1. ARRANGEMENT OF CRANES ON SHIP . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

2.2. ARRANGEMENT OF THE MAIN PARTS OF THE CRANE . . . . . . . . . . . . 2.4

2.2.1. SLEWING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.2.2. JIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

2.3. TECHNICAL DESCRIPTION OF THE LIEBHERR DECK CRANE . . . . . . 2.9

2.3.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.3.2. HOISTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.3.3. LUFFING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.3.4. SLEWING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.3.5. POWER REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.3.6. CRANE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.3.7. HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.3.8. COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.3.9. OPERATOR’S CABIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.3.10. SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.3.11. EMERGENCY DESCENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.3.12. LOAD DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

2.4. LAYOUT OF THE OPERATOR’S CABIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13

2.4.1. EXPLANATION OF CONTROL ELEMENTS ON THE CONTROL STAND . . . . . . . . . . . . 2.14
2.4.2. SWITCH UNIT X20 FOR CRANE CONTROL, LIGHTING AND HEATING . . . . . . . . . . . . 2.15

2.5. CONTROLS ON THE SWITCH CABINET X1 . . . . . . . . . . . . . . . . . . . . . . . 2.19

2.6. PREPARATIONS FOR CRANE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 2.20

2.6.1. START UP OF CRANE (FROM PARKING POSITION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
2.6.2. SHUT DOWN THE CRANE (FOR WORK BREAK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
2.6.3. STARTING UP (AFTER A WORK BREAK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
2.6.4. SHUT DOWN OF CRANE (FOR PARKING POSITION) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

2.7. ADDITIONAL CRANE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

2.7.1. WORKING CAGE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

−2.1− 979/2
GENERAL DESCRIPTION

979/2 −2.2−
 GENERAL DESCRIPTION

2. GENERAL DESCRIPTION

2.1. ARRANGEMENT OF CRANES ON SHIP

Crane no. 1

Crane no. 2

Crane no. 3

Crane no. 4

−2.3− 979/2
 2.2.

13
1

979/2
12

2
GENERAL DESCRIPTION

3
11
8
7
6
4

5
9

−2.4−
1 Hoisting winch
2 Air escape hood
3 Slewing column 10
4 Roller slewing bearing
5 Base column
6 Operator’s cabin
7 Jib displacement cylinder
8 Jib
ARRANGEMENT OF THE MAIN PARTS OF THE CRANE

9 Upper hook block

10 Lower hook block
11 Flood light jib head
12 Rope sheave at jib head
13 Hoisting rope
 GENERAL DESCRIPTION
2.2.1. SLEWING COLUMN

The slewing column comprises a robust metal housing devided into three different levels:
In level 1, the central pump assembly as well as the slewing gears are located.
In level 2, the hydraulic oil tank as well as the switch cabinet X1 for motor control are located. This level
provides access to the operator’s cabin.
On top of the slewing column the hoist winch, the hydraulic oil cooler as well as the jib pivot point is located.

ARRANGEMENT OF THE MAIN COMPONENTS ON THE SLEWING COLUMN:

12

2
11

10
4

6 9

1 Hoisting winch 7 Roller slewing ring

2 Air escape hood with fan motor 8 Ascent ladder
3 Hydraulic oil tank 9 Floot light
4 Electric main motor 10 Operator’s cabin
5 Hydraulic pump assembly 11 Jib pivot points
6 Slewing gearboxes 12 Luffing cylinders

−2.5− 979/2
GENERAL DESCRIPTION

CABIN LEVEL (LEVEL 2)

1
6

2 8

7
3

4
6
5

1 Hydraulic oil tank (see section MAINTENANCE")

2 Electric main motor with hydraulic pump assembly
3 Slewing gearbox with hydraulic motor and multiple disc brake
4 Switch cabinet X1
5 Access to next lower level
6 Luffing cylinders EU, EV
7 Operator’s cabin
8 Emergency descent

979/2 −2.6−
 GENERAL DESCRIPTION

Top level

5
1
6

7
2

4
6
5

1 Hydraulic motor HU and multiple disc brake H61U for hoisting winch
2 Air escape hood with fan motor 4A−M05
3 Hoisting winch drum
4 Gear cam limit switches
5 Jib pivot
6 Luffing cylinders EU, EV
7 Operator’s cabin
8 Access to next lower level. KEEP HATCH CLOSED DURING SEA VOYAGE !

−2.7− 979/2
GENERAL DESCRIPTION
2.2.2. JIB

The jib consists of a completely enclosed welded box− 2 1

section construction through which a high degree of
stability is obtained. The hinges at both sides are fitted
to the slewing column top and are provided with self
aligning spherical roller bearings. The jib head com

prises the hoisting rope pulley, which guide the hoist
rope.

3
1 Hook block (see detail below)
2 Hoist rope pulley on jib head
3 Hoisting rope
4 Luffing cylinder connection points
5 Connection to the jib hinge sections on the
slewing column
6 Rope fix point on jib head
7 Upper hook block
8 Lower hook block
9 Load hook

3
7

979/2 −2.8−
 GENERAL DESCRIPTION

2.3. TECHNICAL DESCRIPTION OF THE LIEBHERR DECK CRANE

2.3.1. GENERAL
The crane mainly consists of the base column, slewing ring, the slewing column, the jib and the hoisting
and slewing gears.
All electric, hydraulic and mechanic units as well as the control stand required for operating the crane are
housed inside the slewing column.
The crane is electric− hydraulically driven, i.e. all three movements of the hoist−, slew and jib motion oper

ate hydraulically. One main electric motor is installed to drive the hydraulic assembly.

2.3.2. HOISTING SYSTEM

The hoisting gear consists of one axial piston pump with variable delivery, one variable hydraulic motor and
the necessary control units. The hydraulic motor is flange−mounted to the planetary gear of the hoist winch.
The rope drum is situated on top of the slewing column. The multi disc brake is between the hydraulic motor
and the winch gear. The bearing of the hoist drum is sealed against sea water.

2.3.3. LUFFING SYSTEM

The luffing system consists of one axial piston pump (variable delivery), two luffing cylinders and the neces

sary control elements. The jib is guided by the hydraulic cylinders, which work in both directions, and there

fore the jib is under constant control.

2.3.4. SLEWING SYSTEM

The slewing system consists of one axial pistion pump, three hydraulic motors, three multi disc brakes and
the necessary control units. The hydraulical function is similiar to the hoisting gear circuit. The slewing gears
are situated in the lower slewing column and are completely sea water tight.

2.3.5. POWER REGULATION

The hoist speed will be automatically proportional reduced at increasing load by the built−in power regula

tor in the variable pump A11VO.

2.3.6. CRANE CONTROL

The hoisting, luffing and slewing movements can be stepless controlled by full hydraulic joysticks. All move

ments can be carried out simultaneously from the control stand.

2.3.7. HEATING
If the temperature is below appr. + 20°C, the crane heating, which is in level 2 of the slewing column, is
switched on by a room thermostat in switch cabinet X1.
The operator’s cabin can be heated by a seperate fan / heating system.
The switch cabinet, the slip ring, the hydraulic oiltank and the main motor have stand still heaters to avoid
condensation.
THE AUXILLIARY POWER SUPPLY FOR LIGHTING AND HEATING HAS TO BE SWITCHED ON ALL THE
TIME TO AVOID CONDENSATION IN THE ELECTRIC OR HYDRAULIC SYSTEM !

2.3.8. COOLING
In order to eliminate heat occuring during operation, one combined winch gear and hydraulic oil cooler
with one ventilator is installed. The temperature is automatically regulated by thermostates.

2.3.9. OPERATOR’S CABIN

All control elements for crane control as the control stand with hydr. joystick, emergency push button, switch
unit for crane control, lighting and heating, fan forced heating as well as emergency rescue device for emer

gency descent are placed in the cabin.

−2.9− 979/2
GENERAL DESCRIPTION
2.3.10. SAFETY DEVICES

2.3.10.1. HYDRAULICS

−BRAKES
The winch for the hoist system as well as the drive gears for the slewing system are equipped with spring
loaded multiple disc brakes, which are in the applied position without control. The brakes open only if the
corresponding control lever is operated. The brakes close automatically when the control lever is returned
to neutral position, in addition the multiple disc brakes are applied automatically in the event of a power fail

ure on the electric motor or pressure drop in the hydraulic system. The multi disc brakes are automatically
self adjusting, that means the brakes need not to be re−adjusted.

−ADDITIONAL PROTECTION OF THE JIB MOTION

If the hose connection for movement jib up" at the luffing cylinders get damaged, the jib movement down"
stops immediately because of the hose fracture safety valves placed at the bottom of both cylinders.
Falling back of the jib is prevented by the extreme positions of the piston rods of the double acting hydraulic
cylinders.

−OVERPRESSURE PROTECTION
The entire hydraulic system is protected against overpressure by means of pressure limiting valves.

2.3.10.2. ELECTRICS

−EMERGENCY STOP BUTTONS

Emergency stop buttons are installed to ensure an emergency shutdown of the crane if a dangerous situa

tion occures.
They are located:
− at the switch unit X20 (cabin)
− at switch cabinet X1
− at the acsenr ladder

−LIMIT SWITCHES
The winch for the hoist system as well as the luffing system are equipped with with gear cam limit switches
which stop the movement at the corresponding limit position.

2.3.10.3. OTHER SAFETY DEVICES

−EMERGENCY HAND PUMP

The emergency hand pump (seperate delivered) can be used to rest the load at a total black out on the
crane.
For operation of the hand pump refer to section "EMERGENCY OPERATIONS"

−EMERGENCY DESCENT/ENTRANCE
The emergency descent from the crane must be done through the front window of the cabin and by use
of the rescue device (it is stored in the upper right corner of the cabin)
The use of this rescue device is explained on the following page. The front window can be opend by the
provided handle.

979/2 −2.10−
 GENERAL DESCRIPTION
2.3.11. EMERGENCY DESCENT

In case of an fire an emergency descent outside the crane is possible.

Procedure of descent:
1. Unlock the emergency window (front window) in the cabin by the provided handle
2. Push the window out of the frame (the window can’t fall down, it is secured by steel wire)

3. Pull out the complete re
5. Take the harness at the D− 6. Pull over the shoulder−
scue−device from the rings, lift the harness up to straps.
box, hang up at special the shoulders and latch
hook and throw the rope the D−rings in the carabi

outside. ner.
4. Stand with straddled legs
over the harness

STOP: Keep the incoming

rope tight and / or release
the brake lever !

ATTENTION
Don’t use damaged or incom

plete equipment !

7. Sitting in the harness, 8. Incoming rope in one

climb out of the window hand, brake lever in other
hand. Open the brake ca

refully and regulate the
speed with the incoming
rope.

WARNING !
The procedure of roping down shall be trained before an emergency case!
There is a detailed operating and maintenance manual of the manufac

tuarer supplied with the crane !

MAINTENANCE
−Don’t twist the safety rope in order to avoid damges on the rope !
−Brush out dirty rope or clean it with tepid water or fine washing agent (Rinse clear afterwards) !
−A visual inspection has to be done after eyery use of the rescue device !

ATTENTION !
The rescue equipment must be inspected by a competent person once
a year according to the check−list supplied with the rescue−device !

−2.11− 979/2
GENERAL DESCRIPTION
2.3.12. LOAD DIAGRAM

979/2 −2.12−
 GENERAL DESCRIPTION

2.4. LAYOUT OF THE OPERATOR’S CABIN

10

3 3

5 6

1 Cabin heater
2 Joy stick jib / slew motion" (see description EXPLANATION OF CONTROL ELEMENTS)
3 Arm rests
4 Watertank for windscreen washer
5 Driver’s seat
6 Entrance door
7 Rescue device for emergency descent from the crane
8 Switch unit X20
9 Joy stick hoist motion" (see description EXPLANATION OF CONTROL ELEMENTS)
10 Emergency window for emergency descent (see section EMERGENCY DESCENT")

−2.13− 979/2
GENERAL DESCRIPTION
2.4.1. EXPLANATION OF CONTROL ELEMENTS ON THE CONTROL STAND

2.4.1.1. JOY STICK JIB / SLEW MOTION"

Combined joy stick for stepless hydraulic control of the luffing and
slewing system. Both movements can be carried out at the same
time.
The joy stick is spring centered and will automatically return to neu

tral when it is released.
A button on top of the joy stick can be used for operating the horn
outside the cabin.

2.4.1.2. JOY STICK HOIST MOTION"

Joy stick for stepless hydraulic control of the hoist motion opera

tion can be carried out at the same time with luff or slew motion.
The joy stick is spring centered and will automatically return to neu

tral when it is released.

979/2 −2.14−
 GENERAL DESCRIPTION
2.4.2. SWITCH UNIT X20 FOR CRANE CONTROL, LIGHTING AND HEATING

1 13

2 12

3 11

4 10

5 9

6 8

1 Switch
screen wiper front"

Pos. 0": off

Pos. I": screen wiper operation
Pos. II": pump for screen wiper operation

2 Switch
lighting cabin"

For operating the light in the cabin.

3 Pilot light
main motor fault"

The pilot light illuminates if one of the listed faults occurs:

− overtemperature protection (PTC) main motor tripped
− overcurrent relay (PTC) main motor

−2.15− 979/2
GENERAL DESCRIPTION

4 Pilot light
niveau / temperature fault"

The pilot light illuminates if one of the listed faults occurs:

− low level switch in hydraulic tank tripped
− temperature switch hydraulic oil temperature" tripped
− temperature switch gear oil temperature hoisting winch" tripped

5 Pilot light and push button
motor on"

Press push button to start the main motor in following sequence:

− Unlock all EMERGENCY STOP" buttons
− Switch on the manual operated main breaker at switch cabinet X1
− Check if pilot light CRANE ON" illuminates
− All joy sticks must be in neutral position
− Press push button MOTOR ON"
− Check if pilot light MOTOR ON" comes on after a few seconds (run up time main motor)
The main drive fails to start, if:
− the overcurrent relay
− the PTC−protection for the main motor has tripped or
− the hydraulic oil level is too low in the hydraulic tank

6 Push button
motor off"

Stops the electric main motor, if pressed.

ATTENTION !
Before leaving the crane the main drive must always be shut down !

7 Red push button
emergency stop"

If one of the emergency stop buttons is pressed the main motor stops. All brakes close immediately, because
of the pressure loss in the brake lines.

These buttons should be used in emergency case only!

. IMPORTANT !
If using this button during operation with full load, the multiple disc brakes of the hoist winch must
be inspected and checked for proper function !

Other emergency push buttons are located:

− at the switch cabinet door X1
− at the ascent ladder

8 Pilot light
crane on"

illuminates, if the manual operated key switch is on, that means power is available to start the hydraulic
assembly.

9 Push button
crane off"

for switching off the main breaker when crane operation is finished.

10 Pilot light
circuit breaker tripped"

illuminates, if the circuit breaker of the oil cooler motor has tripped.

979/2 −2.16−
 GENERAL DESCRIPTION

11 Push button and pilot light
park position"

If this button is pressed, the jib can be brought into park position" (the limit switch working position" will be
bypassed).
If parking" of the jib is wanted, lower the jib till this light comes on, now press bypass button and lower the
jib into park position".

ATTENTION !
If park position is reached, the movement of the jib is not stopped auto
matically via limit switches !

12 Switch
lighting crane"

For operating the lights inside the slewing column.

An additional switch is located at the ascent ladder.

13 Switch
floodlights"

For operating the flood light at the jib head.

2.4.2.1. ADDITIONAL SWITCH UNIT
HOOK PARKING"

14

14 Key switch
parking"

Operate key switch to preselect parking" of the jib.

ATTENTION !
DO NOT OPERATE KEY SWITCH
PARKING" AS LONG AS LOAD IS
ATTACHED ON THE HOOK !
Remove key after process is finished !

−2.17− 979/2
GENERAL DESCRIPTION

2.4.2.2. ADDITIONAL SWITCH UNIT
SLEWING GEAR INTERLOCK" (for crane no. 4 only!)

15 16 17 18

15 Key switch
preselection slewing interlock "

Turn key switch to preselect interlock of slewing gear.

Precondition: Jib must be in lower limit switch position.

