190 MAIN Operation & Maintenance Manual Rev 00

Vendor Document Front Page
GULF PIPING CO. W.L.L.
Equipment: BOS 7500-300 Litronic (170461)
Purchase Order: 4510041129 (Rev.2)
Suppliers Name: Liebherr Werk Nenzing GmbH (LWN)
Document Title: Operation and Maintenance Manual
Document Number: 170 MAIN 190
Revision Rev. Status

Date
25.09.2013 00 Issued for Information

Operatingmanual EN
Type:
BOS 7500−300 LITRONIC
Serial number:
170461
ORIGINAL 001 − 14.05.2013 / lwnbar3

TECHNICAL INFORMATION FOR - BOS 7500-300 LITRONIC
General
Crane model / type: BOS 7500-300 LITRONIC Crane location: Type: Jack-Up-Vessel (Vessel in Jackup-Position)
Serial No.: 170461 Name: GPC JU 125/300
Manufacturer : LIEBHERR-MCCtec GmbH
Ambient temperature: min -10 [°C] Design temperature: -10 [°C]
max +45 [°C]
Abbreviations and definitions used on the load diagrams and load tables
Lift mode: Onboard lift mode Lifting a load from or to the deck of the installation that the crane is mounted on.
Offboard lift mode Lifting a load from or to anywhere not on the installation that the crane is mounted on.
Personnel lift mode Lifting operation where personnel are lifted by the crane.
Crane location: Type of installation, in general fix supported or floating installation
Crane is lifting to or from: Type of load supporting installation, in general fix supported or floating
SWL: Safe Working Load is the actual hook load permitted for a given operation condition, also called rated load or rated capacity.
Load radius or radius: The load radius or radius is the horizontal distance between the crane's centre line and the hook position under consideration of an
undeformed crane system.
SWH: Significant Wave Height = H1/3 = HSignificant
LCN: Load curve number
Dynamic factor : A variable factor representing the dynamic effects that the working load is exposed to. Also named dynamic coefficient or dynamic hoisting
factor. In connection with subsea- / seabed lifts, the expression DAF (Dynamic Amplification Factor) is used instead of dynamic factor.
H-Load: The H-Load given in the tables is the maximum allowed horizontal load which may act on the hoist point of the active lifting system. The
H-Load includes off- and sidelead effects, wind effects, water flow effects (e.g. during seabed lifts) etc. and may act in any horizontal
direction. The H-Load is given for heavy lift cranes for information to allow the operator to prepare and perform engineered lifts. It is within the
responsibility of the operator (e.g. by pre-calculation of lift scenario), that the allowed H-Loads are not exceeded during the lift.
OPL: Operational Limitation (see user manual)
Elevation: Vertical height between boom pivot point and load supporting deck. For offboard lifts, the installation has to be operated within the given
elevation limits.
Calculation method: Three methods are available for calculating the dynamic forces acting on a crane in a specific load condition:
Method Main characteristic
DDM - Default Dynamic Method A constant value is used for the dynamic factor . The value is given by the valid design code or via
customer specification.
GM - General method The calculation of the dynamic factor is partly based on motion data given in the valid design code.
VSM - Vessel Specific Method The calculation of the dynamic factor is partly based on installation specific motion data
calculated witin a specific motion analysis.
The method used is given on the "LOAD DIAGRAM AND LOAD TABLE"
Motion limits: If applicable, the following motion data are given on each load table. The values are maximum values which shall not be exeeded during lift
operation. The size of the values is based on the calculation method used (s. above). It is within the responsibility of the operator, that the
operation is, among others, done within these limits. If required, the real values occuring in practise must be evaluated by help of measuring
or by help of a motion analysis of the involved installations.

vc : Maximum allowed vertical velocity of the crane boom tip due to movement of the crane base. Only applicable if the crane is located
on a floating unit.
vd : Maximum allowed vertical velocity of the load supporting deck.
az : Maximum allowed vertical crane base acceleration (at top of pedestal). Only applicable if the crane is located on a floating unit.
ay : Maximum allowed horizontal crane base acceleration (at top of pedestal). Only applicable if the crane is located on a floating unit.
vh,min : Minimum required hoisting speed to avoid re-contact with the load supporting deck after the load is lifted.
n.a. not applicable
Seabed or Subsea lift:
• Definition Seabed lift Lifting a load offboard to or from seabed - the hook is not submerged (in air only).
Subsea lift Lifting a load offboard to or from seabed - the hook is submerged.
• Seabed- / Subsea - Lifts are engineered lifts which are to be completely planed by the operator.
• Impact loads which occur during the different phases of the lift are to be determined by the operator e.g. according to "Det Norske Veritas (DNV) Rules for Planing and
Execution of Marine Operations, Part 2, Chapter 6 Sub Sea Operations", 1996
• it is within the responsibility of the crane operator to select a suitable subsea curve which covers the calculated effects during the subsea- / seabed lift. The operation limits
are given on the load chart table (DAF, wind speed, static inclination, off- and sidelead forces / angles, up to water depth, etc.).
Item code: 10597063 Revision / Index: 01

187 200
Hoist gear: Main hoist 1
Reeving: 6
Diagram Control Number (DCN): 1
LOAD DIAGRAM AND LOAD TABLE - BOS 7500-300 LITRONIC

300
250
200
SWL [t]
150
LCN 1 = Onboard
100
LCN 2 = Offboard, up to SWH 0.5m
50 LCN 3 = Offboard, up to SWH 1.0m
0
9.4 42.0
8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42
Radius [m]
Lift mode [-] Onboard Offboard Offboard

LCN [-] 1 2 3
SWH [m] n.a. 0.5 1.0
vc [m/s] 0 0 0
vd [m/s] 0 0.6 0.6
az [g] n.a. 0 0
ay [g] n.a. 0 0
vh,min [m/s] 0 0 0.20
Angle Radius SWL SWL SWL SWL SWL SWL SWL SWL SWL SWL SWL SWL
[°] [m] [t] [t] [t] [t] [t] [t] [t] [t] [t] [t] [t] [t]
82.7 9.4 300.0 300.0 285.0
79.1 12.0 300.0 300.0 285.0
76.3 14.0 300.0 300.0 285.0
73.5 16.0 300.0 300.0 252.6
70.6 18.0 300.0 300.0 222.0
67.6 20.0 278.4 278.4 197.0
64.6 22.0 250.5 250.5 176.2
61.5 24.0 227.0 227.0 158.7
58.3 26.0 207.0 207.0 143.8
54.9 28.0 189.7 189.7 131.0
51.4 30.0 174.6 174.6 119.9
47.7 32.0 161.3 161.3 110.3
43.8 34.0 149.5 149.5 101.9
34.8 38.0 129.5 129.5 88.3
22.7 42.0 113.3 113.3 78.6
Design code: ABS, "Guide for Certification of Lifting Appliances", 2006

Calculation method SWL > 160 t: Heavy Lift Crane, DDM
SWL < 160 t: Offshore Crane, GM Additional hoist gear: DCN LCN
Installation Status: fix none none none
Max. static trim: [°] 0.5
Max. static heel: [°] 0.5
Minimum elevation: [m] 34

Maximum elevation: [m] 39
Crane is lifting to or from (offboard): Supply vessel Available tugger winch Reeving max. avail. line pull
[-] [t] [%]
Max. mean wind speed: [m/s] 18 none
Boom length: [m] 42.00

Reeving luffing gear: [-] 14
1. Operational limitations due to low hoisting velocity: for underlined figures

2. Operational limitations due to exceeding of recommended hoist rope reeving: none
3. Operational limitation for personnel lifting (except for emergency operation): none

187 200
Hoist gear: Auxiliary hoist 1
Reeving: 1
Diagram Control Number (DCN): 2
LOAD DIAGRAM AND LOAD TABLE - BOS 7500-300 LITRONIC

25
20
15
SWL [t]
LCN 1 = Onboard
10 LCN 2 = Offboard, up to SWH 0.5m
5
0
12.0 47.6
10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48
Radius [m]
Lift mode [-] Onboard Offboard Offboard Offboard Offboard

LCN [-] 1 2 3 4 5
SWH [m] n.a. 0.5 1.0 1.5 2.0
vc [m/s] 0 0 0 0 0
vd [m/s] 0 0.3 0.6 0.9 1.2
az [g] n.a. 0 0 0 0
ay [g] n.a. 0 0 0 0
vh,min [m/s] 0 0.15 0.20 0.25 0.30
Angle Radius SWL SWL SWL SWL SWL SWL SWL SWL SWL SWL SWL SWL
[°] [m] [t] [t] [t] [t] [t] [t] [t] [t] [t] [t] [t] [t]
82.7 12.0 25.0 25.0 25.0 25.0 25.0
79.1 14.8 25.0 25.0 25.0 25.0 25.0
76.3 17.1 25.0 25.0 25.0 25.0 25.0
73.5 19.3 25.0 25.0 25.0 25.0 25.0
70.6 21.5 25.0 25.0 25.0 25.0 25.0
67.6 23.7 25.0 25.0 25.0 25.0 25.0
64.6 25.9 25.0 25.0 25.0 25.0 25.0
61.5 28.1 25.0 25.0 25.0 25.0 25.0
58.3 30.3 25.0 25.0 25.0 25.0 25.0
54.9 32.5 25.0 25.0 25.0 25.0 25.0
51.4 34.7 25.0 25.0 25.0 25.0 25.0
47.7 36.9 25.0 25.0 25.0 25.0 25.0
43.8 39.0 25.0 25.0 25.0 25.0 25.0
34.8 43.4 25.0 25.0 25.0 25.0 25.0
22.7 47.6 25.0 25.0 25.0 25.0 25.0
Design code: ABS, "Guide for Certification of Lifting Appliances", 2006

Calculation method: GM
Additional hoist gear: DCN LCN
Installation Status: fix none none none
Max. static trim: [°] 0.5
Max. static heel: [°] 0.5
Minimum elevation: [m] 34

Maximum elevation: [m] 39
Crane is lifting to or from (offboard): Supply vessel Available tugger winch Reeving max. avail. line pull
[-] [t] [%]
Max. mean wind speed: [m/s] 18 none
Boom length: [m] 42.00

Reeving luffing gear: [-] 14
1. Operational limitations due to low hoisting velocity: none

2. Operational limitations due to exceeding of recommended hoist rope reeving: none
3. Operational limitation for personnel lifting (except for emergency operation): none

187 200
Item code 10596993
- Utility Requirements Edition 00
Crane: BOS 7500-300 LITRONIC
Unit Req. / Unit No. of Units Total Type
1. Winches:
- Luffing winch 60 l 1 60 l Gear oil
- Main hoist winch 85 l 1 85 l Gear oil
- Auxiliary hoist winch 1 76 l 1 76 l Gear oil
2. Slewing Gear: 31 l 6 186 l Gear oil
3. Grease:
- Slewing ring + greasing lines 34.7 kg 1 34.7 kg Grease
- All sheaves, bearings 14.9 kg 1 14.9 kg Grease
- All other grease lines 1.8 kg 1 1.8 kg Grease
- Electric Motor 0.11 kg 2 0.22 kg Grease
4. Cabin:
- Windscreen washer 5l 1 5l Anti freeze mixture
5. Distribution Gearbox 3l 2 6l Gear oil
6. Hydraulic System
- Hydraulic tank 900 l 1 900 l Hydraulic oil
- Hydraulic line system 250 l 1 250 l Hydraulic oil
7. Electric Power Consumption:

according to drawing - - - -
10597929 - Outline Power Supply
8. Electric Motor
according to drawing - - - -
10597929 - Outline Power Supply
NOTE: For oil type refer to the attached "Table of lubricants" Id.no. 8099 509 14
08.10.2012 LWN Idt according LIKV workflow

Date Work Prepared Checked Approved
Crane utility quantity data sheet rev007.xls

No copying or duplication of this document without the permission of Liebherr.
This document has been issued eletronically and is valid without signature.
1/1
187 200
INDEX
INDEX
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.1. FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.2. HANDLING OF DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.3. LEGAL NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
2. PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

2.1. TYPE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2. INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.3. NOT INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.4. OPERATIONAL LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.5. LOAD CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
2.6. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.7. GENERAL ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
3. SAFETY GUIDELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.1. DANGER SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.2. AREAS OF RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
3.3. PERSONAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.4. PERSONAL PROTECTIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.5. WORK AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
3.6. SAFETY AND MONITORING DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
3.7. SAFETY SIGNS ON THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.8. MACHINE SPECIFIC DANGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
3.9. ADDITIONAL DANGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
4. CONTROL AND OPERATING ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.1. OPERATOR’S CONTROLSTAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2. CONTROL PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.71
4.3. EMERGENCY STOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
4.4. LITRONIC SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
4.5. CAMERA MONITORING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.60
4.6. VENTILATION AND AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . 4.62
4.7. PA−SYSTEM / AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.63
4.8. SWITCH CABINETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.65
5. CRANE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.1. CHECKS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.2. SAFE OPERATIONS WITH THE CRANE . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3. REQUIREMENTS AND OBLIGATIONS OF THE CRANE DRIVER . . . . 5.3
−0.1− 1760_170461
INDEX
5.4. CHECKS PRIOR TO STARTING OPERATION . . . . . . . . . . . . . . . . . . . . . 5.4

5.5. CRANE ASCENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
5.6. EMERGENCY DESCENT * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
5.7. CHECKS BEFORE START UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.8. DAILY START−UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.9. START/STOP FOR A WORK BREAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
5.10. DAILY SHUT DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
5.11. MAIN FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
5.12. PRESELECTION CRANE OPERATION MODE . . . . . . . . . . . . . . . . . . . . 5.24
5.13. AUXILIARY FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
5.14. LITRONIC® TEST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.63
5.15. ADDITIONAL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.74
6. EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.1. EMERGENCY POWER PACK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.2. EMERGENCY MANUAL LOWERING SYSTEM . . . . . . . . . . . . . . . . . . . . 6.11
7. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
7.1. QUALIFIED PERSONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
7.2. MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.3. MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.4. LUBRICANT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
7.5. MAIN DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
7.6. DISTRIBUTION GEARBOXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
7.7. SLEWING GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
7.8. MAIN HOISTING WINCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
7.9. AUXILIARY HOISTING WINCH* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
7.10. LUFFING WINCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31
7.11. TUGGER WINCHES* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33
7.12. SLEWING BEARING − WEAR MEASUREMENT . . . . . . . . . . . . . . . . . . . 7.35
7.13. EXTERNAL DISC BRAKES * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
7.14. ROPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.39
7.15. ROPE PULLEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.57
7.16. CHECKING HYDRAULIC LINES AND HOSES . . . . . . . . . . . . . . . . . . . . . 7.62
7.17. HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.63
7.18. LIEBHERR OIL DIAGNOSIS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.67
7.19. PRESSURE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.70
7.20. MAINTENANCE OF OIL COOLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.71
7.21. WINDOW CLEANING* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.72
7.22. REPLACEMENT OF BOOM / CHANGE BOOM CONFIGURATION . . . 7.74
7.23. REPLACEMENT OF PRIME MOVERS / GEARBOXES . . . . . . . . . . . . . 7.74
7.24. REPLACEMENT OF WINCHES / WINCH DRUMS . . . . . . . . . . . . . . . . . 7.74
1760_170461 −0.2−
INDEX
7.25. REPLACEMENT OF SLEW BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.74

7.26. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.75
1760_170461
−0.3− 1760_170461
INDEX
1760_170461 −0.4−
1
1
INTRODUCTION
INDEX
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.1. FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.2. HANDLING OF DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

1.2.1. HOW ARE THE OPERATING MANUAL STRUCTURED? . . . . . . . . . . . . . . . . . . . . 1.5
1.2.2. SYSTEM REQUIREMENTS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.2.3. CURRENT DOCUMENTATION STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.2.4. STORAGE OF THE DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.3. LEGAL NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
BOS −1.1− 1760_170461