ATTENTION !
The key switch
slewing interlock" may be operated by trained person
nel only and the key must be removed after process is finished !

16 Pilot light
slewing interlock position"

The pilot light illuminates if the slewing column is in slewing interlock" position

17 Push button and pilot light
park position unlocked"

If this button is pressed, the locking cylinder is activated and the slewing gear will be unlocked. The pilot light
illuminates if the slewing gear is in unlocked position.

18 Push button and pilot light
park position locked"

If this button is pressed, the locking cylinder is activated and the slewing gear will be locked. The pilot light
illuminates if the slewing gear is in locked position.

2.4.2.3. ADDITIONAL SWITCH UNIT
WORKING CAGE OPERATION" (for crane no. 4 only!)

19 20 21

19 Key switch
working cage operation"

Operate switch to preselect aux. winch (operation of winch refer to part Operation")

20 Joy stick
cage operation"

For operation of auxiliary winch in direction lifting or lowering

21 Pilot light
ready"

The pilot light illuminates if aux. winch is ready for operation

979/2 −2.18−
 GENERAL DESCRIPTION

2.5. CONTROLS ON THE SWITCH CABINET X1

4
5
6

1 Air inlet with filter (clean or exchange the filter approx. every 3000 working hours) and fan
X1−M01

2 Air outlet with filter (clean or exchange the filter approx. every 3000 working hours)

3 Ampere meter, meassures the actual current of the main motor

4 Main switch "AUXILIARY SUPPLY" X1−S02. Operates the power supply for the entire lighting
and heating system on the crane. SWITCH OFF ONLY FOR SERVICE WORK IN THIS SYSTEM!

5 Red push button "EMERGENCY STOP". X1−S01. Function see "EMERGENCY STOP" on
SWITCH UNIT X20.

6 MOTOR OPERATION HOURS COUNTER. X1−P01. This value is used to determine the crane’s
maintenance intervalls.

7 Main switch "CRANE POWER SUPPLY". X1−Q01. Turn to switch on. Switch cabinet door can’t
be opened, when the switch is in the "ON" position.

WARNING !
BEFORE OPENING ANY ELECTRICAL EQUIPMENT, IT IS ESSENTIAL
TO SWITCH OFF THE POWER SUPPLY !

−2.19− 979/2
GENERAL DESCRIPTION

2.6. PREPARATIONS FOR CRANE OPERATION

2.6.1. START UP OF CRANE (FROM PARKING POSITION)

−Switch on the main breaker manually at the door of switch cabinet X1. If switching on is not possible, check
if all emergency stop buttons are in unlocked position.
−Check if the hand valve (below the hydraulic tank) for pump supply is in open position !
−Pilot light crane on" (item 8) illuminates
−Press the motor on" button (item 5) at the switch unit X20 (all joy sticks must be in neutral position). Wait
until the pilot light motor on" lights up

ATTENTION !
While starting the hydraulic assembly it is not allowed to operate the
joy sticks until the pilot light
Motor on" illuminates !

− Check if no trouble is indicated at the control switch unit X20

. NOTE !
Following marked item ( with * ) are for crane no. 4 only!
*−Operate key switch slewing interlock" (item 15)
*−Press push button park position unlocked" (item 17) until inserted pilot light illuminates
*−Turn back key switch slewing interlock" to normal position

− Switch over key switch parking" (item 14) to position I"

− Hoist jib until pilot light park position" (item 11) illuminates by pressing push button park position"
(item11) and keep it pressed during operation
− Lower lower hook−block carefully from its hook storage
− Lower jib and hook block into working range
− Turn back key switch parking" (item 14) to position 0"

ATTENTION !
The key switches
parking" (item 14) and
slewing interlock" (item 15)
may be operated by trained personnel only and the keys must be re
moved after process is finished !

The crane is ready for operation.

2.6.2. SHUT DOWN THE CRANE (FOR WORK BREAK)

−Move the jib and load the hook to a position, which will not endanger anyone on board.
−Press the motor off" push button

2.6.3. STARTING UP (AFTER A WORK BREAK)

−Press the motor on" push button
−Press push button "motor on"
−Wait until pilot light motor on" lights up
The crane is now ready to continue work.

979/2 −2.20−
 GENERAL DESCRIPTION

2.6.4. SHUT DOWN OF CRANE (FOR PARKING POSITION)

− Change key switch parking" (item 14) to position I"

− Hoist jib until pilot light park position" (item 11) illuminates
− Hoist lower hook−block carefully in its hook storage
− Lower jib to the rest position by pressing of push button park position" (item 11) until the move

ment jib down" stops.

. NOTE !
Following marked item ( with * ) are for crane no. 4 only!
*−Operate key switch slewing interlock" (item 15) to position I"
*−Turn the crane until it is in its interlock position (pilot light slewing interlock position" (item 16) illuminates)
*−Press push button park position locked" (item 18) until inserted pilot light illuminates
− Press push button motor off" (item 6)
− Switch off the main breaker by push button crane off" (item 9)
− Close firmly all windows and doors

ATTENTION !
The auxiliary supply (3 x 220V, 60 Hz) must remain switched on for
crane heating and standstill heating !

ATTENTION !
The key switches
parking" (item 14) and
slewing interlock" (item 15)
may be operated by trained personnel only and the keys must be re
moved after process is finished !

The crane is now ready for seagoing.

−2.21− 979/2
GENERAL DESCRIPTION

2.7. ADDITIONAL CRANE OPERATION

2.7.1. WORKING CAGE OPERATION

The working cage is used for hoisting rope exchange, greasing rope pulleys and maintenance purpose of
floodlight on jib head.

PREPARATION:

−Hoist hook−block in upper limit

−Turn key switch parking" (item 14) to position I"
−Lower the jib to the rest position 0_" by pressing push button park position" (item 11) until the movement
jib down" stops.

FOLLOWING CONTROL ELEMENTS ARE USED FOR OPERATION:

−Key switch working cage operation" (item 19) for preselection of auxiliary winch
−Pilot light ready" (item 21) which indicates ready for operation"
−Joy stick cage operaqtion" (item20) for aux. winch operation lifting" or lowering"

All control elements are situated on switch unit X20 refer to part 2.4.2.

OPERATION OF WORKING CAGE:

WARNING !
During working cage operation jib must be in park position
0_" and the
hook block in the upper limit !

−Turn switch working cage operation" to position I"

−Wait until pilot light Ready" illuminates
−Lower hoisting rope of auxiliary winch on deck with joy stick cage operation"
−Connect working cage on the hook
−Move working cage to required position for maintenance works at jib head
−After work is done lower working cage on deck
−Disconnect working cage
−Spool up hoisting rope of auxiliary winch with empty hook in its rest position (upper limit)
−Turn key switch working cage operation" to position 0" to switch off aux. winch
−Hoist jib into working range by pressing push button park position" (item 11)
−Turn key switch parking" (item 14) to position 0"

ATTENTION !
The key switches
parking" (item 14) and
working cage operation"
(item 19) may be operated by trained personnel only and the keys must
be removed after process is finished !

979/2 −2.22−
 MAINTENANCE

INDEX

3. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.1.1. MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.1.2. HIGH ADHESION LUBRICANT OR UNDERWATER GREASE . . . . . . . . . . . . . . . . . . . . . 3.3
3.1.3. DISPOSAL OF USED MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.2. SPECIAL SAFETY REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

3.2.1. GENERAL MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.2.2. FIRE AND EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
3.2.3. HANDLING AND DISPOSAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.2.4. LUBRICANTS AND OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.2.5. MAINTENANCE OF OIL COOLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.2.6. HYDRAULIC OIL FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8

3.3. MAINTENANCE OF HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 3.11

3.3.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.3.2. FILTER ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.3.3. HYDRAULIC FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.3.4. FLUSHING OF HYDRAULIC CIRCUIT AND PREFILLING THE PUMPS . . . . . . . . . . . . . 3.11
3.3.5. HYDRAULIC LINES AND HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
3.3.6. VALVE AND FILTER PLATE AGGREGATE ROOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3.3.7. RETURN FLOW FILTER HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

3.4. PRESSURE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

3.4.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
3.4.2. SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
3.4.3. ACCUMULATOR TYPES IN THE CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

3.5. LIEBHERR CONDITION MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16

3.5.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
3.5.2. TECHNIQUES EMPLOYED IN CONDITION MONITORING . . . . . . . . . . . . . . . . . . . . . . . 3.16
3.5.3. OIL SAMPLE / OIL EXCHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
3.5.4. TAKING AN OIL SAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
3.5.5. CONDITION MONITORING REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20

3.6. GEARBOXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21

3.6.1. SLEWING GEARBOXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
3.6.2. HOIST WINCH GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
3.6.3. AUXILLIARY HOIST WINCH GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24

3.7. MULTIPLE DISC BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25

3.8. INSTRUCTIONS FOR USE OF CRANE ROPES . . . . . . . . . . . . . . . . . . . . 3.26

3.8.1. SELECTION OF WIRE ROPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
3.8.2. ROPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
3.8.3. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
3.8.4. INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
3.8.5. INSTRUCTIONS FOR UNTWISTING OF HOIST ROPES . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
3.8.6. DISCARD CRITERIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29

−3.1− 979/2
MAINTENANCE

3.9. REPLACEMENT OF ROPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30

3.9.1. HOISTING WINCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
3.9.2. REEVING AUXILLIARY HOIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32

3.10. ROPE PULLEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

3.10.1. GENERAL LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
3.10.2. STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
3.10.3. TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
3.10.4. DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
3.10.5. INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
3.10.6. RESISTANCE TO CHEMICAL PRODUCTS OF LAMIGAMIDR ROPE PULLEYS . . . . . . 3.36

3.11. ROLLER SLEWING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37

3.12. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38

3.12.1. MAINTENANCE TO THE ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
3.12.2. WET CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38

3.13. MAINTENANCE INSTRUCTIONS FOR SLIP RING UNIT . . . . . . . . . . . . . 3.39

3.13.1. TERMINAL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
3.13.2. POWER SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
3.13.3. SIGNAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
3.13.4. CABLE INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39

3.14. LUBRICATION AND GREASING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . 3.40

3.15. MAINTENANCE LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41

3.15.1. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
3.15.2. OVERVIEW MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
3.15.3. FILLING QUANTITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
3.15.4. EVERY 10 HRS / DAILY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
3.15.5. EVERY 50 HRS / WEEKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
3.15.6. FIRST 100 HRS / AFTER 2 WEEKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47
3.15.7. EVERY 100 HRS / EVERY 2 WEEKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
3.15.8. FIRST 500 HRS / AFTER 3 MONTHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
3.15.9. EVERY 500 HRS / EVERY 3 MONTHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
3.15.10. FIRST 1000 HRS / AFTER 6 MONTHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55
3.15.11. EVERY 2000 HRS / EVERY YEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57

3.16. SERVICE SPARE−PARTS AND STANDARD TOOLS . . . . . . . . . . . . . . . . 3.59

3.16.1. HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59
3.16.2. HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59
3.16.3. WIRE ROPE HOISTING AND LUFFING WINCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59
3.16.4. LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.60
3.16.5. TESTING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.60
3.16.6. SEALING COMPOUNDS AND SECURING COMPOUNDS . . . . . . . . . . . . . . . . . . . . . . . . 3.60
3.16.7. STANDARD TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.60

TABLE OF LUBRICANTS

979/2 −3.2−
 MAINTENANCE

3. MAINTENANCE

3.1. GENERAL

Routine and preventive maintenance measures are essential for a safe and efficient operation of the crane.
Failure of adequate maintenance may result in costly, unscheduled breakdown and dangerous situations.
Cleanliness is required for the operation of the hydraulic system. Filters of any type as well as the hydraulic
oil have to be checked at appropriate intervals.
Periodical exchange of the oil used in the different gearboxes must be done.
All movable parts like winch bearings, hinge sections, rope pulleys, slewing bearing, ropes, doors, ventila

tion flaps etc. must always be greased.
For regular service intervals refer to attached maintenance list in section "MAINTENANCE LIST".

. IMPORTANT !
Special care must be taken when the crane is out of operation. The standstill heatings must be
on. Important pressures should be checked at extreme outside temperatures (e.g. feed pressure,
control pressure etc. It is necessary to check the hose armatures, which are mounted on the out

side of the crane and are exposed to the seawater, at regular intervals.

While greasing the bearings of the winches and the main slewing bearing ring, the winches as well
as the slewing ring has to be turned slowly to ensure an adequate grease distribution.

The maintenance intervals indicated in the maintenance list depend on the actual operating hours
of the crane. Should the crane be standing for more then a month, then the crane has to be oper

ated every month for at least two hours. In that time all the greasing, oil inspections and oil level
checks have to be done.

The crane has to be preserved, if not in operation for more than three months. Preservation instruc

tions are obtainable through the LIEBHERR service department.

The bolts of the main slewing bearing have to be kept greased after erection and regreased after
every inspection.

ATTENTION !
Switch off the heater inside the hydraulic oil tank before exchanging or
draining the oil !

3.1.1. MAINTENANCE INTERVALS

The maintenance intervals mentioned in the section MAINTENANCE LIST are guiding times and should be
observed.

3.1.2. HIGH ADHESION LUBRICANT OR UNDERWATER GREASE

Gear rim of main slewing bearing must always be greased

Ropes must always be greased

3.1.3. DISPOSAL OF USED MATERIALS

DISPOSAL !
WHEN CHANGING OIL AND GREASE, BATTERIES, ETC.−USED MATERIALS MUST BE PROP

ERLY DISPOSED OF IN ACCORDANCE WITH THE RELEVANT STATE REGULATIONS !
CONTAMINATION OF SOIL, SEWAGE AND WATER SYSTEMS MUST BE AVOIDED !

−3.3− 979/2
MAINTENANCE

3.2. SPECIAL SAFETY REGULATIONS

3.2.1. GENERAL MAINTENANCE SAFETY

−STUDY THE INSTRUCTION− AND MAINTENANCE MANUAL before operating or servicing the crane.
Make certain that you have additional information for special attachments of your crane, read it and under

stand it. IF IN DOUBT OR ANY INFORMATION REQUIRED, PLEASE CONTACT YOUR NEAREST LIEB

HERR SERVICE STATION (Contacts to LIEBHERR Service stations see SECTION 1 OF THIS MANUAL).

−ALLOW ONLY TRAINED AND AUTHORIZED PERSONNEL TO OPERATE, MAINTAIN, SERVICE OR RE

PAIR THE LIEBHERR DECK CRANE.

−WHEN MAKING REPLACEMENTS − USE ONLY ORIGINAL LIEBHERR SPARE PARTS ! THIS IS ABSO

LUTELY NECESSARY FOR OPERATING YOUR CRANE SAFELY.

−MAINTENANCE WORK SHOULD BE PERFORMED AS OUTLINED IN THE MAINTENANCE GUIDLINES

AND INTERVALS OF THIS MANUAL.

−PERFORM ONLY WORK YOU UNDERSTAND, USING THE MAINTENANCE MANUAL AND SPARE PART
MANUAL AS GUIDLINE.

−WEAR PROPER WORKING− AND SAFETY CLOTHING (coverall, safety boots, hard hat, safety glasses
and gloves, ear protection, etc.) WHEN PERFORMING SERVICE OR REPAIR WORK.
KNOW YOUR LOCAL SAFETY RULES AND REGULATIONS.

−KEEP UNAUTHORIZED PERSONNEL FROM THE CRANE WHEN PERFORMING MAINTENANCE− or

REPAIR WORK.

−BEFORE SERVICING THE CRANE, ATTACH A "DO NOT OPERATE" TAG ON THE ACCESS LADDER
AND THE CONTROL PANEL.

−DO NOT USE FLAMMABLE FLUIDS TO CLEAN THE CRANE.

−NEVER CHECK FOR LEAKS WITH YOUR BARE HANDS AND / OR WITHOUT SAFETY GLASSES.
Fluids escaping from a small hole can have enough force to penetrate skin.