INTRODUCTION
1760_170461 −1.2− BOS

INTRODUCTION
1. INTRODUCTION
1.1. FOREWORD
The name Liebherr stands not only for products and services. It has also become a term for ideas and
innovations − for advancement proven on the market.
We are constantly and intensely expanding and improving our broad and diverse range of products and
services. Continuous cooperation and ongoing experience exchange with our customers and business
partners around the world is a prerequisite for this. We are therefore grateful for every suggestion and every
improvement recommendation that we receive.
Contact:
LIEBHERR−WERK NENZING GMBH

P.O. Box 10
A−6710 Nenzing
Austria / Europe
Tel: +43 50809 41−0

Fax: +43 50809 41−500
Email: info@liebherr.com
The documentation for this machine is maintained on a customer−specific basis. Please therefore inform us,
if you
F sell the machine on
F purchase the machine from a previous owner
F take the machine out of service
BOS −1.3− 1760_170461

INTRODUCTION
1.2. HANDLING OF DOCUMENTATION
The documents supplied should enable you to

F safely operate the machine
F utilise the full scope of the machine
F conduct routine maintenance on the machine
The following symbols should enable you to access the information required with ease:
Operating manual
Here, you will find information on the commissioning, operation and maintenance of the
machine.
Technical information
Here you will find technical drawings and plans pertaining to electrics and hydraulics.
Spare parts catalogue

Here you will find information on procuring spare parts.
You will find the complete documentation in digital format on the CD−ROM. The symbols shown above provide
details on the contents of the CD.
1760_170461 −1.4− BOS

INTRODUCTION
1.2.1. HOW ARE THE OPERATING MANUAL STRUCTURED?
The operating manual comprise individual, sequentially numbered chapters. These chapters are arranged in
the yellow ledgers in the folder.
The chapter overview at the beginning of the Operating manual provides quick orientation. The table of
contents that follows provides information on the structure of the individual chapters.
At the start of the following chapter you will find a brief description of contents. At the end of every chapter
you will find a page provided for you to add notes.
The numbering of the pages, tables and certain larger−scale diagrams contains the actual chapter number as
a prefix. For example, the page number "2−10" indicates the tenth page of chapter 2 "Product Description".
Optional supplementary equipment *

A wide range of optional supplementary equipment is available for this machine.
Every description relating to an item of supplementary equipment is marked with an * in the operating manual.
You can determine the optional supplementary equipment associated with your machine by referring to the
machine passport (chapter 2.2).
1.2.2. SYSTEM REQUIREMENTS:
Hardware:
F Pentium II PC; min. 500 MHz
F 128 MB RAM
F CD−ROM drive
F Colour depth high colour (800 x 600 Pixel)
Software:
F Windows 2000; XP
F Internet Explorer 5.5
F Acrobat Reader 7.0
Recommendation: Popup blockers should not be activated when working with Liebherr parts. Please also
note that this functionality maybe incorporated into certain web browsers and software firewalls. This can
usually be switched off in the Options menu of the respective program.
1.2.3. CURRENT DOCUMENTATION STATUS
This documentation has been specifically created for the machine supplied with this serial number and is not
transferrable to other machines from the same range.
In order to ensure that the documentation is constantly complete and up−to−date:
F do not remove any documents (you can reprint missing or illegible pages from the CD−ROM, or
request these from the manufacturer)
F exchange outdated versions of documents as soon as possible and destroy old versions (in
particular load diagrams)
F replace the CD−ROM as soon as you have been provided with a new version
F ensure that multilingual documentation is updated in all languages
. IMPORTANT!
The declaration of conformity contains a list of those EU standards applied.
BOS −1.5− 1760_170461

INTRODUCTION
1.2.4. STORAGE OF THE DOCUMENTATION
Store the operating manual together with the current load diagrams in an accessible location in the driver’s
cab at all times.
Ensure that the replacement parts catalogue and the technical information are available to the maintenance
and service personnel where necessary.
1.3. LEGAL NOTICE
Scope of the documentation supplied:

Operating manual
Technical information
Spare parts catalogue
CD−ROM
This documentation reflects the technical status of the machine supplied. In the interest of our customers, we
reserve the right to make changes within the framework of technical advancements.
Copyrights
Litronic is a registered trademark of LIEBHERR.
This documentation is protected by copyright. The copying and duplication of the load diagrams is exclusively
permitted in conjunction with applications planning and the operation of this machine. Any additional
duplication, reproduction, microcopying, translation or saving and amendment in an EDP system of this
documentation, either in whole or part, is prohibited without written permission from LIEBHERR−WERK
NENZING GMBH.
E 2013 Copyright by
LIEBHERR−WERK NENZING GMBH
A−6710 Nenzing
All rights reserved.
1760_170461 −1.6− BOS

2
2
GENERALDESCRIPTION
INDEX
2. PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.1. TYPE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2. INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

2.2.1. OPERATIONAL MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.2.2. LIMITS OF THE OPERATIONAL AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.3. NOT INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.4. OPERATIONAL LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.5. LOAD CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
2.6. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

2.6.1. CONSTRUCTION CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.6.2. ENVIRONMENTAL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.6.3. PERMISSIBLE CAPACITIES / SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.6.4. ELECTRIC POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.6.5. HAZARDOUS AREA RATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.7. GENERAL ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

2.7.1. MAIN PARTS OF THE CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.7.2. SLEWING COLUMN FRONT VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
2.7.3. SLEWING COLUMN BACK VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
2.7.4. MACHINERY ROOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
2.7.5. CABIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
2.7.6. BOOM PIVOT PIECE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
2.7.7. BOOM MID PIECE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
2.7.8. BOOM HEAD PIECE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
−2.1− 1760_170461
GENERALDESCRIPTION
1760_170461 −2.2−
GENERALDESCRIPTION
2. PRODUCT DESCRIPTION
This chapter
F gives information about the machine application possibilities and warns against incorrect or improper use,
F describes the components of the machine.
F lists important technical data.
2.1. TYPE PLATE
The type plate is arranged on the operator’s cabin door.
1 Ex marking 2 CE marking
If the machine is in accordance with the Ex−construction the name plate have the Ex marking (1).
If the machine is in accordance with the directive 2006/42/EG the name plate have the CE marking (2).
Write the relevant data into the following table.
Serial / Order no.:

Type:
Year built:
First start−up(day/month /year):
This informations are required for e.g. ordering spare parts.
−2.3− 1760_170461
GENERALDESCRIPTION
2.2. INTENDED USE
The crane is mounted on a installation and serves to load and unload vessel and platform work using the lifting
equipment supplied and approved by the manufacturer (hooks etc.).
The crane is to be operated only by appropriately trained personnel, in a competent physical and psychological
condition!
In principal the machine may only be used for applications as stipulated in the operating manual.
The machine is used as intended when
F national safety regulations are adhered to,
F all safety instructions in this operating manual are kept,
F when all required safety devices are in place and operational,
F when the operating conditions described in chapter "Technical data" are adhered to and all the
recommended oils and lubricants are used.
Included in use as intended is also timely and complete service and maintenance works by qualified and autho
rized personnel.
Special application not listed here
F are to be cleared with the manufacturer,
F may only be carried out with the written consent of the manufacturer.
The machine is used for every kind of crane application and is designed for optimal economic operations.
2.2.1. OPERATIONAL MODES
The following operational modes of the machine are possible:

F Main hook operation
F Auxiliary hook operation
F Personnel rescue
F MOB boat handling
Every other application or applications beyond the described ones are not intended uses of the machine and
without an explicit agreement in writing by the manufacturer, the crane operator is responsible for any damage
incurred.
2.2.2. LIMITS OF THE OPERATIONAL AREA
The limits of the operational area, is the maximum working area of the crane, plus the distance covered by
a swinging load. This area is also to be known as the area of danger. The hazardous zone is also known
as Ex protected area.
1760_170461 −2.4−
GENERALDESCRIPTION
2.3. NOT INTENDED USE
Not intended use of the machine includes any reasonably forseeable misuse.
Examples of not intended use of the machine:
F Bringing the machine into service after:
Mechanical modifications which influence the operational safety.
Changes or mechanical modifications (rope pulleys, main drive or drive gear, winches or winch drums,
slewing bearing, boom length configuration) which alter the standard as supplied originally to the
customer without presence of Liebherr−service personnel.
Installation and use of spare parts, equipment and fluids that are not approved by the original equipment
manufacturer.
F Using the machine to tear/rip away loads that are fixed to the ground, by using the hook or the slewing
gear.
F Lifting a load that is laying on the ground by only using the luffing winch/gear.
F Lifting loads or persons by use of the tugger winch (unless the tugger winch is specified for this function).
F Lifting loads when operating in personnel lift mode (persons with working cage only is permitted).
F Lifting loads with emergency power pack (unless malfunction of the electric power supply).
F Dragging a load across the ground.
F Operation with fire extinguishing system deactivated (if installed).
F Lifting loads when the lifting ropes are not perpendicular
F Using the machine without complying with the relevant load chart (in regards to load, outreach, significant
wave height and operational limitations)
F Cooperative operation with other cranes for lifting loads without permitted operating mode.
F Duty cycle operation without reducing safe working load.
F Non−compliance by the owner in regards to positioning of the crane in respect to the EX−protection zones
as according to the relevant rules and regulations.
F Transit condition without boom in boom cradle. (A decleration of agreement from the Liebherr service
departement is necesseray then.
−2.5− 1760_170461
GENERALDESCRIPTION
2.4. OPERATIONAL LIMITATIONS
If existing, operational limitations are mentioned on the load chart table and indicated on the litronic screen
(yellow text OPL ).
Ope
Operational limitations indication on the litronic screen.
The possible operational limitations are:

1. Operational Limitations due to low hoisting velocity:
Operational limitation where the hoisting velocity of the crane is lower than the required value according to
rules and regulations (e.g. EN 13852−1 Annex B.4.1, DNV No. 2.22 − Ch. 2 Sec. 3 305, API 2C Ch. 4.3.1.a,
Lloyd’s Register of Shipping "Code for Lifting Appliances in a Marine Environment" Ch. 3 Sec. 3.3.5.)
Potential hazards :
l re−contact of load with load supporting deck after the load is lifted (impact !)
l uncontrolled pick up of load from load supporting deck
l uncontrolled load movement due to partial contact with load supporting deck
2. Operational limitation due to low minimum average luffing speed:

Operational limitation where the luffing velocity of the crane is lower than the required value according
to rules and regulastions (e.g. EN 13852−1:2004)
Potential hazards:
lcrane may not be able to follow the horizontal movement of the supply vessel
l uncontroled load movement due to horizontal re−contact with load supporting deck
3. Operational limitation due to low slewing velocity:

Operational limitation where the slewing velocity of the crane is lower than the required value according
to rules and regulastions (e.g. EN 13852−1:2004)
Potential hazards:
l crane may not be able to follow the horizontal movement of the supply vessel

l uncontroled load movement due to horizontal re−contact with load supporting deck
4. Operational Limitations due to exceeding of recommended hoist−rope−reeving:

Operational limitation due to exceeding of recommended hoist rope reeving
(e.g. acc. to EN 13852−1 Annex C).
Potential hazards :
When Automatic Overload Protection System (AOPS) or Manual Overload Protection System (MOPS) is
activated, structural damage of the crane may occur − in this case, the crane is to be inspected according to
user manual chapter "Automatic Overload Protection System − AOPS".
1760_170461 −2.6−
GENERALDESCRIPTION
5. Operational limitation for personnel lift:
Except for rescue operation
Mean wind velocity: 10 m/s

Significant wave height: SWH 2.0 m
Visibility: Daylight only
If personnel lift charts are available for SWH > 2.0 m (see load chart table):
Installation specific risk assessments to be considered by the operator under consideration of hazards which
my occur during lifting of personnel, MOB or FRC.( MOB: Man Over Board Boat, FRC: Fast Rescue Boat)
−2.7− 1760_170461
GENERALDESCRIPTION
2.5. LOAD CHARTS
The load charts are located directly behind the cover page of this operating manual.
1760_170461 −2.8−
GENERALDESCRIPTION
2.6. TECHNICAL DATA
2.6.1. CONSTRUCTION CONDITIONS
Classification, certifying authority LR

Design code EN 13852−1
Additional Rules & Regulat.: NMD, NORSOK
Certificate of conformity Declaration of confirmity acc. Machine Direc
trive 2006/42/EC, NMD 854, Norsok R−002,
S−001, S−002
2.6.2. ENVIRONMENTAL CONDITIONS
Relative humidity see load chart

Ambient temperature see load chart
Maximum static inclination Trim / Heel see load chart
Maximum wind speed for operating see load chart
Maximum gust boom stowed see load chart
Vibrations on the upper limbs of the driver: < 2.5 m/s@
Vibrations on the entire body of the driver: < 0.5 m/s@
Permitted pedestal load: 5 kN/m@
Sound power level in cabin LPA < 70 dB(A)
2.6.3. PERMISSIBLE CAPACITIES / SPEEDS
− Main hoisting gear
Maximal hoisting capacity see load chart

Reeving see load chart
Minimum radius see load chart
Maximum radius see load chart
− Auxiliary hoisting gear*
Maximal hoisting capacity see load chart

Reeving see load chart
Minimum radius see load chart
Maximum radius see load chart
2.6.4. ELECTRIC POWER SUPPLY
Main power supply see outline power supply

Auxiliary supply see outline power supply
UPS supply* see outline power supply
−2.9− 1760_170461
GENERALDESCRIPTION
2.6.5. HAZARDOUS AREA RATING
Section A (Safe Area) Slewing unit, pedestal, winches in boom pivot

section
Rating / Requirement Safe Area
Signing on Nameplate n.a
Section B (EX) Boom (excluding winches in pivot section), hooks

Rating / Requirement Zone 1 / IIB / T3
Signing on Nameplate: EX II 2G IIB T3
1760_170461 −2.10−
GENERALDESCRIPTION
2.7. GENERAL ARRANGEMENT
At the following pages the main components of the crane are described generally.
There may be differences to the actual crane configurations because of customized features!
2.7.1. MAIN PARTS OF THE CRANE
1 Boom
2 A−frame
3 Machinery house
4 Slewing Column
−2.11− 1760_170461
GENERALDESCRIPTION
2.7.2. SLEWING COLUMN FRONT VIEW
1 Flood light (2 x) 5 Maintenance beam (0,5 t)

2 Helicopter warning light* (2 x) 6 Entrance door machinery house
3 Rope pulley (2 x) 7 Operators cabin
4 Wind speed sensor
1760_170461 −2.12−
GENERALDESCRIPTION
2.7.3. SLEWING COLUMN BACK VIEW
1 Luffing winch
2 Sound absorbing shield
3 Maintenance beam (5 t) *
4 Lighting
5 Flood light
−2.13− 1760_170461
GENERALDESCRIPTION
2.7.4. MACHINERY ROOM
1 Hydraulic power pack (2x)

2 Electric motor (2x)
3 Hydraulic oil tank
4 Switch cabinet X1
5 Standstill heating
6 Transformer
7 Switch cabinet X2
1760_170461 −2.14−
GENERALDESCRIPTION
2.7.5. CABIN
1 Inclinometer 9 Radio
2 Control lever (right−handed) 10 Air conditioner*
3 Control panel X25 11 Cabin ligthing and power socket
4 Litronic screen 12 Entrance door
5 Camera monitor* 13 Additional seat
6 Control panel X26 14 Fire extinguisher*
7 Keyboard hand held for camera* 15 Control lever (left−handed)
8 PA−system
−2.15− 1760_170461
GENERALDESCRIPTION
2.7.6. BOOM PIVOT PIECE
1 Rope protection plate 4 Boom pivot bearing (2 x)

2 Auxiliary hoisting winch gear* 5 Boom walkway
3 Main hoisting winch gear 6 Helicopter warning light*
1760_170461 −2.16−
GENERALDESCRIPTION
2.7.7. BOOM MID PIECE
1 Rope protection plate

2 Helicopter warning light* (4 x)
3 Boom walk way
−2.17− 1760_170461
GENERALDESCRIPTION
2.7.8. BOOM HEAD PIECE
1 Flood light (3 x) 6 Camera system main hoist*