−DO NOT DISCONNECT LINES or HOSES, FITTINGS, CAPS or COVERS WHILE THE HYDRAULIC
SYSTEM, ENGINE FUEL or COOLING SYSTEM is PRESSURIZED. ALWAYS LOWER A LOAD OR AT
TACHMENT TO GROUND FIRST − LOWER THE JIB AND TOWER INTO MAINTENANCE POSITION.
SHUT OFF THE MAIN MOTOR, AND RELEASE THE RESSURE FIRST. After servicing, ensure that all lines,
hoses and fittings are properly connected and all caps and covers are closed.

−DO NOT LIFT HEAVY COMPONENTS − USE PROPER LIFTING DEVICES SUCH AS CHAIN BLOCKS,
CRANES, etc.

−NEVER USE DAMAGED OR INSUFFICIENT WIRE ROPES, CHAINS AND SLINGS. Always wear
SAFETY GLOVES when handling wire ropes.

−NEVER USE METAL ON METAL SUPPORTS.

continued / ......

979/2 −3.4−
 MAINTENANCE
3.2.2. FIRE AND EXPLOSION PREVENTION

−WHEN PERFORMING HOT WORK (welding, etc.) ALWAYS HAVE A FIRE EXTINGUISHER ON
STAND−BY.

−NEVER STORE FLAMMABLE FLUIDS ON THE CRANE EXCEPT IN THE STORAGE TANKS
INSTALLED FOR THE CRANE OPERATION.

−FREQUENTLY CHECK THE ELECTRICAL SYSTEM AND CORRECT ALL WIRING DEFECTS.

−DO NOT USE FLAMMABLE MATERIALS / FLUIDS TO CLEAN THE CRANE.

−INSPECT PERIODICALLY ALL COMPONENTS, LINES, TUBES AND HOSES FOR EVENTUAL LEAK

AGES OR MECHANICAL DAMAGE. REPLACE OR REPAIR ANY DAMAGED COMPONENTS.
BE AWARE, OILLEAKS CAN CAUSE FIRES !

−KNOW THE LOCATION OF THE FIRE EXTINGUISHERS AND BE FAMILIAR WITH ITS OPERATION.

−3.5− 979/2
MAINTENANCE
3.2.3. HANDLING AND DISPOSAL INSTRUCTIONS

GENERAL

THE ENVIRONMENT IS OF GREAT IMPORTANCE TO LIEBHERR BOTH IN THE FAC

TORY DURING PRODUCTION OF OUR GOODS AND IN THE DESIGN OF OUR PRODUCTS.

−energy saving crane powering concept

−less pollutants, lower gasoline consumption, lower noise levels

HANDLING AND DISPOSAL INSTRUCTIONS

When chemical cleaning, testing compounds and lubricants are used, the pertinent danger and also han

dling information on the packing units is to be adhered to and appropriate protective devices to be used.

. IMPORTANT !
DO NOT USE FLAMMABLE FLUIDS TO CLEAN THE CRANE ! NEVER STORE FLAMMABLE OR
OTHER DANGEROUS FLUIDS / GOODS ON THE CRANE !

DANGERS

EXPLOSIVE POISONOUS

HIGHLY INFLAMMABLE NOXIOUS

FIRE SUPPORTIVE MATERIALS CORROSIVE, CAUSTIC

. IMPORTANT !
LUBRICANTS, PAINTS, THINNERS AND CLEANING COMPONENTS ARE TO BE STORED OR
PRESERVED ALWAYS IN CLOSED VESSELS.
NEVER STORE FLAMMABLE FLUIDS ON THE CRANE EXCEPT IN THE STORAGE TANKS
(HYDRAULIC OIL, etc.) INSTALLED FOR THE CRANE OPERATION.

ATTENTION !
FILLED UP AND LABELLED PACKING UNITS OF USED LUBRICANTS,
OLD PARTS, PAINTS, THINNERS AND CLEANING COMPONENTS TO BE
RETURNED UNDER MAXIMUM SAFETY AND IN COMPLIANCE TO
SPECIAL LOCAL RULES AND REGULATIONS TO YOUR NEXT DISPOSAL
DEPOSITION.

979/2 −3.6−
 MAINTENANCE
3.2.4. LUBRICANTS AND OILS

Should only be chosen from the TABLE OF LUBRICANTS, which is attached to the end of this section.
NOTE:
Since we know that the ordinary commercialized multi purpose greases do not always comply with the re

quirements of our cranes, we have developed a grease paste in close collaboration with our suppliers.
This new grease paste has, after extensive tests, proved to be very suitable for the best greasing of our
cranes and thus has been used for some time now in our factory for the greasing of cranes.
The working temperature of this grease paste range is from − 50°C to + 90°C. The grease paste is ex

tremely resistant to pressure, water, can easily be conveyed through grease pipes and has a very high drip

ping point.
We are pleased to offer this grease paste as follows:
1) for greasing with automatic grease gun:

AVIALITH 2EP special paste in buckets to 25 kg

2) for greasing with manual press:

AVIALITH 2EP special paste in cartridges to 400 g

3.2.5. MAINTENANCE OF OIL COOLERS

The cooling lamellas of the hydraulic oil cooler unit and winch gear oil cooler unit have to be FREE OF DIRT
to achieve the maximum cooling capacity.
Therefore the lamellas have to be inspected visually at least every week and cleaned if necessary.

3.2.5.1. CLEANING OF OIL COOLER UNIT

Depending on the kind of the dirt on the oil cooler unit the following methods may be used:
DRY DUST = > Clean with air pressure (max. pressure 10 bar)
WET DUST = > Clean with steam cleaner (max. pressure 150 bar)
OILY DUST = > Clean with steam cleaner (max. pressure 150 bar) and add solvent cleaner

. NOTE !
If in doubt of the correct cleaning method for a certain type of dirt, contact any LIEBHERR represen

tative for advice !

−3.7− 979/2
MAINTENANCE
3.2.6. HYDRAULIC OIL FILLING

Check the oil level at the inspection glass on the front wall of the hydraulic oil tank. The oil level should always
be between the MAXIMUM and MINIMUM mark.

. NOTE !
Jib must be in the jib rest, when checking hydraulic oil level !

Components at hydraulic tank:

1 2 3

Connection point
(Breather filter) for
KNF Vacuum−pump

6 7 8

1 Air breather 5 Inspection cover

2 Oil level and temperature sensor 6 Drainage cock
3 Flow back filter 7 Oil supply shut−off valve
4 Inspection glasses (oil level and temperature) 8 Tank heater

ATTENTION !
Keep SUCTION SHUT OFF VALVE open all the time ! Close ONLY for
inspection or service purpose. Before start−up of main motor check
open position of shut off valve !

979/2 −3.8−
 MAINTENANCE
HYDRAULIC OIL FILLING SYSTEM

LAYOUT:

Detail 1:

Hose connection 4
for tank filling

Hydraulic tank

Detail 2:

Supply hose Hose connection 3

for drainage

Detail 3:

Hose connection 2
for hydr. oil supply

Shut−off
valve

Hose connection 1
for external hydr. oil supply

−3.9− 979/2
MAINTENANCE
HYDRAULIC OIL FILLING PROCEDURE

ATTENTION !
Filling of tanks must be performed by two persons, one person checks oil
level, the other one must switch off oil supply when max. level at hydraulic tank
is reached !

−Connect supply hose to the provided hose connections 2 and 4 (see details )
−Connect external hydraulic oil supply to hose connection 1
−Open shut−off valve
−Fill hydraulic tank with hydraulic oil to upper level limit of oil sight glass (jib must be in rest position)
−Close shut−off valve when filling of tank is complete
−Remove external supply hose from hose connection 1
−Remove supply hose from hose connections 2 and 4
−Store supply hose to provided place (detail below) in base column

. NOTE !
COMBINE CONNECTIONS TO AVOID POLLUTION !

979/2 −3.10−
 MAINTENANCE

3.3. MAINTENANCE OF HYDRAULIC SYSTEM

3.3.1. GENERAL
The correct function of the hydraulic system depends on maintenance. The biggest problem is impurity of
the hydraulic oil. The checking of filters is very important and the renewing as well as the cleaning of filters
and oil should be carried out according to the maintenance list.

Check the hydraulic system daily for leakages.

3.3.2. FILTER ELEMENTS

Initially the filter cartridge must be exchanged after 100 working hours and then every 500 working
hours.
PRESSURE FILTER RETURN FLOW FILTER Filter cover
Electric or mechanic to be removed
dirt indicatior for exchange

Tank plate
Safety bypass valve Oil inlet
in case of dirty filter

Oil outlet Oil inlet

Filter element

Filter element

Oil outlet Oil outlet

Filter cover
to be removed
for exchange

3.3.3. HYDRAULIC FLUID

Change the oil initially after apporximately 500 working hours and then every 1500 working hours.
We recommend that a oil sample of the used hydraulic fluid (approx. 0,25 l), which has to be drawn from
the system (out of a filter), is submitted to the oil supplier for analysis. The oil supplier will inform you about
the condition of the oil and recommend a new time for an oil exchange.
Hydraulic oil cleanliness requirement code: 18/15 ISO 4406
9 NAS 1638
At first operation used hydraulic oil: FLUID ATF 66 M of AVIA (temp. range: −25°C to +45°C)

3.3.4. FLUSHING OF HYDRAULIC CIRCUIT AND PREFILLING THE PUMPS

It is necessary to flush the hydraulic circuits, if any dirt or solid particles have penetrated. This can occur
when a pump or motor is damaged or a valve or cylinder (ram) fails. Depending on the nature and extent
of the damage, flush thoroughly all affected pipes, filters and the hydraulic oil tank.

. IMPORTANT !
Before operating the crane after an oil exchange or an pump repair, all pumps and respective suc

ction lines must be prefilled with hydraulic oil !

−3.11− 979/2
MAINTENANCE
3.3.5. HYDRAULIC LINES AND HOSES
3.3.5.1. GENERAL

. IMPORTANT !
HYDRAULIC LINES, HOSES AND FITTINGS MAY NEVER BE REPAIRED !
Any damaged sections must be replaced immediately.

ATTENTION !
Pressurized oil can cause body injuries or fires !

3.3.5.2. STORAGE
Even when hoses and lines are installed, stored and used according to specification − they undergo a natu

ral aging process. For that reason, their service life is limited.
Improper storage, mechanical damage and improper use are the most frequent causes of hose fractures.

. NOTE !
USE ONLY ORIGINAL SPARE PARTS according to manufacturers specification.
For replacement to the units we recommend that you acquire the necessary knowledge first or you
ask for assistance / advise from your local LIEBHERR CUSTOMER SERVICE.

3.3.5.3. SERVICE LIFE

. NOTE !
THE SERVICE LIFE OF A HYDRAULIC HOSE MAY NOT EXCEED 6 YEARS, FROM THE DATE OF
THE LIEBHERR LABEL DATE ON THE HOSE CONNECTION. ADDITIONALLY CHECK THE
MANUFACTURES DATE ON THE HOSE. THE DATE BETWEEN THE MANUFACTURES DATE
AND THE DATE OF THE LIEBHERR LABEL SHOULD NOT EXCEED 2 YEARS.

3.3.5.4. INDICATION OF HOSES

Using hoses and lines close to the permitted working limit can shorten the service life (for example
at high temperatures, frequent working cycles, extreme high impulse frequencies, multi shift opera
tion or round the clock operations).
3.3.5.5. REPLACEMENT AND INSPECTION OF HOSES
Hoses and lines must be replaced if any of the following points are found during an inspection:
− Damage on the external layer into the inner layer (such as chaffing, cuts and rips)
− Brittleness of the outer layer (crack formation of the hose material)
− Changes in shape, which differ from the natural shape of the hose or line, when under pressure or
when not pressurized, or in bends and curves − such as separation of layers, blister or
bubble formation.
− Leakages
− Non observance of installation requirements
− Damage or deformation of hose fittings, which might reduce the strengths of the fitting or the
connection between hose and fitting
− Any movement of the hose away from the fitting
− Corrosion on fittings, which might reduce the function or the strength of the fitting
− Storage or service life has been exceeded

. NOTE !
To avoid excessive leaks a KNF VACUUM−PUMP could be connected to the hydraulic oil tank.
Route or install the hoses and lines properly. DO NOT MIX UP CONNECTIONS !

DISPOSAL !
USED MATERIALS MUST BE PROPERLY DISPOSED OF IN
ACCORDANCE WITH THE RELEVANT STATE REGULATIONS !

979/2 −3.12−
 MAINTENANCE
3.3.6. VALVE AND FILTER PLATE AGGREGATE ROOM

1 2

1 Filter sensor
2 Filter sensor
3 Filter ( A22 ) for oil cooling circuit
4 Filter ( A2 ) for feed pressure circuit
5 Oil tray

3
4

5
3.3.6.1. MAINTENANCE TO FILTERS

− During operation of the crane the filters are monitored

by the filter sensors installed on top of the filters.
− Check leaktightness, tight fit of sensor ( 1, 2 ) and clean the
oil tray ( 5 ) if required at appropriate intervals.
− Should one of the filter sensors indicate (red colour)
pressure filter clogged", the Filter element (insert)
has to be checked and to be replaced immediately.

3.3.6.2. REPLACEMENT OF FILTER ELEMENTS

− Lower the load / auxiliary equipment safe to ground and

shut off the main motor. Wait a few minutes till the
pressure is reduced to 0 bar.

WARNING !
Prior replacing the filter element (insert), wait until the pressure
reads 0 bar and all parts and the hydraulic oil are down to low
temperature.

− Unscrew the lower housing ( 1 ) gently by using a spanner

− Pull out gently used filter element ( 2 ) of the lower housing

− Drain the remaining hydr. oil of the lower housing
DISPOSAL !
USED MATERIALS MUST BE PROPERLY DISPOSED OF IN
ACCORDANCE WITH THE RELEVANT STATE REGULATIONS !

− Clean all parts carefully, check O−ring ( 4 ) for good condition (replace if required)
− Insert new filter element, check correct seat of O−ring ( 3, 4 )− and screw lower housing clockwise
(by hand only) to the upper part again.
− Tighten lower housing ( 1 ) gently with combination spanner clockwise (max. turn 30 − 45°), check
tight fit of filter sensor ( 5 ) .
− Start main motor − watch the filter sensors − check for tightness
of housing after appr. 5 minutes again.

−3.13− 979/2
MAINTENANCE
3.3.7. RETURN FLOW FILTER HYDRAULIC OIL TANK

1 2
ARRANGEMENT

1 Filter indication device:

green = satisfactory,
red = filter element blocked
2 Filter cover 3

3 Filter housing of Return flow filter A7

4 Hydraulic oil tank 4

3.3.7.1. MAINTENANCE TO RETURN FLOW FILTERS

1 2
− Check leaktightness, tight fit at appropriate intervals.
− Should the indication device reads red = filter element
clogged"
Filter element (insert) has to be checked and to be
3
replaced immediately (latest at next working brake).

3.3.7.2. REPLACEMENT OF FILTER ELEMENTS 6 4

7
− Lower the load / auxiliary equipment safe to ground and
shut off the main motor. Wait a few minutes till the 5
pressure is reduced to 0 bar.

WARNING !
Prior replacing the filter element (insert), wait until the
pressure reads 0 bar , all parts and the hydraulic oil are down
to low temperature. 9
1 screw, washer
− Remove the cover ( 2 ) gently 2 cover
by using a spanner for the screws (1) of adequate size. 3 sealing ring
4 magnet stick
− Pull out gently magnet piece (4) and tension spring (5),
5 tension spring
pressure piece (6), O−ring (7) and used filter element (8) of
the filter housing,Check the magnetic rod (there must be only 6 pressure piece
metal dust = normal abbrasion) 7 O−ring

DISPOSAL ! 8 filter element

USED MATERIALS MUST BE PROPERLY DISPOSED OF IN 9 filter housing
ACCORDANCE WITH THE RELEVANT STATE REGULATIONS !

− Clean all parts carefully (1 − 7, 9), check Sealing ring (3) and O−ring (7)
for good condition (replace damaged parts if required)
− Insert new filter element (8) into center of the filter housing, parts 7 − 4, check correct seat of sealing
ring and O−ring, screw the cover (2) onto the housing.
− Tighten all screws (1) on the cover plate with a spanner.
− Start the main motor − watch indication on the indication device − check for tightness
of cover after 5 minutes again.

979/2 −3.14−
 MAINTENANCE

3.4. PRESSURE ACCUMULATORS

3.4.1. GENERAL

For hydraulic accumulators, the relevant regulations at the place of installation must be adhered to prior to
commissioning and during operation.

3.4.2. SAFETY INSTRUCTIONS

−On no account should welding, soldering or any mechanical work be carried out on the accumulator shell.
−Work on systems with accumulators (repairs, connection of pressure gauges etc.) should only be carried
out once the pressure fluid has been drained out. Once the hydraulics have been connected, all air should
be completely vented.
−New or repaired accumulators must be charged with nitrogen prior to commissioning.
−Never use oxygen or air! Danger of explosion!
−If the accumulator is supplied already pre−charged with the requested gas charging pressure, the
pressure is marked.
−Note the limits of gas charging pressure and operating temperature!

3.4.3. ACCUMULATOR TYPES IN THE CRANE

. IMPORTANT !
TO ENSURE THE SAFETY OF THE LIFTING APPLIANCE THE PRESSURE ACCUMULATORS
HAVE TO BE CHECKED OR REPLACED EVERY TWO YEARS !

−3.15− 979/2
MAINTENANCE

3.5. LIEBHERR CONDITION MONITORING

3.5.1. GENERAL

The LIEBHERR CONDITION MONITORING system for major components in a crane (e.g. diesel engine,
distribution gear, winch gear etc.) relies on oil analysis.
Objectives: − Prevent major failure
− Reduce downtime
− Minimise repair cost.
The idea of condition monitoring by spectrometric analysis of used oils is not new, it was first used in preven

tative maintenance programmes to solve the problem of short engine life.
Economically it is therefore essential for crane owners/operators to be aware of abnormal conditions before
they become critical problems.
Condition monitoring through oil analysis is an excellent way to achieve this in units such as engines, trans

missions and other oil filled systems.

3.5.2. TECHNIQUES EMPLOYED IN CONDITION MONITORING

Condition monitoring involves monitoring wear metals and physical parameters. Comprehensive and reli

able programmes are made up of three parts:
a) spectroscopic metal analysis
b) physical and chemical oil tests
c) Interpretation and diagnosis of data
Specific oil tests and spectrometric metal analysis are necessary to evaluate the true machine and oil condi

tion.
The ideal combination of tests are given below, with the information to be gained from each. It will be evident
that the purposes of the tests tend to overlap other tests. This is deliberate action, to ensure results of one
test is confirmed by data from another. The work is repeated if this is not the case.
Used tests:
− Wear and additive metal analysis
− Viscosity
− Fuel dilution
− Oil condition index OCI
− Dispersancy
− Water/Glycol/Antifreeze
− Environmetal dirt
− Total base number
− Particle count

979/2 −3.16−
 MAINTENANCE
3.5.2.1. SPECTROSCOPIC METAL ANALYSIS AND SIGNIFICANCE

Metals determined Significance

Barium Additive metals
Calcium Oil type
Magnesium contamination by other oil
Zinc Additive metals
Sodium Additive metals
Silicon Coolant contamination
Aluminium Upper cylinder and bearing, wear accessory drives, thrust
washers
Chromium Ring and seal wear, hydraulic rod wear
Molybdenum Additive metal, ring and seal wear
Copper bearing and bushing wear, thrust washers and clutch discs,
cooler and turbo wear
Lead Bearing and cooler wear, corrosion, petrol contamination
Tin Bearing and liner wear
Manganese Wear to steel components
Titanium Environmental contamination in special cases
Nickel compressor tube wear, special steel component wear, fuel
contamination
Silver Bearing and liner wear in special cases
Vanadium Valve stem wear, special steel component wear, fuel contami

nation
The level of wear metals used to assess abnormal conditions differ for each engine or unit type, indeed they
differ slightly for particular units of one type.
The information required must, therefore, be built−up for each unit by regular monitoring. Nevertheless,
regular condition monitoring on a particular machine ultimately relies, not on the actual metallic values, but
on sudden increases from the average.

3.5.2.2. VISCOSITY

The viscosity of the oil is important for its performance. It depends very much on the working conditions (e.g.
temperature) and the time the oil has been in use. A viscosity change of 10 % is considered abnormal.

3.5.2.3. FUEL DILUTION

This is measured by either distillation or flash point. This test is essential to detect over rich mixtures, faulty
injector systems and leaking pipework etc. An excess of fuel can lead to poor lubrication and excessive wear
or failure. 5 % is considered abnormal.

3.5.2.4. OIL CONDITION INDEX OCI

The OCI is a measure of the conductivity of the oil. It indicates the concentration of soot and other conducting
materials present in the sample, e.g. water and metal particles. An arbitrary scal of 0−40 is used. A value
of 10−12 is typical of new oils and values up to 28 are typical of used oils in good condition. Higher values
indicate a problem may exist. Again to establish the cause of an increase in the OCI value, other tests must
be carried out.

−3.17− 979/2
MAINTENANCE
3.5.2.5. DISPERSANCY

This is relevant to engine oils only, and is simply assessed by the blotter spot method.
Engine oils contain detergents and dispersants to disperse soot and other insoluble carbon residues
throughout the oil. If insufficient is present the solids will coagulate to form sludges. These will tend to block
passage ways etc. and prevent lubrication of vital components.
Generally, an even distribution of soot is a good sign and a non−even distribution is a poor sign. This in

formation is used with the other data to assess the condition of the oil.

3.5.2.6. GLYCOL − ANTIFREEZE − WATER

Where water is detected it is measured by distillation or other means to establish its concentration. More
than 0.2% is considered significat. Having established water is present, it is necessary to identify its origin.
The options include:
1. Coolant contamination
2. Condensation
3. supply tank contamination

3.5.2.7. ENVIRONMENTAL DIRT

The third major cause of engine or machine failure is dirt contamination. It acts as an abrasive on pistons
rings, liners and bearings, etc. to cause severe problems.

3.5.2.8. TOTAL BASE NUMBER

To protect the crankcase from acid attack by corrosive acids produced in the combustion chamber, the lubri

cant contains a degree of reserve alkalinity. This reserve alkalinity is expressed as mg of KoH/gm of oil and
is described as the Total Base Number (TBN). It is measured by one of two methods adopted by the Institute
of Petroleum under the numbers IP177 and IP276 . The TBN is a measure of the neturalizing properties of
the oil.

3.5.3. OIL SAMPLE / OIL EXCHANGE

3.5.3.1. GENERAL

The FIRST OIL EXCHANGE has to be performed as stated in the MAINTENANCE LIST of the crane. This
oil exchange can not be delayed as at the "start up" period of any engine or transmission higher contamina

tion of the oil can occur. NO OIL SAMPLE IS TAKEN !

3.5.3.2. SAMPLING PERIODS

AFTER the FIRST OIL EXCHANGE the sampling periods are the same as the in the MAINTENANCE LIST
required oil exchange periods for that specific engine or transmission.

3.5.3.3. OIL EXCHANGE

NO SAMPLE HAS BEEN TAKEN: The oil has to be exchanged as stated in the crane’s MAINTE

NANCE LIST
SAMPLE HAS BEEN TAKEN: The CONDITION MONITORING REPORT will tell, if:
− the oil is still in good condition and no exchange is needed
− another sample is required
− the oil has to be exchanged
− further actions are required

979/2 −3.18−
 MAINTENANCE
3.5.4. TAKING AN OIL SAMPLE

3.5.4.1. GENERAL

For taking an oil sample a special PLASTIC SYRINGE−CUM−BOTTLE−KIT is avialable:

LIEBHERR Id. No.: 885601814
The kit consists of: − Plastic syringe / bottle to take and contain the sample
− 1,5 m of plastic tubing for easier access of the oil
− Postal carton
− Sample information form to state all important data about the oil and the unit
is was used in.

syringe
plunger tall
nozzled cap
to fit syringe

LABORATORY
LIEBHERR

plastic tube

blank cap
of syringe

PLASTIC
SYRINGE / SAMPLE
BOTTLE PLASTIC TUBE POSTAL CARTON INFORMATION FORM

3.5.4.2. HOW TO TAKE A REPRESENTATIVE OIL SAMPLE

−Ensure the engine or other units has been working for at least 15 minutes just prior to taking the sample.
−To obtain from the DRAIN PLUG allow about a quarter litre oil to empty away before holding the sampling
vessel under the free flowing oil stream.
−Drain approx. 200 ml of oil into the sampling vessel
−Close the drainage hole again and check the oil level of that system − refill if necessary
−Connect the nozzled cap with the tube to the syringe
−Shorten the plastic tube to the minimum needed lenght
−Hold the free end of the plastic tube into the sampling vessel and fill the syringe with the sampling oil by
pulling its plunger, while holding the syringe vertically with the nozzle pointing upwards.
−If the oil stops flowing before the syringe is full, loosen the cap and gently push the oil level to the top.
Re−tighten the cap and continue drawing the oil.
−When the syringe is full, discard the nozzled cap, tubing and plunger tall (twist−off). fit the blank cap
tightly.
−Fill in the provided SAMPLE INFORMATION FORM (completely !)
−Put the SAMPLE INFORMATION FORM toghether with the SYRINGE / BOTTLE into the POSTAL CARTON
−Send it to the the in section ADRESS stated adress

−3.19− 979/2
MAINTENANCE
3.5.4.3. SAMPLING POINTS (EXAMPLES)

HYDRAULIC OIL TANK SLEWING GEAR

SYRINGE

SYRINGE

HOISTING WINCH

SAMPLING VESSEL

SYRINGE

SAMPLING VESSEL

3.5.4.4. POST ADDRESS

LABORATORY: LLANDUDNO
GWYNEDD LL30 1SA
UNITED KINGDOM

3.5.5. CONDITION MONITORING REPORT

The results of the oil sample examination are all stated in the CONDITION MONITORING REPORT which
is sent to the in the SAMPLE INFORMATION FORM stated address. In this report a diagnosis of the oil sample
is given as well as a advice for further action.
Four different symbols are indicated to signalize the main action:

INDICATES Normal

INDICATES High result reading obtained, submit second sample for recheck

INDICATES Change oil as indicated

INDICATES Action required as indicated

979/2 −3.20−
 MAINTENANCE

3.6. GEARBOXES

3.6.1. SLEWING GEARBOXES

Each slewing gearbox has a splash lubrication system.

Before setting into operation fill in gear oil (oil types see "TABLE OF LUBRICANTS", which is attached to
the end of this section.)
The oil change is made by using the marked points of the figure below (oil quantities and intervals see
MAINTENANCE LIST).
The oil level inspection can be carried out by the provided oilsight glass.
The correct oil level is in the middle of the oil sight glass.

. IMPORTANT !
Check oil level only, if the crane is shut down.
1

1 Hydraulic motor
2 Gear oil filling and air release of gear 3
3 Multi disc brake
4 Oil sight glass
5 Slewing gear box 4
6 Drainage plug
5
7 Protection cover
8 Slewing pinion (engaged to gear rim
of slewing bearing)

ATTENTION:
Before assembling motor,
fill brake with 0,2 l hydraulic 7
oil ATF

Recommendation for service

Oil change should be carried out at the working temperature of the gearbox.
It is recommended to flush the gear with a little preheated new oil. In this way any abrasives and contamina

tion can be washed off.

−3.21− 979/2
MAINTENANCE
3.6.2. HOIST WINCH GEARBOX

There is one main winch gearbox used in the crane.

It has a splash lubrication system.
Before setting into operation fill in gear oil (oil types see "TABLE OF LUBRICANTS", which is attached to
the end of this section.)
The oil change is made by using the marked points of the figure below.(oil quantities and intervals see
MAINTENANCE LIST)
Remove the breather plug when exchanging the oil, but don’t forget to put it on again after the oil exchange.
The oil level inspection can be carried out by the provided dip stick on the side of the winch drum. For the
inspection do screw−in dipstick.

. NOTE !
The MAXIMUM OIL LEVEL in a winch gearbox should be up to center line only, however check
for correct level with provided DIPSTICK.
Check oil level only, if the crane is shut down.

LAYOUT OF WINCH: 1
2

5 6

1 Rope drum
2 Air breather
3 Dipstick and gear oil filling
4 Winch frame
5 Gearoil drainage
6 Flange for hydr. motores

Recommendation for service

Oil change should be carried out at the working temperature of the gearbox.
It is recommended to flush the gear with a little preheated new oil. In this way any abrasives and contamina

tion can be washed off.

979/2 −3.22−
 MAINTENANCE

ROPE KICKER (DEFLECTOR):

. NOTE !
Following maintenance works must be performed every 500 operations hours or every three
months.

− Check wear and if neccessary remove chaffing from rope kicker

− Check if screws are in counter sunk position (Detail 1)

Detail 1
Detail 2

Rope
Rope
kicker
drum

In case of excessive wear exchange rope kicker to avoid damages of the hoisting rope

. NOTE !
When mounting new rope kicker check, if in correct alignment (Detail 2)

−3.23− 979/2
MAINTENANCE
3.6.3. AUXILLIARY HOIST WINCH GEARBOX

There is one aux. winch gearbox used in the crane.

It has a splash lubrication system.
Before setting into operation fill in gear oil (oil types see "TABLE OF LUBRICANTS", which is attached to
the end of this section.)
The oil change is made by using the marked points of the figure below.(oil quantities and intervals see
MAINTENANCE LIST)
Remove the breather plug when exchanging the oil, but don’t forget to put it on again after the oil exchange.

LAYOUT OF WINCH:

1 2

3 4 5

1 Gear oil filling

2 Rope fix point
3 Gearoil drainage plug at the rope drum
4 Gearoil drainage plug at at the drive
5 Breather
6 E−motor

Recommendation for service

Oil change should be carried out at the working temperature of the gearbox.
It is recommended to flush the gear with a little preheated new oil. In this way any abrasives and contamina

tion can be washed off.

979/2 −3.24−
 MAINTENANCE

3.7. INSTRUCTIONS FOR USE OF CRANE ROPES

3.7.1. SELECTION OF WIRE ROPES

Rope constructions listed in this crane manual have been chosen after extensive testing. They provide the
best possible match between crane and rope characteristics. Based on many years of experience these
ropes guarantee an optimal crane performance. Characteristics of ropes, although of equal standard, may
vary considerably if rope construction, number of strands or tensile strength is modified − even if offering
equal rotation resistant properties.

WARNING !
If ropes are exchanged only use ropes of the same construction and
tensile strength as the original rope. Should it be necessary to use a
different rope crane manufacturer must be contacted for consent.

Max. actual rope diameter must be 4 %, in the case of hoist ropes for truck mounted cranes exceeding 25
mm dia. it should be max. 3 %, above the nominal diameter. A right−hand rope is to be mounted on a left−
hand drum and vice versa. If reeved in multi layers a Lang’s lay rope provides better wear resistant properties
than a regular lay rope.

3.7.2. ROPE INSTALLATION

Wire ropes are easily affected by external damage, i.e. they must be handled with utmost care during trans

port and unloading. All wire ropes should be stored clean, dry and cool, soil contact must be excluded.
Only an installation of an untwisted rope free of any outer damage will guarantee a trouble−free operation.
Ropes always must be uncoiled from the reel or the ring in the direction of winding (picture 1). Lateral uncoil

ing causes the rope to be twisted until its total destruction by kink formation.
It is recommended to use a frame−mounted reel for coiling the rope on the drum (picture 2). Coiling in the
direction of bend prevents additional tension build−up in the rope and results in an excellent fit of the rope
on the drum. Never drag ropes through soil or dirt.
For the installation the new rope is fixed to the old rope still mounted or it is to be fixed to a auxiliary rope.
Connection between the two ropes can be achieved either by a basket or two welded eyes. Any transmis

sion of torsion from either the old or the auxiliary rope to the new rope must be definitively excluded. Rota

tion−resistant ropes must be protected from torsion by inserted swivels.
Multi−layer reeving requires that even the lower layers must be tightly coiled with a pretension of 1 − 2 %
of minimum breaking load of the rope. This pretension is achieved by braking the reel.
For multi strand reeving hoisting rope and drum should have the same direction. If it is required to spread
out a limited rope length on the floor for mounting the rope into the crane block it is important to avoid any
twist or torsion in the rope.
Non−rotation free ropes may be used with fixed points at both ends only.
A test−run of several lifts under partial load and later with alternately loaded and unloaded crane block is
required. Thus a flexible adaptation of the rope to bending direction and bending radii of pulleys and drum
will be achieved.