2 Helicopter warning light (2 x) 7 Hook block main hoist
3 Hook garage auxiliary hoist* 8 Camera system auxiliary hoist*
4 Rope pulley block 9 Hook block auxiliary hoist
5 Hook garage main hoist*
1760_170461 −2.18−
GENERALDESCRIPTION
−2.19− 1760_170461
3
3
SAFETYGUIDELINES
INDEX
3. SAFETY GUIDELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.1. DANGER SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.2. AREAS OF RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
3.3. PERSONAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.4. PERSONAL PROTECTIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.5. WORK AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
3.6. SAFETY AND MONITORING DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
3.7. SAFETY SIGNS ON THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11

3.7.1. MEANING OF THE SAFETY SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.8. MACHINE SPECIFIC DANGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

3.8.1. INJURIES CAUSED BY MECHANICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
3.8.2. INJURIES DUE TO HYDRAULIC ENERGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
3.8.3. DANGER OF BURNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
3.8.4. CHEMICAL BURNS * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
3.8.5. DANGER OF FIRE AND EXPLOSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
3.8.6. DANGER OF POISONING AND ASPHYXIATION . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
3.8.7. ENDANGERING THE ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
3.8.8. ELECTROMAGNETIC EFFECTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
3.9. ADDITIONAL DANGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20

3.9.1. EFFECTS FROM WIND AND STORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
3.9.2. SNOW AND ICE LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
3.9.3. LIGHTNING STRIKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
3.9.4. HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
−3.1− 1760_170461
SAFETYGUIDELINES
1760_170461 −3.2−
SAFETYGUIDELINES
3. SAFETY GUIDELINE
Your safety − as machine operator or maintenance technician − is of utmost priority. Any number of occurring
situations, problems or malfunctions on the machine can represent serious risk to safety, if you are not fully
aware of the measures to take to avoid and prevent possible dangers.
This chapter
F contains generally valid information on safety and safety guidelines,
F explains the meaning of symbols and pictograms used in this operating manual and the signs on
the machine
F gives information about the necessary protective equipment and which requirements apply to the
operating and maintenance personnel,
F shows the location of the safety and monitoring devices on the machine,
F gives information concerning dangers and other risks which can also occur during operation of the
machine as directed.
Special handling and situation related notes an safety are specified in the following chapters of this operating
manual and in further sections of the documentation included in delivery.
State−of−the−art technology
Upon delivery the machine features technology that is currently considered state−of−the−art.
The standards that were met are stated in the declaration of conformity.
Nevertheless, dangers around the machine must be taken into consideration if the notes on safety in this oper
ating manual are not observed and implemented.
−3.3− 1760_170461
SAFETYGUIDELINES
3.1. DANGER SYMBOLS
In the operating manual hazards, important information and tips on utilization are characterized with special
symbols and signal words. They are always in front of the relevant work step and are marked as follows:
DANGER !
Indicates an imminently hazardous situation which, if not avoided, will result
in death or serious injury.
− Refers to action to reduce or avoid the danger(s).
WARNING !
Indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
CAUTION !
Indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury.
. IMPORTANT !
Indicates tips on readiness of operation that the user has to adhere to.
Disregarding these hints may lead to property and other knock on damages.
. NOTE !
− Relates to operating and maintenance procedures.
− Relates to technical aspects that are helpful and that the user must adhere to.
1760_170461 −3.4−
SAFETYGUIDELINES
3.2. AREAS OF RESPONSIBILITY
The manufacturer
F is responsible for the technically safe condition of the machine supplied,together with accessories and
documentation.
F is aware of its duty to monitor product performance and document all
maintenance and repair work carried out by LIEBHERR personnel.
F ensures that the machine is kept operational by a worldwide maintenance andrepair service.
F runs a training centre and provides training for the owner’s operating and main−tenance personnel as a
service.
The Owner
F ensures that the machine is operated and maintained by qualified personnel only.
F checks that all individuals who come into contact with the machine are fully qualified, and authorises
them to work.
F specifies the skills and responsibilities of all those working with or near the machine.
F provides all necessary protective equipment to individuals working with or near the machine.
F regularly checks that personnel carry out their work in a safety conscious manner.
F is responsible for ensuring the safe condition of the machine.
F completely removes the machine from use upon the discovery of any faults that may affect safety.
F performs inspections on the machine based on national regulations in addition to the inspections stipu
lated by LIEBHERR.
F informs the manufacturer of any accident involving the machine leading to serious injury or major da
mage to property.
F allows LIEBHERR personnel unlimited access to the machine in order that they may fulfil their duty to
monitor the product.
F will not carry out any alterations on the machine without first consulting the manufacturer.
F uses only original LIEBHERR spare parts.
The machine operator

F has read and understood the operating manual.
F operates the machine for the purposes intended, within the limits specified in the load chart and in ac
cordance with the setup and the operating manual.
F wears protective clothing.
F reports to the owner any alteration to the machine that affects safety.
F halts operation immediately if safe operation is no longer possible.
F will not carry out any alterations on the machine without first consulting the manufacturer.
F uses only original LIEBHERR spare parts.
−3.5− 1760_170461
SAFETYGUIDELINES
The Rigger
F is responsible for the correct selection and fitting/removal of the slinging equipment on the load or rig
ging material.
F gives the approval to move and/or accompany the load.
The Signalman
F conveys signals from the rigger to the machine operator.
F gives signals to the machine operator if he is the only person responsible.
The Maintenance personnel

F maintain the machine to ensure that it remains in a safe and reliable condition.
F have read and understood the operating manual.
F wear protective clothing.
F perform all specified maintenance tasks.
F will not carry out any alterations on the machine without first consulting the
manufacturer.
F use only original LIEBHERR spare parts.
1760_170461 −3.6−
SAFETYGUIDELINES
3.3. PERSONAL REQUIREMENTS
The Machine operator

F has reached the statutory minimum age.
F is physically capable (adequate eyesight and hearing, quick reactions) of safely operating the ma
chine.
F can accurately estimate distances, heights and clearances.
F is trained:
− to operate this type of machine
− in attaching and signalling
− to operate fire extinguishing equipment
F is aware of the escape routes in the event of an emergency.
F is not suffering from any physical or psychological ailments that lower any of the specified require
ments.
The Rigger
F is physically capable (adequate eyesight and hearing, quick reactions) of safely using/moving the slin
ging equipment.
F is authorised to rig loads.
F is able:
− to accurately estimate distances, heights and clearances
− to accurately estimate mass and load distribution
− to operate radios and use them to give clear instructions
− to guide the load and ensure the safe movement of the load and the machine
F is trained:
− in attaching slinging equipment
− in signalling and knows the signal signs
− in selecting the correct slinging equipment
− in securing against unexpected detachment
− in preventing damage to the slinging equipment
F is not suffering from any physical or psychological ailments that lower any of thespecified require
ments.
F is not under the influence of alcohol or drugs.
−3.7− 1760_170461
SAFETYGUIDELINES
The Signalman
F is physically capable (adequate eyesight and hearing, quick reactions).
F is authorised to give signal signs.
F is able:
− to accurately estimate distances, heights and clearances
− to operate radios and use them to give clear instructions
− to guide the load and ensure the safe movement of the load and the machine
F is trained in signalling and knows the signal signs.
F is not suffering from any physical or psychological ailments that lower any of thespecified require
ments.
F is not under the influence of alcohol or drugs.
The Maintenance personnel

F have reached the statutory minimum age.
F are physically capable (adequate eyesight and hearing, quick reactions).
F are familiar with the machine and the dangers.
F are familiar with all maintenance procedures and measures.
F are trained to perform maintenance duties, including on specialist equipment.
F are not suffering from any physical or psychological ailments that lower any ofthe specified require
ments.
F are not under the influence of alcohol or drugs.
1760_170461 −3.8−
SAFETYGUIDELINES
3.4. PERSONAL PROTECTIVE GEAR
Always wear tight fitting protective clothing when operating, maintaining or starting up the machine as well as
the correct personal protective gear for each respective task.
WARNING !
There is serious danger of injury from getting stuck in, caught up in or pulled into moving machine
parts.
− Do not wear loose clothing, scarves, open jackets or open shirt sleeves.
− Do not wear jewellry (rings, bracelets, earrings or similar).
The personal protective gear may comprise of:

F Protective helmet, if head injuries can be expected due to
− bumping into something,
− objects swinging, dropping, falling over or flying around,
− long, loose hair.
F Protective glasses, if eye injuries are possible due to
− searing or pressurized liquids,
− loose flying parts.
F Ear protectors, if the sound level is expected to exceed 80 dB(A).
F Dust filter mask, for health damaging gases, steam, mist or dust collecting in the vicinity of operation.
F Protective gloves, if injuries to the hand are possible due to
− burns,
− pointed or sharp edged objects,
− searing or pressurized liquids.
F Safety boots, if injuries to the feet are possible due to
− banging them into something or jamming them somewhere,
− stepping on pointed or sharp objects,
− objects falling down or rolling around.
F Wearing reflective clothing of striking colors, if immediate recognition by other personnel is nec
essary.
F Special protective clothing, against danger from burns, freezing, chemical burns, stabbing or cut
ting injuries to the body.
. NOTE !
The crane operator is responsible himself for
− wearing the required personal protective gear,
− also for regularly washing and caring for it,
− for replacing damaged and useless pieces of the protective gear.
−3.9− 1760_170461
SAFETYGUIDELINES
3.5. WORK AREA
In accordance with the rules of machine guidance the following guidelines were determined for the operations
of the machine:
required operating personnel 1 crane operator
Prescribed working area operator’s cab on the slewing column
While operating the machine
F no one beside the crane operator may be on the crane,
F the crane operator may not leave the cab −not even for a brief spell.
The controls may only be used from the operator’s seat. Activating any controls through the door of the cab
is strictly prohibited.
The requirements for a safe working environment:
F Keep the operator’s cab clean: empty ash trays regularly, only place drinking bottles in the pro
vided holders.
F Do not place magazines or other objects on the control panel.
F Do not keep tools in the operator’s cab.
F Clothing or parts of the protective gear must not block the exit doors nor limit access to the control
panel of the machine.
F Keep the entrance to the operator’s cab clean, free from snow and ice and do not block it off with
any object.
F Keep the windows of the operator’s cab clean, free of condensation and ice.
3.6. SAFETY AND MONITORING DEVICES
− Warning light
− Electronic load moment limiter
− Anemometer
− Emergency stop keys
− Horn and acoustic signal transmitter outside
− Acoustic signal transmitter inside cabin
− Fire extinguisher (inside cabin, machinery house)
− Switch for main battery
− Shut−off valve for diesel tank
− Shut−off valve for hydraulic tank
Functions of the signaling devices:

F The warning lights (optional) signal an obstacle in the darkness for air traffic.
F The horn can be sounded by the crane operator.
1760_170461 −3.10−
SAFETYGUIDELINES
3.7. SAFETY SIGNS ON THE MACHINE
Important safety signs are mounted on the machine. If they are not followed it could lead to serious injuries
or even to deaths.
WARNING !
There is a brake down in safety if any safety signs are missing, damaged or illegible.
Preventive measures:
− Constantly check safety signals for their completeness and legibility.
− Immediately replace missing or illegible safety signs with original ones.
− At the delivery of the machine the safety signs are in the language of the relevant country.
If the crane is sold to another country the buyer is obligated to acquire new safety signs in the language of that
country from the manufacturer and to mount them on the crane.
The number and location of where the safety signs are to be mounted is shown in the following illustration.
3.7.1. MEANING OF THE SAFETY SIGNS
The symbols on the safety signs

F have an exact meaning,
F are divided into three groups with different shapes and colors.
Prohibition signs
These symbols
F are round and have a red signal color,
F are located wherever an action is prohibited that would create dangerous situations.
Fire, naked flames and smoking prohibited.
Access for unauthorized personnel prohibited.
Access for persons with pacemakers prohibited.
−3.11− 1760_170461
SAFETYGUIDELINES
Warning signs
These symbols
F are triangular and have a yellow signal color,
F should draw attention to obstacles and situations that could bring about danger to life and limb.
Warning of hovering load.
Warning of dangerous machine drives.
Warning of hot surfaces.
Warning of danger of slipping.
Warning of danger from batteries.
Warning of electromagnetic fields.
Warning of high tension.
Warning of dangerous spot.
Fire protection signs

These symbols
F are rectangular and have a red signal color,
F should draw attention to objects and how to use them in case of fire.
Fire extinguisher
1760_170461 −3.12−
SAFETYGUIDELINES
Command signs
These symbols
F are round and blue,
F command wearing personal protective clothing to protect against dangers.
General command signs.
Wear protective helmet.
Wear ear protection.
Wear protective gloves.
Wear protective glasses.
Wear breath protection.
Wear protective boots.
Environmental sign
Keep the environment in mind.
−3.13− 1760_170461
SAFETYGUIDELINES
3.8. MACHINE SPECIFIC DANGERS
3.8.1. INJURIES CAUSED BY MECHANICAL PARTS
WARNING !
Numerous areas on and around and situations working with the machine can cause injuries.
Therefore keep the following safety instructions and preventive measures in mind:
F Do not stand under a hovering load!
F No one may stand in the danger zones of the machine.
F Do not reach into moving drives or parts of the machine.
F Only remove protective and safety covers
− when the machine is at a total standstill and
− isolated against accidental restart.
F Access to the slewing column is only permitted
− to carry out assembly, maintenance or service work,
− with appropriate safety measures such as wearing slip−free protective boots.
F Do not walk on the roof of the operator’s cab.
F Before starting operation, check if all
− protective covers and casings are mounted correctly,
− engine compartment doors are locked,
− safety devices are functional.
F Do not use damaged slings or slings and chains that are not up to lifting the specified load.
F Always wear protective gloves when handling wire rope slings.
F When driving in bolts and pins
− never align the bolt connections by hand,
− always use appropriate specialized tools (mandrel, stud wrench, etc.),
− always wear protective glasses; there is always danger of chipped− off particles of the hardened metal
surface hitting the eyes.
F Do not let any object come into contact with the engine ventilator. Objects that fall into the ventilator or
are dropped into it are shredded and hurled back and can cause severe injuries.
1760_170461 −3.14−
SAFETYGUIDELINES
3.8.2. INJURIES DUE TO HYDRAULIC ENERGY
WARNING !
Hydraulic oil spraying out under high pressure penetrates clothing and the skin and causes
severe injuries.
First aid for injuries:

Bandage injured area with anti−bacterial bandage and call on a medical doctor.
Preventive measures:
F Repairs to hydraulic systems may only be carried out by experienced and specialized technicians.
F Before starting the repairs depressurize all system sections to be opened and all pressure hoses.
F Do not attempt to locate hydraulic oil leakage from small, hard to see orifices by hand but by using a
piece of cardboard or wood.
F Check all hoses, hose connections and fittings regularly, at least however annually, for possible leakage
and damages.
F Damages hoses and hose connections are
− to be replaced by original Liebherr−spare parts,
− basically not to be repaired.
3.8.3. DANGER OF BURNS
WARNING !
Certain surfaces and operating units of the machine attain an operating temperature of over 65 °C.
First aid for burns:

First
F run cold water over the burn and cool it down, then
F cover the burn with anti−bacterial bandage and call on a medical doctor.
These safety instructions and preventive measures protect against burns:
F Always wear protective gloves when working on hot components.
F The engine cooling system is pressurized and steam emitting from it can cause injuries. Only check the
coolant after the cover on the equalizing reservoir has cooled to the point where it can be touched, then
turn the cover carefully by 90°, to release the pressure.
F Avoid touching
− coolant and hydraulic oil bearing parts,
− hot hydraulic or engine oil,
− hot exhaust and the turbo charger.
F Carry out cleaning and maintenance work on the cooled down machine.
−3.15− 1760_170461
SAFETYGUIDELINES
3.8.4. CHEMICAL BURNS *
WARNING !
Both batteries of the machine
− are filled with acidic electrolyte,
− produce detonating gas under intense charging or discharging.
Battery acid
− can lead to blindness if it comes into contact with the eyes,
− can lead to chemical skin burns and may destroy body tissue,
− ruins clothing.
First aid after contact with battery acid:

1. Acid sprayed into the eyes or on the skin must be rinsed away as quickly as possible with a lot of clean water.
If possible use an eye rinse for the eyes.
2. Then cover the injured area with anti−bacterial bandage and call on a medical doctor.
3. Neutralize leaked out battery acid with a soda solution:
Dissolve soda powder, available as detergent or baking powder, in water. Pour the solution carefully on the
acid until it no longer foams.
Follow these safety instructions:
F In the vicinity of battery acid
− smoking is prohibited,
− fires and open flames are prohibited,
− there can be no devices that ignite fires ( e.g. electrical devices).
F When working near batteries always wear protective glasses and gloves.
F Never short circuit the battery. Never place any tools on the battery.
F Discharged batteries
− may freeze and burst open,
− must always be charged and stored in freeze proof rooms.
F In storage
− always keep battery horizontal,
− never keep battery near hot objects such as radiators,
− protect battery from direct sunlight
− in 4 week intervals check charge and if required recharge battery.
1760_170461 −3.16−
SAFETYGUIDELINES
3.8.5. DANGER OF FIRE AND EXPLOSION
WARNING !
While tanking the machine an explosive mixture of gases may be created.
Leaking fuel oil or hydraulic oil may ignite on hot surfaces.
The two batteries of the machine produce explosive detonating gas while charging.
Procedure in case of fire:

1. Stop engine/motor.
2. If possible call for help over the radio.
3. Turn ignition key to the 0 position and leave the operator’s cab.
4. Evaluate the situation:
In a dangerous situation leave the machine and call the fire brigade.
Only if there is no danger to your person should you start to fight the fire.
5. To fight the fire remove the fire extinguisher from its mount on the machine and prepare it for use.
DANGER !
Hydraulic oil that has caught fire
− can only be successfully put out with the fire extinguisher at the very start of the fire,
− mostly leads after a short time to a full fledged fire and to the total loss of the machine !
6. Finding the seat of the fire. Fight the fire with several short bursts from the fire extinguisher. Only spray the
fire from below.
7. While fighting the fire call on the coworkers to
− alarm the fire brigade,
− help with putting out the fire by bringing in more fire extinguishers filled with appropriate substances.
Follow these safety instructions and preventive measures:
F Inform yourself on the number and location of the fire extinguishers, familiarize yourself with their
usage.
F Only tank the machine in a well ventilated area.
F Before filling the fuel tank or the hydraulic tank
− turn off the engine,
− turn off the cab heater,
− turn off the optional standby heater.
F While filling the fuel tank or the hydraulic tank
− smoking and any kind of handling of fire or open flame is prohibited,
− no one may remain in the operator’s cab(they might start the machine by accident).
F While tanking the fuel electrostatic discharges could take place between the machine and the fuel
tank. Make sure there is a good metallic contact between fuel nozzle and fuel tank inlet or else
create a conductive connection between the machine and the fuel rig.
F Fuel that spilled during tanking
− has to be rinsed off the machine at once,
− has to be neutralized with a bonding agent.
F After tanking only start the diesel engine when
− the tank cover is closed,
− the hose of the rig has been removed ,
− no personnel is in the vicinity of the machine.
F Only start the diesel engine as instructed in this operation manual.
Do not use any starting agents containing ethers − DANGER OF EXPLOSIONS!
F No containers with combustible liquids may be carried on the machine!
F To clean the machine no combustible liquids may be used!
−3.17− 1760_170461
SAFETYGUIDELINES
F In the platform area

− no cleaning towels, rags, etc. may be stored,
− flammable residues must be removed regularly (e.g. oily spots, dry leaves, fir needles, ashes,
waste paper, etc.).
F At the site where the machine is being used, only the amount fuel may be stored as is required
for the work at hand.
3.8.6. DANGER OF POISONING AND ASPHYXIATION
DANGER !
The machine’s engine exhaust contains carbon−monoxide and further composites which are
damaging to health. Possible contact with materials and gases that are damaging to health
during operation of the machine in locations with dangerous materials, for example, toxic waste
dumps.
DANGER !
Carbon−monoxide
− blocks the intake of oxygen and leads to death by asphyxiation,
− is a gas without colour or smell,
− is created by incomplete buring procedures,
− is heavier than air and collects on the ground.
Symptoms of carbon−monoxide poisoning with increasing intensity:

o Light: Headaches, shortness of breath with undemanding tasks, palpitations.
o Medium: Excessive fatigue, dizziness and dazed feelings.
o Serious: Impairment of judgement, nausea with vomiting, cramps and unconsciousness.
Death by respiratory and circulatory failure.
First−aid for initial carbon−monoxide poisoning
If symptoms of carbon−monoxide poisoning are discovered
− Switch off the machine’s engine and all fuel−powered components,
− Leave the operator’s cabin and the machine’s immediate vicinity immediately,
− breathe plenty of fresh air and seek medical attention.
Self−protection measures when saving unconscious persons: Thoroughly ventilate enclosed areas before en
tering.
Please note the following safety guidelines and countermeasures:
o First ensure that there is sufficient ventilation before operating the machine in enclosed areas.
o Do not operate the optional stand−by heating in enclosed areas.
Check adjustment of the time switch clock to rule out an unexpected start−up.
o Always wear the corresponding protective equipment in areas with dangerous materials.
o Always wear the necessary dust filter mask and replace their filters punctually.
1760_170461 −3.18−
SAFETYGUIDELINES
3.8.7. ENDANGERING THE ENVIRONMENT
WARNING !
Fuel, oil, cleansing agents or similar mustn’t reach the ground, the waters, or the sewerage !
− Fix any leaks on the machine immediately.
− Neutralize escaped oil or fuel straight away with a binding agent.
− Comply with the environmental protection regulations relating to the disposal of fuels and lubri
cants applicable in the particular country. If in doubt, discuss suitable methods of disposal for
the various fuels and lubricants with the competent collection point or recycling center.
− When draining fuels and lubricants, use only containers that are big enough, do not leak and
are resistant to oil, fuel and chemicals.
− Use separate containers to collect and dispose of the different fuels and lubricants.
3.8.8. ELECTROMAGNETIC EFFECTS
WARNING !
During operation of the machine in the vicinity of transmitter, directional radio or radar stations
− the Litronic−control may temporarily malfunction of may even sustain enough damage that
in completely fails,
− a dangerous electric voltage can be induced in the metal parts of the machine of the load,
causing painful electric shocks.
Electrical equipment installed in the operator’s cab afterwards (walkie−talkie, mobile phone, etc.) can interfere
with the control in unfavorable conditions.
Sensitive electronic equipment or electrically operated medical implements could malfunction in the vicinity
of the machine.
. NOTE !
The Litronic−control with internal VME−Bus fulfils the requirements in accordance with ISO DIN
13766. The electrical and electronic components correspond at least to EN 55022, or EN 55024.
At the site of machine operation

− level values and frequency distribution of the electronic disturbance however, is mostly unknown,
− permissible limiting values of the EMV−standards are substantially exceeded in certain conditions.
Unusual displays or reactions of the control in the vicinity of transmitter or radar stations are an indication of
electromagnetic influences. There are no evident reproducible characteristics for electromagnetic influences.
Countermeasures:
o Operate the machine with extreme awareness when in the vicinity of transmitter or radar stations.
Control and protection functions, such as for example, the optional electronic load moment limitation, will
no longer function in certain conditions without attraction the attention of the operator.
o As soon as electromagnetic influences are suspected the machine may no longer be operated.
o The user receiving the machine must authorize suitably trained personnel to locate and eliminate the
source of the error. If the disturbance radiation can not be eliminated, special shielding measures are
required for the machine before operation can be resumed.
−3.19− 1760_170461
SAFETYGUIDELINES
. NOTE !
The manufacturer
− understands the specialist knowledge for effective elimination of the effects caused by the
malfunction,
− is responsible for the necessary shielding measures for the machine if required.
Please note the following safety guidelines and countermeasures:

o It is prohibited for persons with pacemakers to stand in the immediate vicinity of the machine if options and
additional equipment have been installed, generating strong electromagnetic fields,
o No equipment is to be installed into the control’s switch cabinet without subsequent, written authorization
from the manufacturer!
o Only install walkie−talkies with frequencies in UHF or VHF, if
− the machine fulfils the standards EN 50082, part 2 and IEC 801−3,
− the maximum transmission power is equal or less than 2 watts,
− the site of installation is more than a meter from the switch cabinet.
o Portable walkie−talkies (cell phones) with a maximum transmission power over 2 watts have to be used at
a distance of at least 2 meters of the switch cabinet.
o Do not lay electrical lines from the radio equipment, etc. parallel to the control lines in the operator’s cab!
o Get the customer to inform you of all transmission frequencies, transmission power and transmission times
of any transmission situations in the area.
3.9. ADDITIONAL DANGERS

3.9.1. EFFECTS FROM WIND AND STORM
The permissible wind speeds within which unlimited operation of the machine or with only reduced load only
is possible, depend on the selected operation type and the set−up stage.
This also applies for the maximum permissible wind speeds which when exceeded, operation of the machine
should be shut down immediately.
WARNING !
There is great danger of injury if the maximum permissible wind speeds are neglected during
operation of the machine!
Wind load on the rear side of the boom has the effect of an additional load on the rope hook.
Effects of wind at the rear side of the load
− increase the tail radius,
− possibly lead to oscillation of the load.
Effects of the wind from behind
WARNING !
Optionally mounted walkways on the boom sections reinforce the wind load on the boom.
Wind load on the front side of the boom is especially dangerous with maximum boom angle without load.
Effects of the wind on the front side of the load can lead to oscillation of the load. If the load comes into contact
with the boom, the boom could be damaged or destroyed.
Effects of wind from the front side
WARNING !
Optionally mounted walkways on the boom sections reinforce the wind load on the boom.
Wind load on the boom and load has the effect of an additional inclined hoist
1760_170461 −3.20−
SAFETYGUIDELINES
If it is possible to estimate wind forces and wind speeds using the following charts, if the machine is not in
operation.
Wind force Description of the state of the sea Wind range Sea state Wave
speed height
Beau Description knots m
fort
0 Calm Sea like a mirror 0 <1 Calm 0
1 Light air Ripples with the appearance of scales are 2 1−3 Smooth 0,1
formed, but without foam crests.
2 Light Small wavelets, still short but more pro 5 4−6 Smooth 0,2
breeze nounced. Crests have a glassy appearance
and do not break.
3 Gentle Large wavelets. Crests begin to break. Foam 9 7−10 Slight 0,6
breeze of glassy appearance. Scattered white
horses.
4 Moderate Small waves, becoming longer, fairly frequent 13 11−16 Moderate 1
breeze white horses.
5 Fresh Moderate waves, taking a more pronounced 19 17−21 Rough 2
breeze long form; many white horses are formed.
Chance of some spray.
6 Strong Large waves begin to form; white foam crests 24 22−27 Very 3
breeze are more extensive everywhere. Probably rough
some spray.
7 Near gale Sea heaps up and white foam from breaking 30 28−33 High 4
waves begins to be blown in streaks along the
direction of the wind.
8 Gale Moderately high waves of greater length; 37 34−40 Very high 5,5
edges of crests begin to break into spindrift.
The foam is blown in well−marked streaks
along the direction of the wind.
9 Strong gale High waves. Dense streaks of foam along the 44 41−47 Very high 7
direction of the wind. Crests of waves begin to
topple, tumble and roll over. Spray may affect
visibility.
10 Storm Very high waves with long over−hanging 52 48−55 Phenom 9
crests. The resulting foam, in great patches, is enal
blown in dense white streaks along the direc
tion of wind. On the whole the surface of the
sea takes a white appearance. The ’tumbling’
of the sea becomes heavy and shock−like.
Visibility is affected.
11 Violent Exceptionally high waves (small & medium 60 56−63 Phenom 11,5
storm sized ships might be lost to view for a time enal
behind the waves). The sea is completely
covered with long white patches of foam lying
along the direction of the wind. Everywhere
the edges of the wave crests are blown into
froth. Visibility is affected.
12 Hurricane The air is filled with foam and spray. Sea com 64+ 14
pletely white with driving spray; visibility very
seriously affected
−3.21− 1760_170461
SAFETYGUIDELINES
CAUTION !
Please note in particular all wind−related safety guidelines and protective measures in the initial
pages of the valid load chart, as well as the following additional points:
o Even before the application planning, the wind conditions for the job site and the weather predictions for the
period of operation planned must be known and taken into consideration.
o The machine operator must be aware of the weather report and the actual wind speed at the machine’s job
site before beginning work. If impermissibly high wind speeds are expected in the next few hours, operation
should be aborted and protective measures against the storm damage should be taken.
o During operation of the machine with permissible wind speeds
− respect dangerously high gusts of wind,
− use large items with expansive surfaces only with reduced load (e.g. prefabricated limits),
− move the loads carefully and slowly and avoid every oscillation.
DANGER !
If the maximum permissible wind speed is exceeded, shut down operation immediately:
Lower the load and leave the machine in the parking position.
The parking position

− is suitable for conditions above the maximum permissible wind speed during crane operation, up to maximum
wind speed
− is determined for the different main operation types under point "Parking position".
DANGER !
It is hazardous to remain in the immediate vicinity of the machine during maximum wind speeds!
The occurring wind loads could lead to partial or complete destruction of the boom.
Countermeasures:
At maximum allowed wind speeds, the boom must be laid down in rest position.
3.9.2. SNOW AND ICE LOADS
DANGER !
Danger of accident due to chunks of ice breaking loose and falling down.
Increased danger of damage due of frozen hoist limit switch on the boom.
− Lay down the boom and carefully chip off the larger deposits of ice.
− Remove ice from all sensitive parts, such as hoist limit switches, guides, etc.
CAUTION !
Deposits of snow and ice on the boom
− increase the weight of the boom,
− enlarge the surfaces susceptible to wind.
These factors lead to a higher load it can no longer be operated with the maximum permissible load.
Considerable amounts of snow can accumulate on the optionally mounted walkways on the boom.
1760_170461 −3.22−
SAFETYGUIDELINES
3.9.3. LIGHTNING STRIKES
WARNING !
When lightning strikes, there is danger of injury to all persons in the immedi
ate vicinity of the machine from electric shocks or dangerous level of voltage.
Countermeasures:
o Lay down the boom of the machine punctually before the storm begins.
o Do not remain or leave any large metal objects in the immediate vicinity of the machine during the
thunderstorm.
. NOTE !
Within the interior of the locked operator’s cab, the machine operator is largely protected from the
direct affects of the lightning. The operator’s cab acts as a Faraday cage and channels the lightning
charge safely over the machine.
Laying down the main boom is discretionary and is the responsibility of the machine operator, especially at
sites with regular thunder storms or restricted working area.
The manufacturer expressly recommends that the main boom be lain down punctually when a thunderstorm
is brewing
− with long boom lengths,
− on exposed terrain,
− near riverbanks.
CAUTION !
A strike can cause major damage to the machine, including:
o Total shut−down of the Litronic−control.

o Local welds and damage to bearings on the rotary connection between slewing platform and mast.
Measures in accordance with a confirmed or suspected lighting strike to the machine:
o Thoroughly inspect the machine. (Especially for damaged electric cables.)
o Check functioning of the entire control.
o Move the swing gear slowly listening for distinct noises coming from the rotary connection, especially in the
swing.
o Lay down the boom and inspect for damage. Repair any damage to the paintwork at the point of impact.
−3.23− 1760_170461
SAFETYGUIDELINES
3.9.4. HAND SIGNALS