PICTURE 1
RIGHT WRONG

PICTURE 2
RIGHT WRONG
REEL REEL
DRUM DRUM

−3.25− 979/2
MAINTENANCE
3.7.3. MAINTENANCE

Maintenance at regular intervals guarantees safe crane operation and considerably increases rope life. Wire
ropes must be regreased at regular intervals according to crane operation, this especially applies to the
bending zones at the drums and pulleys. When exposed to the same test condition a well−greased rope
has shown four times as many working cycles than an ungreased rope. Relubricants must be compatible
with the original lubricant used.
The following lubricants are recommended:
All standard lubricants recommended by the crane manufacturer for open gears
Special lubricants like e.g.:Texaco Novatex Grease EP2, Rocol RD 105, Aral Aralub LFZ1
For ropes being reeved in multiple layers and therefore being exposed to extreme wear use of graph
ite containing lubricants is recommended like e.g.: Reiner Ceplattyn KG 10, Texaco Novatex FK 10
Heavily soiled wire ropes have to be cleaned regularly with a brush. If the lower layers on the drum are sel

domly used or not used at all, ropes have to be unreeled from time to time and then have to be reinstalled
under prestress. A rope operates most economical when used in its whole length. Therefore it is recom

mended to always use the appropriate rope length according to crane operation; this is mainly true if crane
is operated continously for a long period of time.
If a rope is unequally loaded it may be reversed. The formerly free end is fixed in the drum by positioning
unworn zones at zones mostly exposed to wear thus rope life can be extended considerably.
If wear mainly occurs if rope is multi−layer reeved on the Lebus drum, rope life may be increased by cut

ting−off one length according to 1/3 of drum circumference. This procedure can be repeated up to three
times per rope.

3.7.4. INSPECTION

Wire ropes have been dimensioned to provide sufficient safety margins after the occurence of first signs of
a wire breakage before a replacement of the rope is required. The ropes have to be inspected in regular
intervals; especially in the time period following directly after its installation. In addition special attention is
required if a rope has been exposed to excessive wear, if non−visible damage is supected or if there are
other indications for rope damage.
The following criteria for a safe operation of the ropes can be applied:
− type and number of wire breakages (see table)
− position and time sequence of the wire breakages
− decrease of rope diameter
− corrosion, abrasion, deformation
− heat−effects
− length of period of running
First signs of a change in rope behaviour must be carefully monitored.

ATTENTION !
A twisting and waving of strands above the crane block can be an in
dication for a severly damaged rope. This twisting/waving is caused al
ways by an additional torsion in the rotation−resistant hoisting rope
originating from a number of adverse effects but may also be due to
an overstretching of the hoist rope during heavy duty operation or due
to shockloads resp. tearing on sticky container in hold. The torsion has
to be untwisted at the rope fixpoint and requires extreme care and re
spective know−how. Therefore inspection is necessary at regular in
tervals especially shortly after the new rope has been installed.

Untwisting of crane pulley block with rotation−stable rope fixed point:

− Set down of pulley block
− Determine direction of twist.
− Detach rope from fixpoint and turn rope at the end approx. 180 − 360° into the direction which compen−
sates the twisting resp. waving of the rope.
− Connect rope at fixpoint and carefully lift pulley block, operate crane unloaded with pulley block and also
with crane trolley if present
− Repeat if necessary

979/2 −3.26−
 MAINTENANCE

. IMPORTANT !
Make sure that twist is distributed to a long free rope end. By operating the crane in unloaded con

dition twist is to be distributed to the entire rope length. By operating the crane in unloaded condi

tion twist is to be distributed to the entire rope length. By no means forcefully twist a short length
of rope; this may permanently damage rope structure.
If the hoisting rope was operated with open swivel an untwisting can be achieved by operating the trolley
several times under no load conditions and with unloaded hook. If not successful, follow same procedure
given for ropes with fixed point, e.g. if crane does not provide of a swivel, if rope is predamaged or if causes
of twist can not be remedied otherwise. At the same time a regular check of all rope end terminations and
suspensions for proper function is required. Individual components of rope drive unit, drums and pulleys
must turn freely in their bearings. Grooves should not show any rope marks. Minimum groove radius on
drums and pulleys should be 0,53 x nominal rope diameter.

3.7.5. INSTRUCTIONS FOR UNTWISTING OF HOIST ROPES

1) Twisting of a multi−reeved crane block may be due to a number of causes. Any faults in the rope drive
must be eliminated, the load/stretch torsion will "seat in" after some time of rope operation.
2) If a hoist rope is operated with open swivel an untwisting by several runs with unloaded hook will be suffi

cient in most cases. If this procedure prooves to be ineffective refer to the instructions given for compensa

tion of twist for ropes with rotation− stable fixed point, e.g. − if no swivel is provided
− if the rope is predamaged or
− if the causes of the twist can’t be eliminated.
3) Determination of direction of twist
At first the direction of the twist of the crane pulley block must be determined. Pictures 1 and 2 show a pos

sible twist of a right hand lay rope, on picture 3 + 4 of a left hand lay rope. In the right hand corner of each
picture a sketch shows the occurence of multiple twist. The respective direction of twist is indicated by a
continously drawn arrow printed in boldface. If it is difficult to identify the direction of twist for large hoisting
heights turn rope in direction of arrow with dashed line once thus eliminating "braid". For compensation turn
rope end shown separately in the direction of the continous arrow. It is important that the correct reference
point is selected i.e. the crane operator must hold the rope in front of himself.
The direction of untwist can be determined also by simulating this situation by simply using a string.

4) Untwisting of crane pulley block with rotation−stable rope fixed point:

− Set down of pulley block
− Determine direction of twist
− Detach rope at fixed point
− Carefully turn rope at free end of at least 15 m length up to max. 180 − 360 degrees to compensate
pulley block twist
− Reattach rope at the fixed point
− Carefully lift pulley block and operate unloaded crane with pulley block and jib
− Repeat if necessary

. IMPORTANT !
Make sure that twist is distributed to a long free rope end. By operating the crane in unloaded con

dition twist is to be distributed to the entire rope length. By no means forcefully twist a short length
of rope; this may permanently damage rope structure.

−3.27− 979/2
MAINTENANCE
3.7.6. DISCARD CRITERIA

Warning for safety reasons crane ropes have

to be discarded if showing one of the following
criteria:
− Break of one strand
− Accumulation of wire breaks
− Number of wire breaks as defined in table
− Corkscrew−type deformations of more than
1/3 rope diameter (pict. 1)
− Basketlike distortions Picture 1
− Hair−pin type extrusion of wire or groups of
wire (pict. 3)
− Decrease of rope diameter by 15 % against
nominal diameter of rope or
− by 10 % if there are signs of corrosion and / or
abrasion (pict. 4)
− Loosening of rope structure (pict. 4)
− Local decrease of rope diameter (pict. 5) Picture 2
− Bends and local crushing (pict. 6 + 8)
− Kinks or resulting permanent deformations
(pict. 7)
If special rope damage is found, the cause has to
be determined and eliminated before a new rope
will be installed. Damage or stress markings at
crane components provide valuable information
for possible causes of rope damage. Picture 3

If in doubt discard rope or consult expert for fur

ther assistance.

Picture 4

Picture 5

Picture 6

Picture 8 Picture 7

979/2 −3.28−
 MAINTENANCE

3.8. ROLLER SLEWING RING

The roller slewing ring connects the base column with the crane. It is equipped with hardened roller tracks
and absorbes all vertical and horizontal forces as well as the tilt moment occuring during operation. The ring
is attached by means of high tensile bolts. The pretension load for these bolts is shown on the sketch below.
The gear ring and the slewing pinion, which engages with the slewing ring are housed within the crane su

perstructure and protected against seewater.

Sealed with
SIKAFLEX
all around

2
7
3

5
4

Pretensioning load: 665 KN

Pretensioning acc. to working−instruction: QSA 09.601.00−xx

Pretension jacking tool: LWN 2−17−028 Idt.−No. 519618714

1 Steel structure of slewing column

2 Outer bolt
3 Roller slewing bearing. Grease every 100 working hours
4 Protection cap (filled with grease)
5 Inner bolt
6 Grease nipple of roller slewing ring
7 Gear rim of roller slewing ring. Keep greased all the time !

. IMPORTANT !
Gear rim (Pos 7): to be greased, we recommend to use GREASE SP−F AVIA ALUPLEX 2 RHY

. IMPORTANT !
Bolts (Pos 2+5): thread greased, use no MOLYCOTES or GRAPHITIZED GREASES !

−3.29− 979/2
MAINTENANCE

3.9. MULTIPLE DISC BRAKES

GENERAL:
The spring loaded multiple disc brakes on our machines are used as HOLDING BRAKES ONLY, as the slow
down of any movement is done by the hydraulic system. Therfore they are subject to very little wear. The
brakes are only on high wear, in the case of an EMERGENCY STOP SITUATION with full load. In this case
the mulitple disc brake of the winch(es) must be inspected and checked for proper function.
The maximum holding moment of a respective machine or drive is determined by the various arrangements
of the disks and springs in these brakes.

WARNING !
For this reason, the arrangement and layout of the multi−disc−brake must
always be exact and special caution must always be exercised, when re

pairs are carried out or when brakes are replaced. Only an exact arrange

ment protects the drives from overloading as well as guaranteeing the maxi

mum holding moment !

THE PROPER ARRANGEMENT OF THE DISCS AND SPRINGS IN THE BRAKES FOR THE WINCHES
AS WELL AS FOR THE SLEWING GEAR ARE SHOWN IN THE CROSS SECTION DRAWINGS IN THE
SPARE − PARTS − LIST OF THIS CRANE !

PRINCIPLE BRAKE LAYOUT:

1 Piston 12
2 Housing 11
3 Hydraulic pressure connection
1
4 Brake disc with outer gear rim (AL)
5 Brake disc with inner gear rim (IL) 10
6 Discs bracket
7 Leak oil connection 2
8 Friction faces (RFL)
9 Outer seal 9 3

10 Inner seal
11 Outer spring for brake force (AF) 4
12 Inner spring for brake force (IF) 8
HYDRAULIC MOTOR
1 2 5
12 11

ÉÉ Ç Ç ÇÉÉ
ÇÇ É
ÉÉ Ç Ç ÇÉÉ
ÇÇ É
ÉÉÉ
ÇÇÇÇÇÇ
3
Ç ÇÉÉ
ÇÇ É 4

ÉÉÉ ÇÇÇ
ÉÉÉ
Ç Ç
ÉÉ
ÇÇ
ÇÇÇ
ÉÉ
ÇÇ É 7

ÇÇÇ
ÇÇÇÇÇÉÉÉ
ÉÉÉ
ÉÉ
ÇÇ
ÇÇÇ
ÇÇ
ÉÉ
ÇÇÇ
ÇÇÇ ÇÇÇ
6

8 5 4
GEAR−BOX

979/2 −7.78−
 MAINTENANCE

3.10. REPLACEMENT OF ROPES

3.10.1. HOISTING WINCH

See also drawing ROPE REEVING PLAN in section DRAWINGS.

. NOTE ! ONLY QUALIFIED AND AUTHORIZED SERVICE PERSONS ARE ALLOWED

TO PERFORM MAINTENANCE OR SERVICE TO THE CRANE !

. IMPORTANT !
PRIOR STARTING TO REPLACE THE ROPES READ CAREFULLY SECTION
INSTRUCTIONS
FOR USE OF CRANE ROPES" (INSTALLATION, MAINTENANCE, INSPECTION, ETC.).
ALWAYS LOWER THE JIB INTO ITS REST POSITION FOR SAFETY REASONS !
− Always use adequate safety equipment (safety boots, safety gloves, hard hat)
− Disconnect auxiliary devices and lower the jib into its rest position (refer to part 2)
− It is advisable to discard the old rope first and install the new one afterwards
− Put hook block on deck and secure hoisting rope at rope fix point 1.
− Sufficient slack rope is required to allow disconnecting the rope from rope fix point 1.
− Use an auxilliary rope to lower hoisting rope to deck
− Drive hoisting winch in direction lowering until lower limit switch tripped to pull off the old rope to the
front (sufficient space is required). Watch the rope on the drum.
− Bypass now the lower limit switch lowering".

. IMPORTANT !
BYPASSING OF SAFETY DEVICES ( LIMIT SWITCHES, ETC. ) FOR SERVICE PURPOSES ONLY−
TO BE PERFORMED BY QUALIFIED AND TRAINED PERSONAL !
− Continue spooling off the old rope until rope fix point 2
− Secure the rope at rope fix point 2
− Release hoisting rope from rope fix point 2 and connect a cable pulling strap (chinese fingers) on the
rope
− Connect an auxiliary standard ’nylon rope’ of adequate strength and length to the cable pulling strap
− Pull off the old hoisting rope to the front
− Disconnect the old rope from the cable pulling strap and connect new rope instead
− Use the auxiliary rope (nylon rope) and the pulling strap again to pull the new wire rope correctly into
the system.

. NOTE !
Any transmission of torsion from the auxiliary rope to the new rope must be definitively excluded.
Rotation−resistant ropes must be protected from torsion by inserted swivels.
− Secure the rope next to the drum
− connect the new rope to the rope fix points 1 and 2, pull the rope onto the drum till three (3) safety
windings are on the drum, adjust (check) limit switch lowering".
− First a test−run of several lifts under unloaded load and partial load is required. Thus a flexible
adaptation of the rope to bending direction and bending radii of pulleys and drum will be achieved.
Check correct adjustments and function of all limit switches and all rope protection devices !

. IMPORTANT !
CHECK ALL SAFTY DEVICES AND LIMIT SWITCHES AFTER EACH REPLACEMENT OF ROPES!

−3.31− 979/2
MAINTENANCE
3.10.1.1. REEVING 4−FALL OPERATION

Rope sheaves
at jib head

Rope fix point 1

Rope, righthanded,
Ø 25 mm
l = 315 m

rope pulling strap

(chinese finger)

Hook
block
Hoisting
winch TAPE for safety
reasons

Rope fix point 2

3.10.1.2. ROPE FIX POINT 2 (HOISTING WINCH)

TIGHTENING TORQUE 210 Nm

BOLT GRADE M16 8.8
THREAD GREASED, USE NO MOLYKOTE
OR GRAPHITIZED GREASES

. IMPORTANT !
AFTER THE FIRST TEST−RUN OF SEVERAL LIFTS CHECK ROPE FIX POINTS, ROPE PULLEYS
AND ROPE PROTECTION DEVICES AGAIN !

. NOTE !
SHOULD YOU HAVE ANY QUESTIONS RELATING TO OPERATION, SERVICE, REPAIRS
OR PARTS OF THE WINCH SYSTEM INSTALLED ON YOUR CRANE, PLEASE CONTACT
THE LIEBHERR CUSTOMER SERVICE.

979/2 −3.32−
 MAINTENANCE
3.10.2. REEVING AUXILLIARY HOIST

See also drawing REEVING PLAN AUX. HOIST in section DRAWINGS.

. IMPORTANT !
ONLY QUALIFIED AND AUTHORIZED SERVICE PERSONS ARE ALLOWED TO PERFORM
MAINTENANCE OR SERVICE TO THE CRANE !

. IMPORTANT !
PRIOR STARTING TO REPLACE THE ROPES READ CAREFULLY SECTION
INSTRUCTIONS
FOR USE OF CRANE ROPES" (INSTALLATION, MAINTENANCE, INSPECTION, ETC.).
ALWAYS LOWER THE JIB INTO ITS REST POSITION FOR SAFETY REASONS !

− Always use adequate safety equipment (safety boots, safety gloves, hard hat)
− Disconnect auxiliary devices (working cage) and lower the jib into its rest position
− It is advisable to discard the old rope first and install the new one afterwards
− Put hook on deck
− Drive aux. hoisting winch in direction lowering until lower limit switch tripped to pull off the old rope
to the front (sufficient space is required). Watch the rope on the drum.
− Bypass now the lower limit switch lowering".

. IMPORTANT !
BYPASSING OF SAFETY DEVICES ( LIMIT SWITCHES, ETC. ) FOR SERVICE PURPOSES ONLY−
TO BE PERFORMED BY QUALIFIED AND TRAINED PERSONAL !
− Continue spooling off the old rope until rope fix point
− Secure the rope at rope fix point next to the drum
− Release hoisting rope from rope fix point and connect a cable pulling strap (chinese fingers) on
the rope
− Connect an auxiliary standard ’nylon rope’ of adequate strength and length to the cable pulling strap
− Pull off the old hoisting rope to the front
− Disconnect the old rope from the cable pulling strap and connect new rope instead
− Use the auxiliary rope (nylon rope) and the pulling strap again to pull the new wire rope correctly into
the system.

. NOTE !
Any transmission of torsion from the auxiliary rope to the new rope must be definitively excluded.
Rotation−resistant ropes must be protected from torsion by inserted swivels.
− Secure the rope next to the drum
− Connect the new rope to the rope fix point, pull the rope onto the drum till three (3) safety
windings are on the drum, adjust (check) limit switch lowering".
− First a test−run of several lifts under unloaded load and partial load is required. Thus a flexible
adaptation of the rope to bending direction and bending radii of pulleys and drum will be achieved.
Check correct adjustments and function of all limit switches and all rope protection devices !

. IMPORTANT !
CHECK ALL SAFTY DEVICES AND LIMIT SWITCHES AFTER EACH REPLACEMENT OF ROPES!

−3.33− 979/2
MAINTENANCE
3.10.2.1. LAYOUT OF REEVING

Rope fix point

(outside the drum)

Cam limit switch

Rope, righthanded,
Ø 10 mm
l = 30 m

Hook

3.10.2.2. ROPE FIX POINT

. IMPORTANT !
AFTER THE FIRST TEST−RUN OF SEVERAL LIFTS CHECK ROPE FIX POINT AND ROPE
PROTECTION DEVICES AGAIN !

. NOTE !
SHOULD YOU HAVE ANY QUESTIONS RELATING TO OPERATION, SERVICE, REPAIRS
OR PARTS OF THE WINCH SYSTEM INSTALLED ON YOUR CRANE, PLEASE CONTACT
THE LIEBHERR CUSTOMER SERVICE.

979/2 −3.34−
 MAINTENANCE

3.11. ROPE PULLEYS

3.11.1. GENERAL LAYOUT

Rope pulleys are constructed and manufactured as a result of many years of experience and knowledge
of expectations and requirements of heavy machinery.

Smooth and reliable running of the equipment can however, only to be obtained if regular maintenance and
care is given. Adhering to regular service intervals and use of correct lubricants as per the lubricants chart
are also part of this. Special tools are not required for servicing.
All rope pulleys are designed with large diameters and with anti−friction bearings.

steel rope pulley / sheave LAMIGAMIDR rope pulley / sheave

grease nippel

1 1

3 2

2 3
lubrication lubrication
groove groove

1 Rope pulley / sheave

2 Anti−friction bearing
3 Circlip

3.11.2. STORAGE

Rope pulleys in storage should be kept away from steam or hot water pipes, heated air ducts or any other
source of heat, which can thin out lubricant and cause it to drain out of the rope pulley.
When storing rope pulleys − the following rule should be applied: FIRST IN − FIRST OUT. That means the
rope pulleys should be used in the order of delivery. In this way it can be avoided that certain rope pulleys
are only put into service after being stored for many years.

3.11.3. TRANSPORT

Rope pulleys are easily affected by external damage, i.e. they must be handled with utmost care during
transport and unloading.

−3.35− 979/2
MAINTENANCE
3.11.4. DURING OPERATION

Rope pulleys are easily affected by external damage, i.e. they never should rub against the provided rope
guard device, never to be layed down to ground without proper protection device. Thus could cause exces

sive wear to the components or even damaging the pulleys.
Damaged pulleys must be replaced immediately.

inexpert resting of hook block ! inexpert resting of jib tip !

broken ! worn out cable groove !

3.11.5. INSPECTION AND MAINTENANCE

The rope pulleys have to be inspected in regular intervals; especially in the time period following directly
after its installation. In addition special attention is required, if a rope has been exposed to excessive wear,
if non−visible damage is suspected or if there are other indications for damage.

. NOTE !
HEAVILY DIRTY OR SOILED WIRE ROPES HAVE TO BE CLEANED REGULARLY !

The frequency of rope pulley inspection is influenced by:

− Statutory requirements
− Type of appliance
− Operational environmental conditions
− Method and frequency of operation
− Manufacturer’s recommendations
− Results of previous inspections
− Experience with previous rope pulleys on the appliance or system

979/2 −3.36−
 MAINTENANCE
Service intervals:

Smooth and reliable running of the equipment can however, only to be obtained if regular maintenance and
care is given. Adhering to regular service intervals and use of correct lubricants as per the lubricants chart
are also part of this. Special tools are not required for servicing.

ANTI −FRICTION BEARINGS OF the rope pulleys must be regreased at regular intervals according to crane
operation. Individual components of rope pulleys must turn freely in their bearings.

GROOVES should not show any rope marks.

At the same time a REGULAR CHECK OF THE ROPES for proper function, cleanless and sufficient lubrica

tion is required.

. NOTE !
AFTER FIRST 100 HRS ALL PULLEYS HAVE TO BE CHECKED FOR SMOOTH AND RELIABLE
RUNNING, CORRECT FIT OF ROPE PROTECTION AND OTHER SECURING DEVICES.

THE MINIMUM REQUIREMENT FOR MAINTENANCE / CHECK UP IS EVERY 500 HRS, IF THE
CRANE IS NOT OPERATED AT LEAST TWICE PER YEAR FOR ANY MECHANICAL DAMAGES,
LUBRICATION CONNECTIONS AND CONDITION.

. NOTE !
ENSURE THAT THE GREASE DOES ESCAPE FROM / BETWEEN THE ROPE PULLEYS AT LEAST
EVERY 500 WORKING HOURS.

. NOTE !
CHECK THE WEAR OF THE ROPE GROOVE, FIRST SIGNS OF A CHANGE IN THE ROPE’S
BEHAVIOR OR THE PULLEY ITSELF MUST BE CAREFULLY MONITORED !

CHECK THE PULLEYS GROOVE PROFILE AT LEAST EVERY 500 WORKING HOURS.

At this point we also do recommend to study carefully the INSTRUCTIONS FOR USE OF CRANE ROPES".

3.11.6. RESISTANCE TO CHEMICAL PRODUCTS OF LAMIGAMIDR ROPE PULLEYS

For cleaning of LAMIGAMIDR rope pulleys various benzin may be used. However, the PULLEYS SHOULD
NOT BE CLEANED OR GET IN TOUCH WITH THE FOLLOWING CHEMICALS OR CHEMICAL COM
POUNDS:

RESISTANT FOR

− Petroleum, benzin, kerosin, diesel fuel

LIMITED RESISTANT

− alcohol except ethyl−, methyl− and propyl alcohol

− anorganic chlorides, such as calcium, lithium−, magnesium− and zincchloride

NOT RESISTANT AGAINST

− concentrated mineral acids (i.e. sulphuric acid, hydrochlorid acid, nitric acid)
− concentrated organic acids (i.e. formic acid)
− concentrated alkalines (i.e. sodium, potash lye or caustic potash)
− phenolic resin, phenolic plastic

−3.37− 979/2
MAINTENANCE

3.12. ELECTRICAL SYSTEM

3.12.1. MAINTENANCE TO THE ELECTRICAL SYSTEM

Maintenance of the electrical system is largely restricted to changing fuses and bulbs, if blown and cleaning
the filters on the switch cabinet. The filter on the switch cabinet fan should be renewed or cleaned approxi

mately every 3000 working hours.

. NOTE !
CLEAN DUST FILTERS ON THE SWITCH CABINETS EVERY 3000 OPERATING HOURS. RE

PLACE DAMAGED OR CONTAMINATED FILTERS IMMEDIATELY.

. NOTE !
BLOWN FUSES OR INDICATION LAMPS HAVE TO BE REPLACED IMMEDIATELY.

All screws and bolts used for or with electrical equipment should be retightened in regular intervals. (see
MAINTENANCE LIST)

ATTENTION !
ALL ELECTRIC SAFETY EQUIPMENT (E.G LIMIT SWITCHES, EMER

GENCY STOP BUTTONS ETC.) SHOULD BE CHECKED IN REGULAR IN

TERVALS AS WELL TO ENSURE A SAFE OPERATION OF THE CRANE.
(SEE MAINTENANCE LIST)

WARNING !
BEFORE OPENING ANY ELECTRIC EQUIPMENT, it is essential to
SWITCH OFF THE POWER SUPPLY.

3.12.2. WET CLEANING

Wet cleaning of the switch box or switch gear is not allowed !

When washing or steam cleaning the crane or components − close all terminal− and switch boxes in order
to prevent water from entering !

979/2 −3.38−
 MAINTENANCE

3.13. MAINTENANCE INSTRUCTIONS FOR SLIP RING UNIT

The slip ring is installed between SLEWING COLUMN and the PEDESTAL ADAPTOR.

. NOTE ! ONLY QUALIFIED AND AUTHORIZED SERVICE PERSONS ARE ALLOWED

TO PERFORM MAINTENANCE OR SERVICE TO THE SYSTEM !

3.13.1. TERMINAL BOX

Every 500 hours a tightness test of a random sample of the terminal clamp screws should be carried out.

3.13.2. POWER SECTION

Due to the low turning speed and the hardness of carbon brushes, the brushes have a relatively long life.
They must be checked every 1500 hours or latest every 6 months, and must be changed in good time
so that it never happens that a metal part of the brush holder touches the slip ring.
During this check it is also necessary to clean any carbon dust from the insulating barriers between the slip

ring ways so as to avoid creeping current. Every 500 hours a random sample of the screw connections
of the copper bus bars should be checked for tightness.

3.13.3. SIGNAL SECTION

The 16 Amp. circuits are fitted with nickel plated and gold plated copper−beryllium wire brushes and with
nickel plated and gold plated sliprings. About every 1000 hours or latest every 6 months the insulating
barriers between the slip−ring ways should be cleaned of metal particles.
To reduce wear the slip−ring ways should be lightly sprayed with a contact oil such as Cramolin B".
A random sample of the terminal screws for the terminals of the cables from the copper−beryllium wire
brushes should be checked for tightness.
The carbon brush blocks must be checked according to point 2 mentioned above.

3.13.4. CABLE INSULATION

The cables have to be checked for any damages in insulation when carrying out an inspection.
When cables connected to the slipring or have to be replaced always asure that the insulation to be kept
as short as possible.

. NOTE !
SHOULD YOU HAVE ANY QUESTIONS RELATING TO OPERATION, SERVICE, REPAIRS
OR PARTS FOR THE SLIP RING INSTALLED ON THE CRANE, PLEASE CONTACT
THE LIEBHERR CUSTOMER SERVICE.

−3.39− 979/2
 3.14.

979/2
MAINTENANCE

−3.40−
HYDRAULIC OIL
LUBRICATION AND GREASING DIAGRAM

GEAR OIL

GREASING
DOORS AND HATCHES − GREASE AS WELL !

GREASING POINTS INSIDE OF THE CRANE

 MAINTENANCE

3.15. MAINTENANCE LISTS

3.15.1. GENERAL INFORMATION

The maintenance intervals mentioned in this section are guiding times and should be observed.

If due to extreme environmental conditions (i.e. dust, tropical conditions) or extreme operational conditions
(i.e. multiple shift operation) a deviation to the given maintenance interval(s) should become necessary, ask
your local LIEBHERR CUSTOMER SERVICE for advice and confirmation to do so.

. NOTE !
IT SHOULD BE NOTED THAT IN PARTICULAR THE MAINTENANCE TIME INTERVALS
INDICATED ARE APPROXIMATE. IN REALITY THESE INTERVALS SHOULD DEPEND
ON CRANE USAGE AND THEREFORE − MAY NEED TO BE UPDATED ACCORDINGLY.

. IMPORTANT !
The maintenance intervals indicated in the maintenance list are based on the
ACTUAL OPERATING HOURS OF THE CRANE. Should the crane be standing for a period of
more then four ( 4 ) weeks − the crane has to be operated ONCE A MONTH FOR AT LEAST
TWO ( 2 ) HOURS. In addition to that all the greasing, oil inspections and oil level checks have
to be done as well.

3.15.2. OVERVIEW MAINTENANCE INTERVALS

FIRST 100 HRS resp. AFTER 2 WEEKS

FIRST 500 HRS resp. AFTER 10 WEEKS
FIRST 1000 HRS resp. AFTER 6 MONTHS

EVERY 10 HRS resp. DAILY

EVERY 50 HRS resp. WEEKLY
EVERY 500 HRS resp. EVERY 3 MONTHS
operating hours counter
EVERY 2000 HRS resp. EVERY YEAR (switch box X1)

Maintenance / Service shall be supervised by LIEBHERR SERVICE TECHNICIAN

Maintenance / Service shall be carried out by LIEBHERR SERVICE TECHNICIAN

3.15.2.1. DISPOSAL OF USED MATERIALS

DISPOSAL !
When changing oil, grease, filter elements, batteries, etc. − used materials must be properly
disposed of in accordance with the relevant state regulations.
Contamination of soil, sewage and water systems must be avoided !

−3.41− 979/2
MAINTENANCE
3.15.2.2. QUALIFIED PERSONS

PERSONS RESPONSIBLE FOR THE SAFETY OF THE CRANE MUST ENSURE THAT:
− qualified persons are only delegated to work on the machinery or apparatus,
− these persons must keep the Operating− and Maintenance Instructions provided, and other documents,
available when carrying out the operations to which they refer and to follow that documentation without fail,
− unauthorised persons are prohibited from working on, or approaching, the machinery or apparatus.
Qualified persons are persons who, as a result of their training, experience and the instruction they have
received, and of their knowledge of the relevant Standards, directives, accident prevention regulations and
operating conditions, have been authorised by those responsible for the safety of the machine to carry out
the particular task required and who are able to recognise and avoid the potential hazards. A knowledge
of first−aid and local rescue equipment is essential. According to regulations, unqualified personnel are
forbidden to work for example on power installations and apparatus.

3.15.3. FILLING QUANTITIES

3 x 11,2 l
FILLING
1050 l

QUANTITIES, appr.

0,6 l
( liter )
6l
− − −

WINCH FOR WORKING CAGE

GEAR RIM SLEWING RING

SLEWING GEAR BOX

GREASING POINTS
HOISTING WINCH
HYDR. OIL TANK

SYSTEM

ROPES

Type of OIL
ATF or simular

SAE, HDC or sim.

GREASE

AVIALITH 2EP
SP−F AVIA
ALUPLEX 2
Ca.−grease EP

... OIL ...GREASE

. NOTE !
See also details provided in section MAINTENANCE for each individual function group and
TABLE OF LUBRICANTS !

979/2 −3.42−
 MAINTENANCE
3.15.4. EVERY 10 HRS / DAILY

EVERY 10 HRS / DAILY CBW

Function Group Work to be performed see Section

GEAR RIM OF MAIN Check condition, greasing 3.11
SLEWING BEARING

ROPES Check condition, lubricants, function 3.8

HYDRAULIC SYSTEM Checking leaktightness and condition 3.2.6, 3.3.5

(hoses, pipes, fittings), check oil level.

CONTROL PANELS Check function and correct indication 2.4

of all control devices

EMERGENCY STOP’s Check correct function

LIMIT SWITCHES Check correct function

(hoisting gears, luffing gear)

Operating hours:

. NOTE !
PRIOR STARTING UP CRANE OPERATION PERFORM FUNCTION TEST
OF HOISTING, SLEWING, LUFFING − INCLUDING LIMIT SWITCHES !