The hand signals
l serve as communication with visual contact between machine operator and ship’s crew, e.g. assistant and
slinger,
l are clearly stipulated in their configuration in certain national standards.
It must therefore be agreed between all persons involved which hand signals are to be used.
The following summary is limited to common hand signals in
l Germany in accordance with BGV A8,
l the United States of America in accordance with ASME/ANSI B30.5.
l special hand signals for lifting gear operation.
General hand signals in accordance with BGV A8
Caution, Start, Attention Stop, Interruption, do not Stop − Danger

continue movement
Hold the right arm stretched up Stretch out both arms to the side, First stretch out both arms to the
wards. horizontally. side, horizontally.
The palm faces forward. The palms face forward. The palms face forward.
Now bend in and stretch out the
arms alternatively.
Hand signs, vertical movements
Lift, Up Lower, Down Slowly

Hold the right arm upwards. Hold the right arm down. Stretch out the right arm horizon
tally
The palm faces forward making a The palm faces inwards making a The palm faces down and is
slow circling motion. slow circling motion. moved slowly up and down.
1760_170461 −3.24−
SAFETYGUIDELINES
Hand signals for lifting operation in accordance with ASME/ANSI B30.5
Lift load Lower load Use main winch

Bend out the right arm and hold it Hold the right arm downwards. Rap on the protective helmet with
upwards. the fist.
The stretched out index finger The stretched out index finger Then give further hand signals.
points upwards. points downwards.
The hand makes small, circular The hand makes small, circular
movements. movements.
Hand signals ASME/ANSI B30.5
Use auxiliary winch Raise main boom Lower main boom

Bend out the right arm and hold Stretch out the right arm horizon Stretch out the right arm horizon
upwards. tally. tally.
Rap on the elbow from under The thumb points upwards, all The thumb points downwards, all
neath with the left hand. other fingers remain closed. other fingers remain closed.
Then give further hand signals.
−3.25− 1760_170461
SAFETYGUIDELINES
Hand signals in accordance with ASME/ANSI B30.5, continuation
Move slowly Lift main boom and lower load Lower main boom and lift load
Give the hand signal for the de Stretch out the right arm horizonStretch out the right arm horizon
sired movement with one hand. tally. The thumb points upwards. tally. The thumb points down
wards.
Hold the other hand above it or Stretch and bend in the remaining Stretch and bend in the remaining
below it. fingers alternatively for as long fingers alternatively for as long as
Example: Raise load slowly. the load has to be lowered. the load has to be lifted.
Hand signals in accordance with ASME/ANSI B30.5
Swinging Stop Emergency stop

Stretch out the right or left arm Stretch out one arm horizontally. Stretch both arms horizontally.
horizontally.
The palm faces downwards. The palm faces downwards. The palms face downwards.
The pointed fingers point in the Swing the arm back and forwards Swing both arms back and for
swing direction. horizontally. wards horizontally.
1760_170461 −3.26−
SAFETYGUIDELINES
Hand signals for lifting operation in accordance with ASME/ANSI B30.5, continuation
Travel Shut down and lock machine Travel with both crawler tracks
Stretch out one arm forwards. Hook in your hands in front of Hold both fists in front of the
your body. body.
The palm faces forward and is Indicate travel direction with cir
gently raised. cular movements (forwards or
Make a movement in the travel backwards).
direction with the open hand.
Hand signals in accordance with ASME/ANSI B30.5
Travel with one crawler track Extend boom (Telescopic arm) Retract boom (Telescopic arm)
Bend out the arm with the fist Hold both fists in front of the Hold both fists in front of the
raised on the side of the crawler body. body.
track that has stopped. The thumbs point outwards. The thumbs point toward each
Bend out the other arm in front of other.
the body.
Indicate the travel direction via
circular movements with the fist
(forwards and backwards).
−3.27− 1760_170461
SAFETYGUIDELINES
Hand signals for lifting operation in accordance with ASME/ANSI B30.5, continuation
Extend boom (Telescopic arm) Retract boom (Telescopic arm)

One−handed signal: One−handed signal:
Hold one fist in front of your Hold one fist in front of your
chest. chest.
The thumbs point to your chest. The thumbs point outwards.
Special hand signals for lifting operation

No special standards have been allocated to these hand signals and they complete the quoted hand signals.
Lift load slowly Lower load slowly Lift main boom slowly
Bend out the right arm and hold it Hold the right arm downwards. Bend out the right arm.
upwards. The pointed index fin The pointed index finger points The thumb points upwards.
ger points upwards. downwards. Hold the left hand above it.
The right hand makes small, cir The hand makes small, circular
cular movements. Stretch out the movements.
left hand and hold it over the right Hold the left hand down.
hand. The palm faces upwards.
1760_170461 −3.28−
SAFETYGUIDELINES
Special signals for lifting operation, continuation
Lower main boom slowly Lift main boom and hold load Lower main boom and hold
load
Bend out the right arm. Bend out the right arm. Bend out the right arm.
The thumb points downwards. The thumb points upwards. The thumb points downwards.
Hold the left hand down. The The left hand makes a fist under The left hand makes a fist under
back of the hand faces upwards. the right hand. the right hand.
Special signals
Lift main boom and lower load Lower main boom and lift load Swing slewing platform to the
right
Bend out the right arm. Bend out the right arm. Bend out left arm and hold up.
The thumb points upwards. The thumb points downwards. The thumb points outwards with
Bend out the left arm. Bend out the left arm. the direction of swing.
The index finger points down The index finger points upwards. Stretch out the right arm down
wards. wards.
Hold the left hand under the right Hold the left hand under the right The index finger points down
hand and rotate. hand and rotate. wards. The hand makes small,
circular movements.
−3.29− 1760_170461
SAFETYGUIDELINES
Special hand signals for lifting operation, continuation
Swing slewing platform to the Open grapple Close grapple

left
Bend out the left arm and hold Stretch out the right arm horizon Stretch out the right arm horizon
up. tally. tally.
The thumb points outwards with Hold the hand downwards with Close the hand into a fist.
the direction of turn. Stretch out fingers semi−open.
the left arm downwards.
The index finger points down
wards. The hand makes small,
circular movements.
1760_170461 −3.30−
4
4
CONTROLANDOPERATINGELEMENTS
INDEX
4. CONTROL AND OPERATING ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.1. OPERATOR’S CONTROLSTAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.1.1. OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
4.1.2. CONTROL LEVER CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.2. CONTROL PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.69

4.2.1. CONTROL PANEL X25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.69
4.2.2. CONTROL PANEL X26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.71
4.2.3. CONTROL PANEL SCREEN WIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.73
4.3. EMERGENCY STOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
4.4. LITRONIC SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16

4.4.1. STATUS BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
4.4.2. MENU BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
4.4.3. SUBMENU BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
4.4.4. PIN CODE PAGE * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
4.4.5. MAIN OPERATING PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
4.4.6. MOTOR PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.28
4.4.7. OPERATING HOURS PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30
4.4.8. ADJUSTMENT PAGE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
4.4.9. ADJUSTMENT PAGE 1 (BYPASS MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.34
4.4.10. ADJUSTMENT PAGE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35
4.4.11. ADJUSTMENT PAGE 2 (BYPASS MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.37
4.4.12. SCOTTI SERVICE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.38
4.4.13. SCOTTI MACHINE DATA PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40
4.4.14. SCOTTI INTERNATIONAL PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.41
4.4.15. SCOTTI LANGUAGE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.42
4.4.16. LITRONIC SERVICE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.43
4.4.17. HYDRAULIC PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.47
4.4.18. GEAR TEMPERATURE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.49
4.4.19. SECTOR LIMIT PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.51
4.4.20. LOAD RECORDER PAGE* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.53
4.4.21. LIFT RECORDER PAGE* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.55
4.4.22. TUGGER WINCH PAGE* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.56
4.4.23. MESSAGE INDICATION PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.58
4.5. CAMERA MONITORING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.60
4.6. VENTILATION AND AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . 4.62

4.6.1. MANUAL CONTROL* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.62
4.7. PA−SYSTEM / AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.63
4.8. SWITCH CABINETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.65

4.8.1. SWITCH CABINET X1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.65
4.8.2. SWITCH CABINET X2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.67
−4.1− 1760_170461
1760_170461 −4.2−
4. CONTROL AND OPERATING ELEMENTS

In this chapter the control and operating elements are described. According the function of the elements, they
are mounted in the cabin or around the crane.
All other authoritative devices for safe crane operation, are listed in chapter 3 SAFETY GUIDELINES" section
safety and supervisory apparatus.
4.1. OPERATOR’S CONTROLSTAND

l The cabin houses all important control− and operation elements.
l The buttons perform either functions or just preselect functions. A preselection only activates
the function. After preselection the designated function is performable.
l Two ergonomic control levers are mounted on both sides of the drivers seat.
The speed of the motions can be controlled stepless from zero to max. speed.
1 Heat and comfort control 9 Key switch service operation

2 Control lever (left−handed) 10 Keyboard hand held for camera*
3 Control lever (right−handed) 11 Control panel X26
4 Litronic screen 12 Radio*
5 Camera monitor* 13 PA−system
6 Emergency stop button 14 Control panel screen wiper
7 Control panel X25 15 Key switch crane control system
8 Key switch bypass mode 16 Operators seat
−4.3− 1760_170461
Key switch Crane control system

Position 1: Crane control system off
Position 2: Crane control system on
Red button Emergency stop"

The motor stops and all brakes apply immediately, if this button is pressed.
Key switch Bypass mode"

Position 1: Bypass mode off
Position 2: Bypass mode on
Key switch Preselection winches" *

Position 1: Hoisting winch 1
Position 2: Hoisting winch 1 + 2
Position 3: Hoisting winch 2
1760_170461 −4.4−
4.1.1. OPERATOR’S SEAT
1 Horizontal adjustment
2 Height and slope adjustment
3 Armrests
4 Backrest adjustment
5 Weight adjustment
−4.5− 1760_170461
4.1.2. CONTROL LEVER CONTROLS
The control lever are spring centered and will automatically return to neutral position, when they are released.
Both movements can be carried out simultaneously. The speed of the motions can be controlled stepless from
zero to max. speed.
CONTROL LEVER LUFF / SLEW MOTION" (LEFT SIDE)
EXPLANATION OF THE DIRECTIONS:

Direction A": Boom motion hoisting"
Direction B": Boom motion lowering"
Direction C": Slew motion right"
Direction D": Slew motion left"
1760_170461 −4.6−
EXPLANATION OF LEVER CONTROLS
1 Button Enable slewing gear free turn"

2 Button Increase tugger winch 1 pull"*
3 Button Bypass sector"
4 Button Decrease tugger winch 1 pull"*
5 not used
6 Button Warning horn"
7 Button Enable VHF radio"
8 Button Bypass lower limit"
9 Button Dead man
−4.7− 1760_170461
CONTROL LEVER HOIST MOTION" (RIGHT SIDE)
EXPLANATION OF THE DIRECTIONS:

Direction A": Hoist motion hoisting"
Direction B": Hoist motion lowering"
Direction C": Tugger winch unwinding"
Direction D": Tugger winch winding up
1760_170461 −4.8−
EXPLANATION OF LEVER CONTROLS

1 Button Enable CT"
2 Button Increase tugger winch 2 pull"*
3 not used
4 Button Decrease tugger winch 2 pull"*
5 Button Enable PA−system"
6 not used
7 Button Bypass hoisting gear"
8 Button Enable UHF−radio"
9 Button Dead man
−4.9− 1760_170461
4.2. CONTROL PANELS
4.2.1. CONTROL PANEL X25
All control and indication elements are explained on the next pages.
1760_170461 −4.10−
Button "Main switch off"
Button and pilot light "Main switch on"
Button and pilot light Main switch tripped"
Button "Crane lighting
Button Flood light"
Key switch personnel lift"
Pilot light Personnel lift"
Yellow button MOPS"
Pilot light MOPS"
−4.11− 1760_170461
4.2.2. CONTROL PANEL X26
tugger1 tugger2
tugger1 tugger2
mooring mooring
X26
1760_170461 −4.12−
All buttons are equipped with a LED (1) that illuminates when the selection of the correspond
ing unit or operation mode has been performed.
Two LED are additionally installed for illumination of the button.
Button Start / stop main motor"
Button Preselection auxiliary hoist"
Button Preselection lashing / hook garage "
tugger1
Button preselection Tugger winch 1*"
tugger2
Button preselection Tugger winch 2*"
tugger1
Button preselection Mooring tugger winch 1*"
mooring
tugger2
Button preselection Mooring tugger winch 2*"
mooring
−4.13− 1760_170461
4.2.3. CONTROL PANEL SCREEN WIPER
1 Screen wiper front window

2 Screen wiper top window
Button Interval operation"
Button Pump operation"
1760_170461 −4.14−
4.3. EMERGENCY STOPS
In case of faults or if conditions require the crane can be switched off immediately at any time by pressing one
of the emergency stop buttons.
EMERGENCY STOPS:
F are components of the safety circuit
F enable a sudden shut down of the crane at emergency situations
A pressed emergency switch

F stops the motor immediatly
F stops all crane functions immediatly
The crane is regularly equipped with following emergency stops:

F Ascent ladder outside (2 x)
F Ascent ladder inside
F Switch cabinet X1
F Switch cabinet X2
F At the aggregate
F On the right side of the operator’s control stand
−4.15− 1760_170461
4.4. LITRONIC SCREEN
The colour LCD screen for the LITRONIC control system has a touch screen function and is used for:
l Crane control and load moment limitation

l Actual electric and hydraulic instrumentation
l Operation hour counters
l Message indication
2 4
1 Status bar
2 Display range
3 Menu bar
4 Submenu bar
1760_170461 −4.16−
4.4.1. STATUS BAR
Bypass LML (Load Moment Limitation)

illuminates whenever LML System is bypassed.
Prewarning
symbol flashes and buzzer sounds when the utilization of the crane is 90 % or higher.
Warning (appears instead of the prewarning symbol)

symbol flashes, buzzer and overload alarm sounds when the utilization of the crane
is 110 % or higher.
. NOTE !
The warning symbol is only available on cranes with a hoisting gear under 150 t SWL.
Overload (appears instead of the warning or prewarning symbol).

symbol flashes, buzzer and overload alarm sounds , if the utilization of the crane
is 130 % or higher.
. NOTE !
On cranes with a hoisting gear from 150 t SWL or higher the motions will stop on 110 %.
On Cranes with a hoisting gear under 150 t SWL the motions will stop on 130 %.
MOPS−system ready
MOPS−system active
MOPS MOPS−system not available
MOPS−system deactivated
CT
Personal transport selected correctly (yellow)
CT
Personal transport not possible to select (red flashing)
−4.17− 1760_170461
MOPS−system locked − main drive not running
MOPS−system locked − diesel engine
MOPS−system locked − personnel transport
AOPS−system ready
AOPS−system active
AOPS AOPS−system not available
AOPS−system deactivated
AOPS−system locked − main drive not running
AOPS−system locked − diesel engine
AOPS−system locked − slewing gear
AOPS−system locked − personnel transport
LBPS
LBPS−system ready for activation but onboard lift selected
LBPS−system active
LBPS
1760_170461 −4.18−
LBPS LBPS−system locked − because of sensor/actuator fault
LBPS LBPS−system locked − main drive not running
LBPS LBPS−system locked − personnel transport
LBPS LBPS−system locked − sector limitation
LBPS
LBPS LBPS−system locked − manual deactivated
°
Seastate
indicates the actually set value of the significant wave height
Ambient temperature*
Hydraulic oil temperature

indicates if the hydraulic oil temperature is under 10 °C.
Disc brake test condition
Hook garage main hoist *
Hook garage auxiliary hoist *
Lifting condition
−4.19− 1760_170461
Slack rope (yellow)
Winches not synchronised (red)

illuminates if the rope lengths differ between the winches
Hook in upper limit (white)

indicates, if the hoisting system reaches its maximum position
The movement stops automatically. Only the opposite movement can be carried out.
Hook in lower limit (white)

indicates, if the hoisting system reaches its minimum position
Boom in upper limit (white)

indicates, if the boom reaches its maximum position
Boom in lower limit (white)

indicates, if the boom reaches its minimum position
Slewing gear right in limitation

indicates, if the slewing system reaches its maximum position
Slewing gear left in limitation (white)

indicates, if the slewing system reaches its maximum position
Hoisting gear upper limit bypassed (yellow)

indicates, by use of the bypass function for upper limit of the hoisting gear
Boom lower limit bypassed (yellow)

indicates, by use of the bypass function for lower limit of the boom.
Slewing gear right limit bypassed (yellow)

indicates, by use of the bypass function for the right limitation of the slewing system
Slewing gear left limitation bypassed (yellow)

indicates, by use of the bypass function for the left limitation of the slewing system
1760_170461 −4.20−
4.4.2. MENU BAR