Date: Name: Signature:

−3.43− 979/2
MAINTENANCE

979/2 −3.44−
 MAINTENANCE
3.15.5. EVERY 50 HRS / WEEKLY

EVERY 50 HRS / WEEKLY CBW

Function Group Work to be performed see Section

CRANE COMPLETE Visual check of all greasing lines, 3.1, 3.2, 3.14
greasing points, regrease as required

HOISTING WINCH Check gear oil level, grease counter− 3.6.2

bearing

SLEWING GEAR BOXES Check gear oil level 3.6.1

MAIN SENSORS Check cables and plug connection

(pressure−, temperature− and level
sensors)

ROPES Check condition and rope fix−points 3.8

Operating hours:

. NOTE !
WHEN REGREASING − STOP GREASING SOON AS NEW GREASE
APPEARS FROM SEALINGS.

Date: Name: Signature:

−3.45− 979/2
MAINTENANCE

979/2 −3.46−
 MAINTENANCE
3.15.6. FIRST 100 HRS / AFTER 2 WEEKS

FIRST 100 HRS / AFTER 2 WEEKS CBW

Function Group Work to be performed see Section

ROLLER SLEWING RING Grease roller bearing 3.11

FEED PRESSURE FILTER Replace filter element 3.3, 3.3.2

OIL COOLER FILTER Replace filter element 3.3, 3.3.2
RETURN FLOW FILTER Replace filter element 3.3, 3.3.2

Operating hours:
Shall be supervised by LIEBHERR SERVICE TECHNICIAN

Shall be carried out by LIEBHERR SERVICE TECHNICIAN

. NOTE !
TEST ALL FUNCTIONS
CHECK COMPLETENESS OF SAFETY DEVICES.

Date: Name: Signature:

−3.47− 979/2
MAINTENANCE

979/2 −3.48−
 MAINTENANCE
3.15.7. EVERY 100 HRS / EVERY 2 WEEKS

EVERY 100 HRS / EVERY 2 WEEKS CBW

Function Group Work to be performed see Section

ROLLER SLEWING RING Grease roller bearing 3.11

Operating hours:
Shall be supervised by LIEBHERR SERVICE TECHNICIAN

Shall be carried out by LIEBHERR SERVICE TECHNICIAN

. NOTE !
TEST ALL FUNCTIONS
CHECK COMPLETENESS OF SAFETY DEVICES.

Date: Name: Signature:

−3.49− 979/2
MAINTENANCE

979/2 −3.50−
 MAINTENANCE
3.15.8. FIRST 500 HRS / AFTER 3 MONTHS

FIRST 500 HRS / AFTER 3 MONTHS CBW

Function Group Work to be performed see Section

CRANE COMPLETE Checking for tight fit of all nuts, bolts 3.1, 3.2
brackets, ladders, platforms
GREASING SYSTEM Regrease all grease points ! 3.14

HYDRAULIC SYSTEM Drive system to working temperature 3.2.6, 3.5

Take oil sample, if required change oil;
drain oil, clean complete tank inside
FEED PRESSURE FILTER Replace filter element 3.3, 3.3.2
OIL COOLER FILTER Replace filter element 3.3, 3.3.2
RETURN FLOW FILTER Replace filter element 3.3, 3.3.2
PRESSURE ADJUSTMENTS Check pressures, adjustments if required

HOISTING WINCH Drive to temperature, 3.6, 3.6.2

SLEWING GEAR BOXES take oil samples, if required renew oil 3.6, 3.6.1
to correct level. Before fitting new oil
flush the gear boxes with a little pre−
heated new oil in order to wash off any
abrasives / contamination
Check level after a short while again.
ROPES Check condition and rope fix−points 3.8
ROPE PULLEYS Check for any damages / wear 3.10
HOOK BLOCK Regrease greasing points 3.11
ELECTRIC SYSTEM Check correct fit of cables, sensors.
LIGHTING SYSTEM Check for completeness, correct function
SLIP RING UNIT Check screw connections, brushes 3.13
CONTROL PANELS Check all functions and correct indication 2.4
FUNCTION TEST Drive all functions, check safety devices
Operating hours:
Shall be supervised by LIEBHERR SERVICE TECHNICIAN

Shall be carried out by LIEBHERR SERVICE TECHNICIAN

. NOTE !
− FOR QUANTITIES OF OILS see section
Filling Quantities ( 3.15.3 )

− LUBRICANTS AND OILS should only be chosen from TABLE OF LUBRICANTS

Date: Name: Signature:

−3.51− 979/2
MAINTENANCE

979/2 −3.52−
 MAINTENANCE
3.15.9. EVERY 500 HRS / EVERY 3 MONTHS

EVERY 500 HRS / EVERY 3 MONTHS CBW

Function Group Work to be performed see Section

CRANE COMPLETE Visual check−up of steel structure, 3.1, 3.2
welds, brackets, ladders, platforms

ELECTRIC SYSTEM Check cable connections, sensors

HOISTING WINCH Check for correct oil level, 3.6.2

SLEWING GEAR BOXES Check air breathers 3.6.1

GREASING SYSTEM Regrease all greasing points, 3.14

Check tightness of greasing lines / blocks

ROPES Check condition and rope fix−points 3.8, 3.9

ROPE PULLEYS Check for any damages / wear 3.10

LIGHTING SYSTEM Check for completeness, correct function

SLIP RING UNIT Check screw connections, brushes, 3.13

grease bearings
CONTROL PANELS Check all functions and correct indication 2.4

HYDRAULIC SYSTEM Drive system to working temperature 3.2.6, 3.5

Check oil level, Take oil sample
Check leaktightness, clean radiator
RETURN FLOW FILTER Replace filter element 3.3, 3.3.2
FEED PRESSURE FILTER Replace filter element 3.3, 3.3.2
OIL COOLER FILTER Replace filter element 3.3, 3.3.2

FUNCTION TEST Drive all functions, check safety devices

Operating hours:

. NOTE !
FOR QUANTITIES OF OILS see section
FILLING QUANTITIES" (3.15.3)

Date: Name: Signature:

−3.53− 979/2
MAINTENANCE

979/2 −3.54−
 MAINTENANCE
3.15.10. FIRST 1000 HRS / AFTER 6 MONTHS

FIRST 1000 HRS / AFTER 6 MONTHS CBW

Function Group Work to be performed see Section

HOISTING WINCH take oil sample on all gearboxes 3.6, 3.6.2

SLEWING GEAR BOX Check for correct oil level, 3.6, 3.6.1
Check air breathers

SWITCH CABINET X1 Check all terminals, ventilation

JUNCTION BOXES Check all terminals, tightness

CONTROL PANNELS Check all functions and correct indication 2.4

Operating hours:
Shall be supervised by LIEBHERR SERVICE TECHNICIAN

Shall be carried out by LIEBHERR SERVICE TECHNICIAN

. NOTE !
− FOR QUANTITIES OF OILS see section
FILLING QUANTITIES" (3.15.3)

− LUBRICANTS AND OILS should only be chosen from TABLE OF LUBRICANTS

Date: Name: Signature:

−3.55− 979/2
MAINTENANCE

979/2 −3.56−
 MAINTENANCE
3.15.11. EVERY 2000 HRS / EVERY YEAR

EVERY 2000 HRS / EVERY YEAR CBW

Function Group Work to be performed see Section
ROLLER SLEWING RING Check correct torque of bolts 3.11

HOISTING WINCH Drive to temperature, 3.6, 3.6.2

SLEWING GEAR BOXES take oil samples, if required renew oil 3.6, 3.6.1
to correct level. Before fitting new oil
flush the gear boxes with a little pre−
heated new oil in order to wash off any
abrasives / contamination
Check level after a short while again.

HYDRAULIC MOTORS Check wear of tooth profile

HYDRAULIC SYSTEM Drive system to working temperature 3.2.6, 3.5

Take oil sample, if required change oil;
Check leaktightness

PRESSURE ADJUSTMENTS Check pressures, adjustments if required

HYDRAULIC OIL TANK Replace air breather filter 3.3.7, 3.16.2

ELECTRIC SYSTEM Check cable connections, sensors

Replace air filter element switch cabinet

PRESSURE ACCUMULATOR Replace (check) every 2 years 3.4

ROPES Check ropes for fatigue 3.8

Operating hours:
Shall be supervised by LIEBHERR SERVICE TECHNICIAN

Shall be carried out by LIEBHERR SERVICE TECHNICIAN

. NOTE !
− FOR QUANTITIES OF OILS see section
FILLING QUANTITIES" (3.15.3)

− LUBRICANTS AND OILS should only be chosen from TABLE OF LUBRICANTS

Date: Name: Signature:

−3.57− 979/2
MAINTENANCE

979/2 −3.58−
 MAINTENANCE

3.16. SERVICE SPARE−PARTS AND STANDARD TOOLS

A comprehensive spare part list is provided for reference when ordering spare parts or replacements. The
drawings reproduced in the spare part manual are for the purpose to assist in identifying spare parts, they
need not necessarily agree exactly with the actual constructional details of the parts involved. In order to
avoid mistakes, it is advisable to use only the terms and expressions used in the these instructions.

It is particularly important that spare part orders should include the following information:

−CRANE TYPE and CRANE SERIAL NUMBER

−LIEBHERR IDENT−NUMBER of each single spare part
−QUANTITY of parts required
−BRIEF DESCRIPTION of parts required
Careful attention to correct ordering is always important as omission of essential information will inevitably
cause delay and may even lead to incorrect parts being supplied.
In order to avoid any delay we kindly ask to provide additionally following details:

−YOUR PURCHASE ORDER− OR REFERENCE NUMBER

−DELIVERY ADDRESS
−DELIVERY MODE
−YOUR CONTACTS (Address, Telephone No., Fax No.)

3.16.1. HYDRAULIC CIRCUIT

QTY. IDENT−No. DESCRIPTION NOTE

1 510658514 Filter element (A2 − feed pressure circuit) 500 hrs

1 510658514 Filter element (A22 − oil cooler circuit) 500 hrs

3.16.2. HYDRAULIC OIL TANK

QTY.. IDENT−No. DESCRIPTION NOTE

1 736877003 Filter element (A27 − return flow filter) 500 hrs

1 510713814 Filter element for air breather 2000 hrs

3.16.3. WIRE ROPE HOISTING AND LUFFING WINCH

QTY.. IDENT−No. DESCRIPTION NOTE

1 790223014 Hoist rope, right handed, galvan., diam. 25 mm, l = 315 m *

1 790218114 Aux. winch rope, right handed, galvan., diam. 10 mm, l = 30 m *

* for maintenance and discard criteria see section "ROPES"

−3.59− 979/2
MAINTENANCE
3.16.4. LUBRICANTS

QTY. IDENT−No. DESCRIPTION

1 861301214 AVIALITH 2EP special paste in tins to 400 g (manual gr. gun)
1 861301508 AVIA ALUPLEX 2RHY grease paste in tins 10 kg
(for greasing of gear rims)
1 774324203 Grease nipple DIN 71412 AM 10x1
1 774324403 Grease nipple DIN 71412 CM 10x1

For other products, type and specification see enclosed "LIEBHERR TABLE OF LUBRICANTS".

3.16.5. TESTING DEVICE

QTY. IDENT−No. DESCRIPTION

1 750001114 Glycerine pressure gauge 0 − 60 bar

1 750003414 Glycerine pressure gauge 0 − 400 bar
1 510694314 Connection fitting for pressure gauge 1620
20 885601814 Plastic syringe−cum−bottle−kit (Condition monitoring) *

* one sample each for winch gear boxes, slewing gear boxes,
distribution gearbox and hydraulic oil tank

3.16.6. SEALING COMPOUNDS AND SECURING COMPOUNDS

QTY. IDENT−No. DESCRIPTION

1 870002014 Hylomar (for protection of screws, fittings, etc. installed outside)

1 870001814 Dirko (high temperature resistant sealing compound)
1 726425414 Sealing compound ‘SIKAFLEX‘ in tins to 310 ml
1 811202114 Loctite 242, 50 ccm
1 862819203 Loctite 243, 250 ccm
1 870001914 Loctite 572, 50 ccm
1 870002114 Loctite 574, 250 ccm
1 870002314 Loctite 586, 250 ccm
1 870002414 Loctite 405, 50 ccm

3.16.7. STANDARD TOOLS

QTY. IDENT−No. DESCRIPTION

1 926365114 COMPLETE TOOL SET (STANDARD) INCL. TOOL BOX

1 790042514 TOOL BOX 530 x 20, blue
1 740814815 KNF−Vacuumpump complete with connection devices

. NOTE !
ALL STANDARD TOOLS SUPPLIED WITH THE CRANE ARE QUALITY TOOLS ACCORDING TO
DIN−STANDARDS.

A COMPLETE LIST UP OF STANDARD SUPPLIED TOOLS, ADDITIONAL SAFETY DEVICES, etc.

IS PROVIDED IN THE SPARE PART MANUAL.

. NOTE !
ALL SPARE PARTS SEE SPARE PART BOOK

979/2 −3.60−
Schmierstofftabelle
für
LIEBHERR
Schiffs- und Containerkrane
Offshorekrane
Seilbagger
Hafen-Mobilkrane

Table of lubricants
for
LIEBHERR
Ship- and Container-Cranes
Offshore-Cranes
Cable Excavators
Harbour Mobile Cranes

1/6
LIEBHERR - Werk Nenzing GmbH

A-6710 Nenzing / Austria

Telefon 0043 - (0) 5525 - 606-0
Telefax 0043 - (0) 5525 - 606-20

LIEBHERR Sunderland Works

Ayres Quay, Deptford Terrace

Sunderland
Tyne and Wear, SR4 6DD
England / UK
Telefon 0044 - (0)191 - 514-3001
Telefax 0044 - (0)191 - 514-4191

2/6
Schmierstoffanforderungen / requirements of lubricants

Nummer Schmierstellen
Außentemperatur Typ / Type Spezifikation
Number Lubrication Points
Outside-temperature ISO VG / SAE Specification

1. Motor / Engine1) ganzjährig / all the year SAE 15W-40 ACEA E2 / E3

bis / to - 10 °C API CD / CE / CF-4
2. Ölbadluftfilter bis / to - 20 °C SAE 10W-40 MIL-L-2104 C/D
Oilbath air cleaner (SHPD)
3. Mechan. Getriebe und Winden bis / to - 20 °C SAE 90 API GL-5
Mechan. gearboxes and winches MIL-L-2105 B

4. Antriebsachsen bis / to - 25 °C SAE 80W-90

Axles SAE 80W-140
5. Hydrostatischer Antrieb bis / to - 25 °C ATF3) 1. Typ A, Suffix A
Hydrostatic transmission 2. DEXRON II D/E
3. DEXRON III
6. Hydrolenkung ganzjährig / all the year ACEA E2 / E3
Power steering bis / to -20 °C2) SAE 10W-40 API CD / CE / CF-4
MIL-L-2104 C/D
bis / to -10 °C2) SAE 15W-40
7. bis / to - 15 °C2) ISO VG 46 DIN 51 524/2
Typ HLP / HLPD
8. bis / to -25 °C2) ISO VG 46 VDMA 24 568 / Typ HEES
schnell biologisch abbaubar
quickly biodegradable
9. Wälzlager - Anti-friction bearings, alle Bereiche Mehrzweckfett DIN 51 825, NLGI 2
Gleitlager - Plain bearings all sections Lithium verseift KP 2 K-30
Kugel- bzw. Rollendrehkränze Multipurposegrease KPE 2 K-30
Ball resp. Roller shewing rings, Lithium based
Kardangelenke - cardan shafts,
sonstige Fettschmierung
other greasing points
10. Offene Zahnräder und Zahnkränze alle Bereiche Schmier- und Konservierungsmittel DIN 51 502
Open gears and geared rims all sections Lubricant and preservative OGPF 0, -1, -2
11. Seile5) alle Bereiche Schmierfett + EP (Calzium) DIN 51825, NLGI 2
Ropes5) all sections Lubricating grease + EP (Calcium) KP 2 G-30
12. Schmierstellen ü. Schmierleitungen alle Bereiche Spezialfett (Lithium) DIN 51 502, NLGI 00
Points greased through pipes all sections Special grease (Lithium) MPE 00 E-40

1) Die Vorschriften des Motorenherstellers ( siehe Betriebsanleitung ) sind verbindlich! / The instructions of the manufacturer are obligatory ( pay attention to the manual )!
2) Bei laufender Stillstandsheizung können die Außentemperaturen um ca. 15 °C tiefer liegen. / With heating of crane in operation outside temperatures could be appr. 15 °C
lower.
3) Für Seilbaggerhydraulik zwingend vorgeschrieben / For cable excavator hydraulics strictly applied
4) Schnell biologisch abbaubar / quickly biodegradable
5) Siehe auch Betriebsanleitung ! / See also the operating manual!