Pin code page*
Main operating page
Motor page
Operating hours page
Adjustment page
Hydraulic page
Gear temperature page
Sector limitation page
Load recording page
Tugger winch page *
TW
Message page
Buzzer off (illuminates red when active)
−4.21− 1760_170461
4.4.3. SUBMENU BAR

Button adjustment page 1"
Button adjustment page 2"
Button synchronization page
1760_170461 −4.22−
4.4.4. PIN CODE PAGE *
Input field
Numeric pad
Button delete"
Button return"
−4.23− 1760_170461
4.4.5. MAIN OPERATING PAGE
Button slewing gear rapid motion" *
Button slewing gear slow motion" *
act Button tare load"
Button reset rope length"
LBPS Button bypass lateral boom protection system (LBPS)"
1760_170461 −4.24−
Utilization
Green: normal operation
Yellow: overload prewarning
Red: overload situation
Tugger winches*
red: inactive
white: manual mode active
green: mooring (automatic) mode active
Status main drive

red: motor off
yellow: motor starting
green: motor on
Main drive locked
Auxiliary hoisting gear selected
Main hoisting gear selected
Auxiliary hoisting gear (red flashing)

Load limit of auxiliary hoisting gear is reached.
Main hoisting gear (red flashing)

Load limit of main hoisting gear is reached.
Hook traverse selected*
−4.25− 1760_170461
Wind speed
Shows the current wind speed in m/s.
Wind speed (red flashing)

Indicates if wind speed is to high.
Indication status of the sector limit position
Boom outreach
Shows the current outreach in m.
Boom outreach (red flashing)

Indicates if outreach is to high.
1760_170461 −4.26−
Status and warning elements (symbolic picture)
1 Heel and trim

2 Slewing angle
3 Selected load chart
4 Boom angle
5 Selected fall setup of hoisting gear
6 Operational limitations
7 Max. outreach
8 Current load weight
9 Tare load weight
10 Rope length hoisting winch
11 Rope speed hoisting winch
12 Maximum permissible load
−4.27− 1760_170461
4.4.6. MOTOR PAGE
Indication motor off" (indicates red)
Indication motor on (indicates green)
1760_170461 −4.28−
Indication engine speed"

shows the current engine speed in rpm
Indication engine amperage"

shows the current amperage in A
−4.29− 1760_170461
4.4.7. OPERATING HOURS PAGE
Operation hours counter of motor 1
Operation hours counter of motor 2
Operation hours counter of main hoisting winch
Operation hours counter of auxiliary hoisting winch
Operation hours counter of tugger winch 1*
1760_170461 −4.30−
Operation hours counter of luffing gear
Operation hours counter of slewing gear
−4.31− 1760_170461
4.4.8. ADJUSTMENT PAGE 1
Indication selected load chart"*
Indication selected rope reeving"*
Indication selected rope reeving auxiliary hoist"*

Appears instead of main hoist.
Indication selected boom length"*
Indication selected lifting condition"*
Indication wind speed"

15.0 m/s
trim 0.5 ° Indication heel and trim"

heel 0.5 °
1760_170461 −4.32−
0 Button sea state"
Button test system"
Button service page
Button change language"
Button change region"
−4.33− 1760_170461
4.4.9. ADJUSTMENT PAGE 1 (BYPASS MODE)
Monitor buttons: (only available when bypass mode is preselected)
Button change load chart"*
Button change rope reeving"*
Button change lift condition"*
1760_170461 −4.34−
4.4.10. ADJUSTMENT PAGE 2
B1 AOPS LBPS
B2
300 300
0.0 m/min 200 400 200 400
bar bar
100 500 100 500
0 600 0 600
B1
00.0 °
300 300
200 200 400 200 400
bar bar
100 bar 300 100 500 100 500
0 600 0 600
0 400
TW
Indication brake hoisting gear"*

B1
Indication additional brake hoisting gear"*

B2
Indication test brake luffing gear"*

B1
Button AOPS test"*

AOPS
Button LBPS test"

LBPS
−4.35− 1760_170461
Indication luffing circuit pressure"
Indication pump pressure
Indication test pressure
1760_170461 −4.36−
4.4.11. ADJUSTMENT PAGE 2 (BYPASS MODE)
B1 AOPS LBPS
B2
300 300
0.0 m/min 200 400 200 400
bar bar
100 500 100 500
0 600 0 600
B1
00.0 °
300 300
200 200 400 200 400
bar bar
100 bar 300 100 500 100 500
0 600 0 600
0 400
TW
Monitor buttons: (only available when bypass mode is preselected)
Button test brake hoisting gear"*
Button test additional brake hoisting gear"*
Button test brake luffing gear*
−4.37− 1760_170461
4.4.12. SCOTTI SERVICE PAGE
Button change time zone"
Button change message language"
Button canbus information"
Button change priority level
Button test system"
Button help"
1760_170461 −4.38−
Button machine data"
Button process info"
Button sw info"
Button hw info"
−4.39− 1760_170461
4.4.13. SCOTTI MACHINE DATA PAGE
Button store machine data"
1760_170461 −4.40−
4.4.14. SCOTTI INTERNATIONAL PAGE
Button and indication change time zone
Indication date
Button and indication change time
−4.41− 1760_170461
4.4.15. SCOTTI LANGUAGE PAGE
Button confirm/unconfirm language
1760_170461 −4.42−
4.4.16. LITRONIC SERVICE PANEL
++
−−
Button test system"
Button keyboard"
Button increase volume"

+
−4.43− 1760_170461
Button decrease volume of panel speaker"

−
Button increase brightness"

+
Button decrease brightness"

−
1760_170461 −4.44−
7 8 9
4 5 6
1 2 3
0 .* P
+/− + E
− − +
ENTER
Button minimize"
switches from keyboard menu to menu bar
7 8 9 Numeric keypad with decimal point
4 5 6
1 2 3
0 .* P
+/− Button +/− to enter negative numbers
E Button exponent"
−4.45− 1760_170461
+ Button increase brightness"
− Button decrease brightness"
−
Button decrease volume of panel speaker"
+
Button increase volume of panel speaker"
Button correction values

for changing to the correction values page
Button crane picture"

to return to the service page
Button test system"

test system picture will be refreshed.
Button "enter"
ENTER the entered values are accepted by the Litronic control system.
Button "cursor back"

to correct an entered value in the selected (inverse) numeric field on the LCD screen.
Button "cursor next"

the cursor on the LCD screen moves to the next numeric field.
Button service"
only for authorized service personnel
1760_170461 −4.46−
4.4.17. HYDRAULIC PAGE
Monitor symbols
Indication of "hydraulic oil temperature"

shows the current temperature of the hydraulic oil in _C
Indication of working pressure main hoisting circuit"

shows the current working pressure in the main hoisting circuit
−4.47− 1760_170461
Indication of "working pressure in slewing left circuit".

shows the actual pressure in the slewing system
Indication of "working pressure slewing right circuit".

shows the actual pressure in the slewing system
Indication of working pressure in luffing circuit"

shows the actual pressure in the luffing system
1760_170461 −4.48−
4.4.18. GEAR TEMPERATURE PAGE
70 70 70 70
45 °C 95 45 °C 95 45 °C 95 45 °C 95
20 120 20 120 20 120 20 120
Monitor symbols
70
45 °C 95
Indication of "distribution gear temperature"
shows the actual temperature of distribution gear
20 120
70
45 °C 95 Indication of auxiliary hoisting temperature" *

shows the actual auxiliary hoisting temperature
20 120
70
45 °C 95 Indication of main hoisting temperature"

shows the actual main hoisting temperature
20 120
−4.49− 1760_170461
70
45 °C 95 Indication of luffing gear temperature"

shows the actual luffing gear temperature
20 120
1760_170461 −4.50−
4.4.19. SECTOR LIMIT PAGE
Monitor symbols:
Button select sector range"
Button delete sector"
Button left sector point"
Button right sector point"
Indication outreach"
Indication right slewing position"
Indication left slewing position"
−4.51− 1760_170461
2 3
1 Sector range
2 Sector range (active)
3 Current boom outreach

4 Current slewing angle
1760_170461 −4.52−
4.4.20. LOAD RECORDER PAGE*
0.0 t
0.0 t
0.0 t
123
0
MB
0 % 100
90.0 °
Monitor symbols:
Button start record"

(illuminates red when active)
Button stop record"
Button pause load recording"

(illuminates yellow when active)
Button trigger point"
Button lift recorder page"
−4.53− 1760_170461
Indication weight of load"
Indication weight of tare load"
Indication weight of load with tare load"
Indication load cycle"
MB Flash card space

0 % 100
1760_170461 −4.54−
4.4.21. LIFT RECORDER PAGE*
123 185
184
24
MB
0 % 100
Indication record active"

(illuminates red )
Button stop record"
Indication file started"

123
Indication actual lift identifier"

184
Indication overload alarm counter
MB Flash card space

0 % 100
−4.55− 1760_170461
4.4.22. TUGGER WINCH PAGE*
% %
100 100
75 75
50 50
TW1 TW2
25 25
0 0
300 300
200 400 200 400
bar bar
100 500 100 500
0 600 0 600
TW
Indication of "utilization tugger winch 1"

shows the actual utilization of tugger winch 1
TW1
Indication of "utilization tugger winch 2"

shows the actual utilization of tugger winch 2
TW2
1760_170461 −4.56−
300
200 400
bar Indication of "working pressure tugger winch 1
100 500 shows the actual pressure for tugger winch 1
0 600
300
200 400
bar Indication of "working pressure tugger winch 2
100 500 shows the actual pressure for tugger winch 2
0 600
−4.57− 1760_170461
4.4.23. MESSAGE INDICATION PAGE
Monitor symbols
New message
Confirmed message
1760_170461 −4.58−
Explanation of the messages:
1 2
1 Message number
2 Short description
3 Identifer of the responsible I/O Module
−4.59− 1760_170461
4.5. CAMERA MONITORING SYSTEM

COLOUR DISPLAY
1 Selection/setting plus 5 Brightness

2 Selecton/setting minus 6 Contrast
3 Menu/confirmation 7 Automatic brightness on/off
4 Option 8 Camera selection
. NOTE !
For a detailed description refer to Volume Technical description" chapter Additional Documen
tation.
1760_170461 −4.60−
KEYBOARD HAND−HELD
Pan left
Tilt up
Pan right
F1 F2 F3 Zoom in
Tilt down
Zoom out
Zero Lux
Next cam
Brightness
Focus near
F1
Focus auto
F2
Focus far
F3
−4.61− 1760_170461
4.6. VENTILATION AND AIR CONDITIONING SYSTEM
9 10 11 12
8
7
5 13
4 14
3 2 1
1 Button Auto" 8 Pilot light Auto"

2 Button Defrost / Reheat" 9 Pilot light °C"
3 Button Circulating air" 10 Pilot light °F"
4 Button Nominal temperature down" 11 Indication Temperature"
5 Button Nominal temperature up" 12 Indication Blower stage"
6 Pilot light Circulating air" 13 Button Blower stage up"
7 Pilot light Defrost / Reheat" 14 Button Blower stage down"
. NOTE !
For a detailed description refer to volume Technical information" chapter Additional documenta
tion".
4.6.1. MANUAL CONTROL*
I 2
1 Switch automatic control off"

1 0 2 Switch automatic control on"
1760_170461 −4.62−
4.7. PA−SYSTEM / AMPLIFIER

9
8 7 6 5 4 3 2 1
1 Stereo inputs for auxiliary source 6 Volume control for microphone inputs
2 MONO switch 7 DIN input for microphones
3 ATT switch 8 XLR input for microphones
4 Tone control 9 On / Off switch with inserted LED
5 Volume control for auxiliary inputs
Stereo inputs for auxiliary sources

The DIN socket enables the connection of two stereo sources with signal output at 0 dB (car
radio, CD−player, etc.). When the two inputs are driven simultaneously, the signals from the two
sources are transmitted in the mixed mode..
MONO" switch
This knob adjusts the response to the low frequencies, which are emphasized or attenuated
when the knob is turned clockwise or anti−clockwise, respectively. With the knob in the middle
position, the frequency is not modified.
ATT." switch
When lowered, this switch activates the circuit for attenuating the auxiliary source. This function
makes it possible to give priority to microphone announcements, which are otherwise trans
mitted together with the auxiliary source.
Tone control
This knob adjusts the response to the low frequencies, which are emphasized or attenuated
when the knob is turned clockwise or anti−clockwise, respectively. With the knob in the middle
position, the frequency is not modified.
Volume control for auxiliary inputs

This knob adjusts the volume of the microphones connected to the AUX IN" input. The volume
is increased by turning the knob clockwise.
Volume control for microphone inputs

This knob adjusts the volume of the microphones connected to the MIC" inputs (DIN and XLR).
The volume is increased by turning the knob clockwise.
−4.63− 1760_170461
DIN input for microphones

Enables the connection of dynamic microphones with balanced or unbalanced microphones.
When this input is used at the same time as the XLR input, the signals related to the two micro
phones are transmitted in mixed mode. Special terminals of the socket make it possible to
manually control music attenuation (see description ATT. switch") and to supply a LED for indi
cating that the microphone is on.
XLR input for microphones

Like the DIN microphone input, this input enables the connection of dynamic microphones with
balanced or unbalanced output. When this input is used at the same time as the DIN input, the
signals related to the two microphones are transmitted.
On / Off switch with inserted LED

For switching on the unit, indicated by the LED on the key. Before switching the amplifier on,
make sure that the volume controls (4) and (5) are set to the minimum (knob turned all the way
anti−clockwise).
CONNECTIONS AT THE REAR OF THE AMPLIFIER

− power input": supply of the amplifier 12 / 24 V DC
− power output": supply for additional unit 12 V DC
− siren control": connection for siren control (not used)
− spk right": loudspeaker right side
− spk left": loudspeaker left side
1760_170461 −4.64−
4.8. SWITCH CABINETS

4.8.1. SWITCH CABINET X1
Switch Aircraft warning light"
0 I
Red button "Emergency stop"

The main motor stops and all brakes apply immediately, if this button is pressed.
−4.65− 1760_170461
Main switch "Auxiliary power supply"

Operates the auxiliary power supply for the entire lighting and heating system on the crane.
1760_170461 −4.66−
4.8.2. SWITCH CABINET X2
Operation hours counter of main motors
Red button "Emergency stop"

The main motor stops and all brakes apply immediately, if this button is pressed.
−4.67− 1760_170461
Control panel for manual operating
Button "Main switch off"
Button and pilot light "Main switch on"
Pilot light Main switch tripped"
1760_170461 −4.68−
5
5
CRANEOPERATION
INDEX
5. CRANE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.1. CHECKS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.2. SAFE OPERATIONS WITH THE CRANE . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3. REQUIREMENTS AND OBLIGATIONS OF THE CRANE DRIVER . . . . 5.3
5.4. CHECKS PRIOR TO STARTING OPERATION . . . . . . . . . . . . . . . . . . . . . 5.4
5.5. CRANE ASCENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
5.6. EMERGENCY DESCENT * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
5.7. CHECKS BEFORE START UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9

5.7.1.INSPECTION TOUR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.7.2.CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.8. DAILY START−UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10

5.8.1.PRESELECTION POWER PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.8.2.MAIN SWITCH TRIPPED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.8.3.RESET SOFTSTARTER* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.8.4.SWITCH ON CRANE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.8.5.ENTER PIN CODE * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.8.6.START MAIN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
5.8.7.MOVE CRANE FROM PARKING POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
5.8.8.MOVE HOOK(S) OUT OF HOOK GARAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
5.9. START/STOP FOR A WORK BREAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14