3/6
LIEBHERR Für die Schmierung unserer Schiffs- und Containerkrane, Offshorekrane, Seilbagger und Hafen-Mobilkrane empfehlen wir die
nachstehend aufgeführten oder nachweislich gleichwertigen Betriebsstoffe.

We recommend the following products or those of proven equivalent quality for use when lubricating our Ship- and Container-
Cranes, Offshore-Cranes, Cable Excavators and Harbour Mobile Cranes.
Nummer
Number

Agip BLITUM T Aral Multi Turboral SAE AVIA MULTI HDC PLUS Vanellus C 3 Extra Castrol Turbomax Chevron RPM Heavy Duty ELF PERFORMANCE
1. Agip SIGMA TURBO 15W-40 AVIA MULTI HDC EXTRA Vanellus Multigrad Castrol RX Super Plus Motor Oil SAE 15W-40 TROPHY 15W-40
Aral Plus Turboral SAE 15W/40 *) Chevron Delo 400 PERFORMANCE 3 D
Agip MULTIFLEET AVIA MULTI HDC 15W-40
15W-40 Multigrade SAE 15W-40 15W-40
Agip PROFI
PERFORMANCE XR
15W-40
Agip SIGMA TFE Aral Extra Turboral SAE AVIA TURBOSYNTH HT-E Vanellus HT Extra Castrol RX Super 15W/40 Chevron RPM Heavy Duty ELF ECOMAX FE PLUS
2. Agip SIGMA SUPER TFE 10W-40 10W-40 Vanellus HT Motor Oil SAE 15W-40 10W-40
Aral High Turboral SAE AVIA TURBOSYNTH *) Chevron Delo 400 ELF ECOMAX FE 10W-
Agip SIGMA ULTRA TFE Vanellus FE Extra
10W-40 10W-40 Multigrade SAE 15W-40 40
Vanellus FE
Aral Mega Turboral SAE AVIA MULTI CFE PLUS ELF PERFORMANCE
10W-40 10W-40 EXPERTY 7,5W-40
AVIA MULTI CFE 10W-40

Agip ROTRA MP DB Aral Getriebeöl HYP SAE AVIA HYPOID 90 EP Energear Hypo 90 Castrol EPX 90 TRANSELF TYP B SAE
3. 85W-90 Castrol Hypoy B EP 90 90

Agip ROTRA MP 80W-90 Aral Getriebeöl HYP AVIA SYNTOGEAR FE Energear HT Castrol EPX 80W/90 *) Chevron Delo Gear TRANSELF TYP B SAE
4. Agip ROTRA MP 85W-140 SAE 85W-90 80W-90 Energear FE Castrol Hypoy B EP Lubricant SAE 80W-90 80W-90
Aral Getriebeöl HYP AVIA HYPOID FE 80W-140 80W/90 *) Chevron Delo Gear TRANSELF TYP B SAE
SAE 85W-140 Lubricant SAE 85W-140 85W-140
Castrol Hypoy B
EP 80W/140

1. Agip ROTRA ATF 1. Aral Getriebeöl ATF 22 1. AVIA FLUID ATF 66 M 1. Autran ATF 1. - 1. - 1. ELF TRANS-O-MATIC
5. 2. Agip ATF D 2. Aral Getriebeöl ATF E-S 2. AVIA FLUID ATF 92 S 2. Autran DX II 2. Castrol TQ Dexron II 2. - 2. ELFMATIC G 2
Agip ATF D 309 3. Aral Getriebeöl ATF 55 AVIA FLUID ATF 86 3. Autran DX III 3. - 3. Chevron Automatic 3. ELFMATIC G 3
Transmission Fluid
Agip ATF II E 3. -
3. Agip ATF III D
Agip SIGMA TFE Aral Extra Turboral SAE AVIA MULTI CFE 10W-40 Vanellus FE Castrol RX Super 10W/40 Chevron RPM Heavy Duty ELF ECOMAX FE PLUS
6. Agip SIGMA SUPER TFE 10W-40 AVIA MULTI HDC 15W-40 Vanellus C 3 Extra Castrol Turbomax Motor Oil SAE 15W-40 10W-40
Aral Multi Turboral SAE *) Chevron Delo 400
Agip BLITUM T Castrol RX Super Plus
15W-40 Multigrade SAE 15W-40
15W/40
Agip SIGMA TURBO
Agip MULTIFLEET
Agip OSO 46 Aral Vitam GF 46 AVIA FLUID RSL 46 Energol HLP 46 Castrol Hyspin AWS 46 Chevron Mechanism LPS ELFOLNA 46
7. Agip ARNICA 46 Aral Vitam DE 46 AVIA FLUID HLPD 46 Energol HLP-D 46 Castrol Hyspin AWH-M 46 46 ELFOLNA DS 46
Agip OSO D 46 Castrol Hyspin SP 46 Chevron Hydraulic Oil AW ELFOLNA HLPD 46
MV 46
Castrol Hydrauliköl
HLPD 46 SF

8. Auf Anfrage bei Liebherr

Only on request at Liebherr
Agip GR MU EP 2 Aral Langzeitfett H AVIALITH 2 Energrease LS-EP 2 Castrol Spheerol AP 2 Chevron Dura-Lith Grease EPEXELF 2
9. Agip Longtime - Grease 2 Aralub HLP 2 AVIALITH 2 EP Biogrease EP 2 Castrol LZV-EP EP 2
Chevron Ulti-Plex Synthetic
Agip GREASE 30 Aralub BAB EP 2 AVIA SYNTOGREASE 2 4) Castrol Spheerol EPL 2
Grease EP
Grease
AUTOL TOP 2000

Agip FIN 332 F Aralub MK-Z 1 AVIA SYNTOTAC Open Gear Grease No. 2 Castrol Spheerol LMM Chevron Open Gear ELF CARDREXA GR
10. AUTOL Hochleistungs- AVIA ALUPLEX 0 RHS Grease Lubricant 250 NC 1 - AL
Zahnradspray AVIA ALUPLEX 2 RHY
AVIA ALUPLEX RHS
FLUID

Agip GR PV 2 Aralub MKC 2 AVIACAL 2 LD Castrol Spheerol SX2 *) Chevron RPM ELF PALISSA 2
11. AUTOL TOP 2000 Grease Automotive Grease EP 2

AUTOL ZSA synth. Aral Fließfett N AVIALITH 000 Bio Biogrease EP 00 Castrol CLS-Grease *) Chevron Dura-Lith ELF MULTI BT 000
12. AUTOL ZSA Aral Fließfett BAB 000 Grease EP 00

Die Schmierstoff- bzw. Betriebsstoffmengen sowie die Wartungsfristen sind aus der Betriebsanleitung ersichtlich!
For lubricant and fuel quantities and maintenance intervals, see operating manual!
*) Unter dieser Bezeichnung in den USA erhältlich / Under this brandname obtainable in the USA

4/6
LIEBHERR Für die Schmierung unserer Schiffs- und Containerkrane, Offshorekrane, Seilbagger und Hafen-Mobilkrane empfehlen wir die
nachstehend aufgeführten oder nachweislich gleichwertigen Betriebsstoffe.

We recommend the following products or those of proven equivalent quality for use when lubricating our Ship- and Container-
Cranes, Offshore-Cranes, Cable Excavators and Harbour Mobile Cranes.
Nummer
Number

ESSOLUBE TDS FINA KAPPA EXTRA TITAN SUPER 1540 Mobil Delvac 1 SHC Shell Myrina X URSA SUPER LA 15W-40 VERKOPLUS 15W40
1. ESSOLUBE MHX FINA KAPPA SUPRA TITAN UNIVERSAL (5W-40) Shell Rimula TX *) URSA PREMIUM TDX SHPD
HD 1540 Mobil Delvac XHP 15W-40 VERKOL TURBO SHPD
ESSOLUBE XD-3+
(10W-40) 15W40
Multigrade TITAN TRUCK 1540

ESSO HD 156 FINA KAPPA ULTRA TITAN UNIVERSAL Mobil Delvac 1400 Super Shell Myrina TX 10W-40 URSA SUPER TDX 10W-
2. ESSOLUBE TDX FINA KAPPA FE 1040 MC 40
TITAN CARGO MC
ESSOLUBE LDX
SAE 10W-40
TITAN CFE 1040 MC

ESSO GEAR OIL GX-D FINA PONTONIC MP TITAN SUPER GEAR Mobilube HD 85W-90-A Shell Spirax MB 90 GEARTEX EP-B 90 MYSTIK JT-7 SAE 90 EP
3. 85W-90 80W-90, 85W-90 8090 MC
FINA PONTONIC FDL TITAN GEAR HYP
75W-90, 80W-90 SAE 85W-90

ESSO GEAR OIL TDL FINA PONTONIC MP TITAN SUPER GEAR Mobilube HD 85W-90-A Shell Spirax AX 80W-90 GEARTEX EP-C MYSTIK JT-7 80W90
4. 80W-90 80W-90 SAE 80W-90 Mobilube SHC 75W-90 LS Shell Spirax HD 85W-140 80W-90 / 80W-140 MYSTIK JT-7 85W140
ESSO GETRIEBEOEL FINA PONTONIC FDL TITAN SUPER GEAR *) MULTIGEAR EP
Mobilube HD 85W-140
GX 85W-140 75W-90, 80W-90 SAE 85W-140 80W-90 / 85W-140

1. ESSO ATF TYPE 1. FINA PURFIMATIC 1. RENOFLUID TF 20 1. Mobil ATF 200 1. Shell Donax TM 1. TEXAMATIC 1585 1. VESTA AS-A
5. SUFFIX A FLUID 2. RENOFLUID 3000 2. Mobil ATF 220 2. Shell Donax TA 2. TEXAMATIC 4261 2. VESTA TD-2
2. ESSO ATF D (21611) 2. FINAMATIC II D-22233 3. TITAN ATF 4000 3. Mobil ATF 3. Shell Donax TX TEXAMATIC 4011 3. -
ESSO ATF LDS FINAMATIC II D-22307 ( F - 30366 ) 3. TEXAMATIC 7045
3. ESSO ATF F-30320 FINAMATIC S 6726 *) HAVOLINE ATF
3. FINAMATIC HP DEXRON III
ESSO HD 156 FINA KAPPA FE 10W-40 TITAN UNIVERSAL Mobil Delvac XHP Shell Myrina TX URSA SUPER TDX 10W- VERKOPLUS 15W40
6. ESSOLUBE TDX FINA KAPPA SUPRA 1040 MC
Mobil Delvac 1400 Super Shell Myrina X 40 SHPD
15W-40 TITAN UNIVERSAL URSA SUPER LA 15W-40 VERKOL TURBO SHPD
ESSOLUBE LDX Shell Rimula TX
HD 1540 15W40
*) URSA PREMIUM TDX
ESSOLUBE TDS
15W-40
ESSOLUBE MHX

NUTO H 46 FINA HYDRAN TS 46 RENOLIN B 15 Mobil DTE 25 Shell Tellus Oil 46 *) RANDO HD 46 VESTA HLP-46
7. HLPD-OEL 46 FINA HYDRAN HLP-D 46 RENOLIN MR 15 Hydraulikoel HLPD 46 Shell Tellus Oil DO 46 ALCOR DD 46 VESTA HLPD-46
Shell Tellus Oil TD 46 *) RANDO HDZ 46

8. Auf Anfrage bei Liebherr

Only on request at Liebherr
BEACON EP 2 FINA MARSON EPL 2 LAGERMEISTER EP 2 Mobilgrease HP 222 Shell Retinax EP2 *) MULTIFAK EP 2 VERKOL RS-2
9. RONEX MP-D FINA LICAL EP 2 STABYL ECO EP 2 Mobilux EP 2 Shell Alvania EP(LF)2 MULTIFAK 20 VERKOL EPX-2
RONEX MP *) 4 MULTIFAK T EP 2 ATLANTA
FINA BIOLICAL EPS 2 )
*) MULTIFAK ALL
PURPOSE 2

CAZAR K 1 FINA CERAN AD Mobiltac 81 Shell Fett S.8327 *) CRATER PREMIUM COBERTONE-00
10. FINA CERAN WR 2
CEPLATTYN 300
Mobiltemp 78 0 und 2 COBERTONE-0
CEPLATTYN KG 10 HMF
COBERTONE-1

NEBULA EP 2 FINA CERAN WR 2 Mobilplex 47 Shell Rhodina EP(LF)2 *) CRATER PREMIUM 2 MYSTIK JT-6
11. FINA CERAN AD
CEDRACON 95/100 N
MYSTIK JT-6-E
CEPLATTYN ECO 300
( NLGI-0 )

FINA MARSON ZS STABYL ECO 00 Shell Retinax CSB00 MULTIFAK 6833 EP 00 VERKOL EPX-00
12. STARFAK EP 00 CENTRALUB GR-00

Die Schmierstoff-bzw. Betreibsstoffmengen sowie die Wartungsfristen sind aus der Betriebsanleitung ersichtlich!
For lubricant and fuel quantities and maintenance intervals, see operating manual!
*) Unter dieser Bezeichnung in den USA erhältlich / Under this brandname obtainable in the USA

5/6
Diese Gesellschaften unterhalten einen Schmiertechnischen Dienst, dessen Ingenieure auf Anforderungen in allen
Schmierungsfragen zur Verfügung stehen.

These companies maintain a Technical Service whose engineers shall be glad to render assistance on all problems
connected with proper lubrication of all machine parts.
Agip Schmiertechnik GmbH, Würzburg
und Agip - Vertriebspartner
Im Ausland: Die Agip - Gesellschaften in der ganzen Welt
Agip Companies all over the world
Aral Lubricants GmbH, Bochum
Im Ausland Aral - Vertriebsgesellschaften in der ganzen Welt
Agencies of Aral all over the world

AVIA Mineralöl-AG, München

AVIA - Gesellschaften in Europa
AVIA Companies in European countries

BP OIL Deutschland GmbH, Hamburg

und ihre Niederlassungen
Im Ausland: Die BP - Gesellschaften in der ganzen Welt
BP Companies all over the world
THE BURMAH OIL (DEUTSCHLAND) GmbH
Castrol Marine Division
Im Ausland: Die BURMAH - CASTROL Gesellschaften in der ganzen Welt
Overseas: THE BURMAH - CASTROL Companies all over the world
CHEVRON GERMANY INC., Hamburg, MARINE ABTEILUNG
Die Chevron - Gesellschaften in der ganzen Welt
Chevron Companies all over the world

ELF Mineralölwerk Osnabrück GmbH, Osnabrück

Im Ausland: Die ELF - Gesellschaften in der ganzen Welt
ELF Companies all over the world

ESSO A.G., Hamburg

und ihre Vertretungen
Im Ausland: Die ESSO / EXXON Gesellschaften in der ganzen Welt
ESSO / EXXON Companies all over the world
FINA Deutschland GmbH, Frankfurt am Main
Im Ausland: PETROFINA - und FINA - Gesellschaften in der ganzen Welt
PETROFINA - und FINA - Companies all over the world

FUCHS LUBRITECH GMBH, Weilerbach

FUCHS AUSTRIA SCHMIERMITTEL Ges. m. b. H., A - Bergheim bei Salzburg
Vertretungen und Lizenzfertigungen in Europa und Übersee auf Anfrage
Addresses of representatives and licencees in Europe and overseas upon request
Mobil Oil AG, Hamburg
Im Ausland: Die Mobil Oil Gesellschaften in der ganzen Welt
Mobil Oil Companies all over the world

Deutsche Shell Aktiengesellschaft, Hamburg

Im Ausland: Die Shell Gesellschaften in der ganzen Welt
Shell Companies all over the world

TEXACO Deutschland GmbH, Düsseldorf

Im Ausland: TEXACO - und CALTEX - Gesellschaften in der ganzen Welt
TEXACO and CALTEX Companies all over the world

VERKOL Spain, Vera de Bidasoa ( Navarra)

VERKOL - Gesellschaften in Europa
VERKOL Companies in European countries

6/6