5.9.1.SHUT DOWN THE CRANE FOR A WORK BREAK . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
5.9.2.STARTING UP THE CRANE AFTER A WORK BREAK . . . . . . . . . . . . . . . . . . . . . . . . 5.14
5.10. DAILY SHUT DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15

5.10.1.MOVE MAIN HOOK INTO HOOK GARAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
5.10.2.MOVE AUXILIARY HOOK INTO HOOK GARAGE* . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
5.10.3.MOVE CRANE TO PARKING POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
5.10.4.SHUT DOWN MAIN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
5.10.5.SWITCH OFF CRANE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
5.10.6.CHECKS WHEN LEAVING CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
5.10.7.LONGER STANDSTILL PERIOD OF THE CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
5.11. MAIN FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20

5.11.1. HOOK LIFTING AND LOWERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
5.11.2. BOOM LIFTING AND LOWERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
5.11.3. SLEWING LEFT AND RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
−5.1− 1760_170461
CRANEOPERATION
5.12. PRESELECTION CRANE OPERATION MODE . . . . . . . . . . . . . . . . . . . . 5.24

5.12.1. PRESELECTION HOIST GEAR* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
5.12.2. TARING THE LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
5.12.3. RESET ROPE LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
5.12.4. PRESELECTION SEASTATE−FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
5.12.5. PRESELECTION SLEWING GEAR SPEED* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
5.12.6. PRESELECTION SUBSEA OPERATION* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
5.13. AUXILIARY FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28

5.13.1. CONSTANT TENSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
5.13.2. MANUAL OVERLOAD PROTECTION SYSTEM (MOPS) . . . . . . . . . . . . . . . . . . . . 5.30
5.13.3. AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS) . . . . . . . . . . . . . . . . . 5.32
5.13.4. LATERAL BOOM PROTECTION SYSTEM (LBPS) . . . . . . . . . . . . . . . . . . . . . . . . . . 5.34
5.13.5. USE OF EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35
5.13.6. BRAKE TEST * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.36
5.13.7. PERSONNEL LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.38
5.13.8. LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40
5.13.9. WINDSCREEN WIPER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41
5.13.10. BYPASS CRANE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42
5.13.11. BYPASS SLACKROPE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44
5.13.12. OPERATE WARNING HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.45
5.13.13. CHANGE LOAD CURVE GROUP * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46
5.13.14. CHANGE LIFT CONDITION * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.47
5.13.15. CHANGE ROPE REEVING * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49
5.13.16. SECTOR OPERATION * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.54
5.13.17. PA−SYSTEM / AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.55
5.13.18. REMOTE ACCESS (LiDAT)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.56
5.13.19. LOAD RECORDING SYSTEM* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.57
5.13.20. SAVED DATA FILES ON FLASH CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.59
5.13.21. LIFT RECORDING SYSTEM* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.60
5.13.22. DATA EXPORT FROM FLASH CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.62
5.14. LITRONIC® TEST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.63

5.14.1. PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.63
5.14.2. STARTING UP OF THE TEST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.64
5.14.3. THE MENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.64
5.14.4. INPUT / OUTPUT PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.65
5.14.5. MEMORY PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.65
5.14.6. MESSAGES PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.68
5.14.7. CORRECTION PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.69
5.14.8. SPECIAL FUNCTIONS PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.70
5.15. ADDITIONAL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.74

5.15.1. AIR CONDITION AND VENTILATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.74
5.15.2. ADJUSTING THE OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.75
1760_170461 −5.2−
CRANEOPERATION
5. CRANE OPERATION
This chapter familiarizes you with the operation of the crane.

It guides you through the work flow and describes the operational steps
F for daily use,
F to operate the main components such as the boom or hook,
F for crane operation with detailed information,
F to safely shut down the crane.
5.1. CHECKS DURING OPERATION
F Correct use of the slings (ropes or chains), vertical hook position above the load balance point.
F Interaction of multiple movements.
F Precautionary measures in order to avoid contact between the load or the load sling and the
crane structure.
F Environmental conditions.
5.2. SAFE OPERATIONS WITH THE CRANE
The crane is equipped with various safety devices to prevent dangerous operational conditions. These safety
devices cannot however prevent damage occurred due to negligence or erroneous operational input.
The crane operator is responsible for the safe operation of the crane.
Pay special attention to the following:
F the safety instructions in chapter 3.
F familiarize yourself with the layout of the controls before starting up the crane (see chapter 4).
F to the Information in this chapter and remember the instructions provided by the crane manufacturer.
DANGER !
Operating errors can endanger human lives and severely damage or destroy the crane!
− Simultaneous lifting and swinging of load with maximum speed is prohibited.
− Do not carry out any jerky movements with the crane; avoid sudden acceleration or braking.
− Start each movement from a stand still position slowly and gently.
− Do not permit any dynamic effects, such as oscillation or jerkily lifting and lowering of load.
− Always work with foresight: allow plenty of time and space for braking a movement.
5.3. REQUIREMENTS AND OBLIGATIONS OF THE CRANE DRIVER
− Check the lifting operations with respect to the planned deployment of the crane
(e.g. crane capacity, outreach, hook height etc.);
− Check the environmental conditions (e.g. wind, significant wave height, snow,
unfavourable temperatures, visibility etc.);
− Check the suitability of all parts for the intended application
(e.g. components, additional devices, lifting equipment, slings etc.);
− Check the support area is suitable for putting down the heaviest load;
− Check the crane configuration (rope reeving, boom length etc.);
− Check those areas where it is recommended that ear protectors are worn;
− Check whether local noise reduction measures are in place and effective, e.g. whether covers are closed.
−5.3− 1760_170461
CRANEOPERATION
5.4. CHECKS PRIOR TO STARTING OPERATION
F Environmental conditions.
F All hoist ropes, winches and rope sheaves; −> covered by tasks in maintenance list .
F Indicators (e.g. working conditions, fluid level, condition of engine, hydraulic pressure, electrical power feed,
inadmissible wear, wind speed etc.);−> covered by tasks in maintenance list or checks prior to start−up.
F Good and unrestricted view of the load and working area. Otherwise check the communication system used
by the supervisor and crane driver to ensure safe operation.
F Required crane capacity (load chart).
F Correct function of the control systems, indicators and restriction devices;
−> covered by tasks in maintenance list.
F Correct function of protection systems such as AOPS, MOPS etc.; −> covered by tasks in maintenance list.
F The dialogue between the crane driver and rigger must correspond to ISO 12480−1:1997, 5.4.1.
1760_170461 −5.4−
CRANEOPERATION
5.5. CRANE ASCENT
WARNING !
Risk of severe injuries or death.
− Never ascend a crane during crane operation.
− Inform the crane operator before you will ascend on the crane.
−5.5− 1760_170461
CRANEOPERATION
5.6. EMERGENCY DESCENT *
In case of an emergency a descent outside the crane is possible. The emergency rescue devise is located
in the drivers cabin.
3
4
1 Anchor point
2 Emergency rescue device
3 Storage box
4 Cover
5 Rope, carabiner, rescue belt
1760_170461 −5.6−
CRANEOPERATION
WARNING
Risk of falling down!
− Don’t use damaged or incomplete equipment.
− The rescue equipment must be inspected by a qualified person once a year.
− The procedure of rescue device shall be trained before an emergency case.
− Don’t twist the safety rope in order to avoid damages on the rope.
− A visual inspection has to be done after every use of the rescue device.
− Pull the complete rescue equipment from the storage box, hook the carabiner at the anchor point and
secure and throw down the rope.
− Stand above the rescue harness with legs apart.
− Grab the rescue harness at the D−rings (1), lift the rescue harness up to below your armpits and latch the
two D−rings into the karabiner.
−5.7− 1760_170461
CRANEOPERATION
− Pull the "braces" (2) up over your shoulders.
− Sitting / Hanging in the rescue harness, climb down.
− With ripe running into your left hand and holding the brake lever (3) in your right hand, carefully open the
brake.
− To stop movement keep the incoming rope tight and / or release the brake lever.
. NOTE !
For cleaning brush out dirty rope or clean it with tepid water or fine washing agent (Rinse clear after
wards).
1760_170461 −5.8−
CRANEOPERATION
5.7. CHECKS BEFORE START UP
WARNING !
Risk of severe injuries or death by using damaged machinery!
− All defects and errors found are to be reported at once to the person responsible.
− They are also to be professionally corrected before start up
− When there is a change in crane operator, defects found are to be passed on to
the next operator.
. NOTE !
Refilling fuels and lubricants is described in chapter "Maintenance", the required safety precautions
are described in chapter "Safety guidelines".
5.7.1.INSPECTION TOUR
The following visual inspection tour has to be performed daily before start up of the crane:
− Check slewing platform and boom if there are
F leaks (hydraulic oil),
F (willful)damages,
F all safety device are in place,
F all bolts are in firmly,
F ropes do not show any sign of wear.
− Check if safety labels are attached and readable.
5.7.2.CHECKS
− Assure a clear view from the operator’s cab:
− Clean wind shield and side window glasses.
− Refill wiper−washer fluid.
− Check fire extinguishers for readiness and intact seal wire (the date of inspection may not have expired)
− Perform daily lubrication according to maintenance plan. (see chapter 7)
− Check hydraulic oil levels. (see chapter 7) .
− Unlock all EMERGENCY−OFF switches by rotating them counter clock−wise.
− Check availability of the auxiliary supply. The auxiliary supply must be switched on all the time.
CAUTION !
The hydraulic system can be destroyed if the engine is started with a closed shut−off valve.
− Check hydraulic tank shut−off (positioned vertically to the suction line).
The shut−offvalve must be open.
−5.9− 1760_170461
CRANEOPERATION
5.8. DAILY START−UP
5.8.1.PRESELECTION POWER PACK
− Press buttons "Main switch on" at control panel X25.

The activated power supply is indicated by a pilot light.
Power supply to power pack I , II is enable.
M1
M2
5.8.2.MAIN SWITCH TRIPPED
If pilot light Main switch tripped" illuminates:
− Press button main switch off" at control panel X25.
− Then press button main switch on" at control panel X25 again.
5.8.3.RESET SOFTSTARTER*
In case of a invalid condition during operation or starting up main motor, the softstarter will be locked.
Therefore an error message will be indicated on the monitor and softstarter must be reset.
− Press button Reset softstarter" at control panel X25.
M1
The softstarter will be unlocked.
1760_170461 −5.10−
CRANEOPERATION
5.8.4.SWITCH ON CRANE CONTROL SYSTEM
− Turn key switch Crane control system" at control panel X26 to position crane control system on (1).
− Wait until crane control system is started up.
5.8.5.ENTER PIN CODE *
The pin code function prevents people without permit code to operate the crane. The only available page
next to the pin code page is the message page.
. NOTE !
Without correct pin code it is not possible to start the power unit or operate the crane.
After ignition is switched on the pin code page will be displayed on the screen.
− Enter the code (max. 7 digit) and press return (A).
If the code was correct:

A beep sounds.
The main screen will be displayed.
Release of control system.
Release of power unit.
If the code was incorrect:.
Input field (B) is cleared and pin code must be entered again.
Control system is blocked.
Power unit is blocked.
−5.11− 1760_170461
CRANEOPERATION
5.8.6.START MAIN MOTOR
. NOTE !
Limited crane performance available until working temperature is reached !
Working temperature: Hydraulic oil temperature is equal or greater than 40°C.
− Press button Start / stop motor" at control panel X26.
Motor is starting up and actual power pack selection is indicated yellow on the screen.
1 2
After a few seconds motor on is indicated green on the screen.
1 2
− Check if no faults indicated on the screen.

− If one or more faults indicated, check reason and eliminate troubles.
5.8.7.MOVE CRANE FROM PARKING POSITION
CAUTION !
Careless and unproper use can lead to damages to the boom!
− If your vision is obscured, locate a banksman to guide you into the parking position and follow his
instructions.
− Avoid sudden starts and stops.
− Release lashing of the hook and boom.

− Raise boom to working range.
As soon as working range is reached, indication boom in lower limit" disappears.
The crane is ready for operation.
1760_170461 −5.12−
CRANEOPERATION
5.8.8.MOVE HOOK(S) OUT OF HOOK GARAGE
. NOTE !
The function for the main and auxiliary hoist is the same but the working radius to move out the hook
of the garage may differ for the auxiliary hoist (0° or approx. 80° angle).
− Hoist the boom to the upper limit switch (approx. 80° angle).
− Boom in upper limit is indicated.
− Lower the hook(s) out of the garage by operate right handed control lever.
If the working position is reached the symbol for hook garage" extinguishes on the screen.
−5.13− 1760_170461
CRANEOPERATION
5.9. START/STOP FOR A WORK BREAK

5.9.1.SHUT DOWN THE CRANE FOR A WORK BREAK
− Lower the load to ground.

− Move the boom and the hook to a position, which will not endanger anyone on board.
− Turn key switch Crane control system" at control panel X26 to position crane control system off (1).
5.9.2.STARTING UP THE CRANE AFTER A WORK BREAK
− Turn key switch Crane control system" at control panel X26 to position crane control system on (1).
− Wait until crane control system is started up.

The crane is now ready to continue work
1760_170461 −5.14−
CRANEOPERATION
5.10. DAILY SHUT DOWN
5.10.1.MOVE MAIN HOOK INTO HOOK GARAGE
PRECONDITIONS:
F No load on the hook.
F No cross beam on the hook.
− Hoist the boom to hook block parking position approx. 80° boom angle.
− Hoist the main hook to the upper limit switch.
Hook in upper limit is indicated.
− Push button preselection hook garage" at control panel X26.
Hook garage main hoist" indicates white on the screen.
− Keep pressed button bypass hoisting gear" (1) on the right control lever.
− Hoist the hook into the garage.
−5.15− 1760_170461
CRANEOPERATION
5.10.2.MOVE AUXILIARY HOOK INTO HOOK GARAGE*
PRECONDITIONS:
F No load on the hook.
F No cross beam on the hook.
. NOTE !
The function for the main and auxiliary hoist is the same but the boom working radius to move the
hook into the garage may differ for the auxiliary hoist (0° or approx. 82° angle)
− Hoist the boom to hook block parking position approx. 80° boom angle.
− Hoist the auxiliary hook to the upper limit switch.
Hook in upper limit is indicated.
− Push button preselection auxiliary hoist" at control panel X26.
Hook garage auxiliary hoist" indicates white on the screen.
− Keep pressed button bypass hoisting gear" (1) on the right control lever.
− Hoist the hook into the garage.
1760_170461 −5.16−
CRANEOPERATION
5.10.3.MOVE CRANE TO PARKING POSITION
CAUTION !
Incorrect and careless handling can cause damages to the boom.
− If your vision is obscured, locate a banksman to guide you into the parking position.
− Avoid sudden starts and stops.
− The boom must be rested firmly in park position.
− Do not pull down the boom with the hook.
− Turn crane over parking position.

− Lower boom to lower working range limit.
As soon as lower limit is reached, indication boom in lower limit" illuminates.
− Press button "Bypass lower limit" (1) on the left control lever and keep it pressed during parking operation.
Boom lower limit bypassed is shown on the screen.
− Lower the boom gently into park position (0°).

− Release the luffing rope, it should be only very slightly pretensioned.
− Lash hook and boom.
−5.17− 1760_170461
CRANEOPERATION
5.10.4.SHUT DOWN MAIN MOTOR
Motor symbol indicates yellow.
1 2
After a few seconds Indication of "Motor off " illuminates (red).
1 2
5.10.5.SWITCH OFF CRANE CONTROL SYSTEM
− Turn key switch Crane control system" at control panel X26 to position crane control system off (1).
− Press buttons "Main switch off" at control panel X25.

Power supply to power pack I and II is disabled.
M1
M2
1760_170461 −5.18−
CRANEOPERATION
5.10.6.CHECKS WHEN LEAVING CRANE
− Remove key for Crane control system" and put away for safekeeping.
− Close and lock firmly all windows and doors.
− Leave the auxiliary supply switch on position on (1) for crane standstill heating.
5.10.7.LONGER STANDSTILL PERIOD OF THE CRANE
Should the crane be shut down for a period more than four (4) weeks − the crane has to be operated once a
month for at least approx. one (1) hour. In addition to that all the greasing, oil inspections and oil level checks
have to be done as well.
The standstill heating must be switched on all the time in order to prevent moisture in the electric and hydraulic
systems. Switch off only for service work !
The crane has to be preserved, if not in operation for more than three (3) months. Detailed preservation instruc
tions are obtainable at your local Liebherr service department.
−5.19− 1760_170461
CRANEOPERATION
5.11. MAIN FUNCTIONS
DANGER !
Non−observance of safety regulations!
Serious material damage and personal injury.
− Remedy error message.
− Stop machine operation in case of load moment limiter error.
− Observe load chart values.
− Perform smooth and gentle crane movements. Avoid swinging load.
− Ensure that lifting device used has required capacity.
− Observe wind speed stated in load chart.
− Ensure that all sensors, limit switches and angle sensors are working properly.
− Ensure that there are no unauthorized persons in the working range and danger zone.
− Ensure that working range is sufficiently illuminated.
− Observe hand signals (see chapter 3.9.4 − Hand signals).
− Establish free view between machine operator and flagman.
WARNING !
Changing the weight of a load on the hook without using hoisting gear!
Danger of droping or jerking load.
− Never change the weight of a load on the hook without using hoisting gear
− Never add additional weight to the hanging load on the hook.
(e.x. filling water from water bags/test weight)
− Never remove weight of the hanging load on the hook.
(e.x. drain water from water bags/test weight)
CAUTION !
Improper procedure with occurring error message!
Damage to machine.
If error message occurs:
− Constantly monitor load and continue work process until safe stopping of
all machine movements is possible.
Once all machine movements have stopped:

− remedy all error causes and acknowledge error messages.
Acknowledging the error message alone will remedy the causes error.
. NOTE !
During the crane operation the "dead man" switch on the control lever must be continuously pressed
to release the control system.
1760_170461 −5.20−
CRANEOPERATION
5.11.1. HOOK LIFTING AND LOWERING
− Move right control lever backward.

Hook lifts.
Direction arrow up" is displayed (green) on screen.
− Move right control lever forward.

Hook lowers.
Direction arrow down" is displayed (green) on screen.
−5.21− 1760_170461
CRANEOPERATION
5.11.2. BOOM LIFTING AND LOWERING
− Move left control lever backward.

Boom starts to rise.
Direction arrow left" is displayed (green) on screen.
− Move left control lever forward.

Boom lowers.
Direction arrow right" is displayed (green) on screen.
1760_170461 −5.22−
CRANEOPERATION
5.11.3. SLEWING LEFT AND RIGHT
− Move left control lever to left.

− Slewing column turns left.
− Move left control lever to right.

− Slewing column turns right.
−5.23− 1760_170461
CRANEOPERATION
5.12. PRESELECTION CRANE OPERATION MODE
After starting up crane control system and motor the last preselected crane operation modes will be activated
and indicated on the crane operation page.
5.12.1. PRESELECTION HOIST GEAR*
. IMPORTANT !
A change of the operation mode is only possible without a load on the hook and a preselected on
board (SWH) lifting condition.
− Press button preselection auxiliary hoist" on control panel X26.

Button LED illuminates.
Auxiliary hoist is selected.
− Auxilary hoist is indicated on the monitor.
− Press button preselection auxiliary hoist" on control panel X26 again.

Auxiliary hoist is deselected.
Button LED extinguishes.
Main hoist is selected.

Main hoist is indicated on the monitor.
. NOTE !
If a change from main to auxiliary hoist is not possible (load limit), operation mode symbol is shown
red and flashing. In this case hoisting and luffing is not possible.
.
1760_170461 −5.24−
CRANEOPERATION
5.12.2. TARING THE LOAD
Ensure that the following conditions are fulfilled:

l Hook is lifted without load.
l Main operation page is displayed on the monitor
− Press button tare load" on the screen.

act
Weight of the tared load appears on the monitor.
Screen section tare load weight shows zero.
5.12.3. RESET ROPE LENGTH

l Main operation page is displayed on the monitor
− Press button reset rope length" on the screen

Screen section rope length hoisting winch shows zero.
−5.25− 1760_170461
CRANEOPERATION
5.12.4. PRESELECTION SEASTATE−FUNCTION
The seastate is installed in order to lift loads from a supply boat during heavy sea.
. IMPORTANT !
Risk of malfunctions by changing from main hoist to auxiliary hoist when sea state func
tion is preselected.
− Always set the number of the sea state to 0 if u want to change the hoist gear.
− Press button Adjustment page" on the litronic screen.
1 − Press button sea state" to select the significant wave height.

The number in the symbol shows the actual selected onboard/offboard lifting capacity
curve according to the valid load chart.
5.12.5. PRESELECTION SLEWING GEAR SPEED*
. NOTE !
Fast slewing gear mode is only available up to SWL 200t.
− Press button Slewing gear rapid motion" on the screen.

Fast slewing speed is selected.
− Press button Slewing gear slow motion" on the screen.

Normal slewing speed is selected.
1760_170461 −5.26−
CRANEOPERATION
5.12.6. PRESELECTION SUBSEA OPERATION*
. NOTE !
During subsea operation the constant tension (CT) and the slewing gear free turn function are deac
tivated for safety reasons.
− Press button preselection subsea" on control panel X26.
Subsea operation is indicated on the main and adjustment page of the screen.
Press button preselection subsea" again to deselect operation.
−5.27− 1760_170461
CRANEOPERATION
5.13. AUXILIARY FUNCTIONS
5.13.1. CONSTANT TENSION OPERATION
The Constant Tension System (CT−System) is installed to be able to lift loads easily off a supply boat.
. IMPORTANT !
The CT−System works only under certain conditions.
l The load must be greater than approx. 10 % SWL.
l The System can be not activated with a load on the hook.
l Use it only to raise the load from a supply boat, which is floating in the sea.
l Activation is only possible, if the hydraulic pressure in the preselected gear is below 100 bar.
CAUTION !
Risk of shock loads due to sudden impact of load to the hoisting rope!
If in CT operation slack rope occurs, slack rope protection will be activated. Hoisting of
load will be possible but lowering of load will not be possible.
− Lower the hook to the load.

− Use a long pendant to avoid "slack rope" and fix hook on the load.
− Keep pressed button Enable CT−system" (1).
− Move the right−handed control lever into direction lifting.
1760_170461 −5.28−
CRANEOPERATION
The hoisting rope is tensioned, but the load is not lifted.

The hook follows the load in the swell (mooring effect).
− At the best moment to lift the load off the supply boat (when the swell is at it’s peak) move the control lever
to minimum speed and release button Enable CT−system".
The load will safely lifted off.
− Move the control lever handle quickly out again to gain a higher speed of the hook.
−5.29− 1760_170461
CRANEOPERATION
5.13.2. MANUAL OVERLOAD PROTECTION SYSTEM (MOPS)

The manual overload protection system enables the crane driver to avoid an excessive overload situation by
releasing the hoist rope by pressing the yellow button MOPS".
It can be used, when the crane hook gets stuck on a supply boat in order to protect the crane from being pulled
down.
Vertical motion, hook tangled Horizontal motion, hook tangled
DANGER !
MOPS can’t be stopped by pressing one of the emergency stop buttons.
Danger to life, risk of serious injuries and material damages.
− To stop this function or to reset the button, turn and release the knob
− Never use at attached load on the hook.
− Use only in emergencies.
− Ensure that there are no persons in the danger zone.
. IMPORTANT !
l The system works also at stopped main motor and activated emergency stop buttons.
l MOPS is operational as long as crane control system is switched on.
l When the system is activated the brakes of the hoisting winch are lifted and the retaining force
of the hydr. system is limited to 10−20% of max. SWL.
l When personnel lift is preselected, MOPS cannot be activated.
l When the MOPS button is activated during standstill of crane, the crane cannot be switched on.
The yellow button is located in the cabin and is protected with a guard bow to prevent from unintentional re
lease.
− Press yellow button MOPS".
Pilot light MOPS" illuminates.

Additionally an acoustic alarm will warn the individuals on the platform.
"MOPS" indicates (green) on the screen.

The multi disc brakes for the selected hoist motion will open
The hoisting rope can be spooled off easily and torn off the rope fixation point on the winch.
1760_170461 −5.30−
CRANEOPERATION
MOPS TEST
. NOTE !
A daily MOPS test shall be carried out by the crane driver.
PRECONDITIONS:
F Ignition on
F Main motor off
F No load on the hook
WARNING !
A sudden lowering of the hook is possible.
− Ensure that there are no persons in the danger zone.
− Leave the danger zone.
− Move the boom over a position where no damage can be caused.
The MOPS test procedure must be separately executed for main and auxiliary hoist gear.
− Move the hook to any height, but don’t rest it on the ground.
− Move the boom to working position.
− Press yellow button MOPS.
If the test is OK:

An alarm will sound inside and outside the cabin.
MOPS−system active is indicated (green) on the screen.
A slowly lowering of the hook is possible.
If the test is not OK:

An error message appears on the screen.
Depending on the fault MOPS−system deactivated is indicated (red) on the screen.
− Clear the fault before start with the crane operation.

− Stop the function by turn and release the knob clockwise.
−5.31− 1760_170461
CRANEOPERATION
5.13.3. AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS)

The Automatic Overload Protection System guards the crane of an excessive overload situation by releasing
automatically the hoist rope against a back pull.
CAUTION !
Risk of destruction the crane!
− Never stop automatic overload protection system by pressing one of the emergency stop buttons!
. NOTE !
The AOPS function is only available in offboard lift mode.
"AOPS" indicates (green) on the screen.
Possible reason: hook block hang on a supply boat during heavy sea
If the supply boat descend in the swell, it is dangerous for damaging the boom or
breakdown the crane from the platform.
After the AOPS−System is disengaging with load on the hook, following checks must be carry out by an Lieb
herr Service Personnel:
l Optical inspection of the stress carrying welding on the boom, boom pivot and slewing bearing.
l Inspection of the hydraulic system, especially the hydraulic motors.
l Optical inspection holding brakes and additional disc brake.
l Optical inspection mounting frame of the winches.
l Optical inspection of the rope pulleys.
l Read−out crane system data and submit to the manufacturer.
. NOTE !
In accordance with the Liebherr Service station, it will be checked, if exchange of the winch and the
hydraulic motors is necessary. Damaged parts are immediately exchanged, otherwise crane opera
tion is not permitted !
1760_170461 −5.32−
CRANEOPERATION
AOPS TEST
. IMPORTANT !
Execute daily AOPS test procedure to guaranty full functionality.
PRECONDITIONS:
l No load on the hoist rope, only hook
l Main motor running
l AOPS−test not activated
− Press button Adjustment page 2" on the litronic screen.
AOPS
− Press button AOPS test" on the litronic screen.
300
200 400
bar AOPS−test is now running and a hour glass symbol" is indicated on
100 500 the screen.
0 600
If the test is completed successfully a checkmark symbol" is indicated

300
on the screen.
200 400
bar
100 500
If the test failed a lock symbol" is indicated on the screen.
0 600
− In this case call LIEBHERR service department for repair the AOPS−
system.
−5.33− 1760_170461
CRANEOPERATION
5.13.4. LATERAL BOOM PROTECTION SYSTEM (LBPS)

The LBPS is used to avoid the boom from side pull. LBPS is active in all normal conditions when off board
is selected.
. NOTE !
The system is inhibited when main drive is not running, personnel lift is selected, hook garage is
selected and if there are sensor or actuator faults.
To avoid side drift of the crane when waiting off board, the LBPS can be deactivated.
LBPS system activated is indicated green on the main screen.
LBPS
− Press button "LBPS" on the main screen.
LBPS
LBPS−system locked / deactivated is indicated yellow on the main screen.
LBPS
LBPS
°
− Move any control lever to activate LBPS again.
LBPS TEST
PRECONDITIONS:
l No load on the hoist rope, only hook, no crane movements, Main motor running at full speed
LBPS
− Press button LBPS test" on the litronic screen.
300 LBPS−test is now running and a hour glass symbol" is indicated on the
200
bar
400 screen.
100 500
0 600
If the test is completed successfully a checkmark symbol" is indicated
on the screen.
300
200 400
bar If the test failed a lock symbol" is indicated on the screen.
100 500
− In this case call LIEBHERR service department for repair the LBPS−
0 600
system.
1760_170461 −5.34−
CRANEOPERATION
5.13.5. USE OF EMERGENCY STOP
CAUTION !
Using this button during operation can lead to injuries and partial damages of the crane.
− Use only in Emergencies, do not use it for regular shut down of the crane.
− After use check the multiple disc brakes of the hoist winch(es) under supervision by Liebherr
Customer Service for proper function.
− After use check slewing platform and boom if there are damages.
− Press red button emergency stop".

The main motor stops and all brakes apply immediately.
When operational safety has been restored:

− Reset the activated emergency stop button by turning it clockwise before starting the crane again.
−5.35− 1760_170461
CRANEOPERATION
5.13.6. BRAKE TEST *
Always execute the brake test procedure before select personnel lift operation. The hoisting gears and the
luffing gear brakes must be tested separately.
l No load is attached on the hook.
l Hook is not stored in hook garage
l Hook is not lashed on deck.
l The crane is in parking position.
l The crane is over platform
l Personnel lift operation is not preselected.
− Press button test brake hoisting gear" on the litronic screen.
− Check if the hoisting gear winch drum is moving.

If the winch is moving, personnel lift operation is not secure.
− Don’t use personnel lift and contact LIEBHERR customer service.
1760_170461 −5.36−
CRANEOPERATION
− Press button test additional brake hoisting gear" on the litronic screen.
− Check if the hoisting gear winch drum is moving.

− Press button test brake luffing gear" on the litronic screen.
− Check if the luffing gear winch drum is moving.

−5.37− 1760_170461
CRANEOPERATION
5.13.7. PERSONNEL LIFT
Personnel lift operation is used to transport personnel inside a working cage and must be activated to guaran
tee the safety of the transported personnel.
DANGER !
Incorrect usage can cause accidents.
− Changing between normal hoist operation and personnel lift operation is only possible without
load on the hook and standstill of the crane
− The crane operator shall have means of continuous communication with the person to be lifted
or via a banksman who has direct view to the personnel being lifted
− Personnel inside working cage must be secured against falling down
− Lifting of personnel with man cages and working from these cages is only allowed, if man cages
are designed and manufactured according to standard ZH1/461 or to European Machinery
Directive 98/37/EG.
− In case of a total standstill of the crane or hoist system, execute emergency operation as
described under chapter 6. Emergency operation"
PRECONDITION:
F Visibility: daylight only
F observe the permissible windspeed (see load chart)
F observe the permissible secure working height (see load chart)
F successfully executed brake test
F To activate/deactivate personnel lift the load has to be lower than 450 kg.
. IMPORTANT !
During personnel lift operation the hoisting and lowering speed is limited and lifting capacity is re
duced. MOPS, AOPS and CT system will be deactivated during operation.
. NOTE !
Personnel lift is only possible when the preconditions for the selection are observed. If the key
is switched at a different time the operation will not be selected.
− Turn key switch personnel lift on control panel X25 to position I".
0 I
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PERSONNEL LIFT SELECTED CORRECT
If the operation mode is selected correct a yellow CT symbol is shown on the screen.
− Personnel lift operation is indicated white on the main page of the litronic screen.
Pilot light personnel lift" is illuminated on control panel X25.
− Attach an approved working cage to the hook.

The crane can now be driven normally with reduced speed and working capacity.
− Lift / lower the working cage with the right−handed control lever.
− After operation, remove working cage.
− Turn key switch personnel lift" to position 0".
PERSONNEL LIFT SELECTED INCORRECT
If the operation mode is not possible to select, a red flashing CT symbol is shown.
The reason is shown in a message (see messages).
− Personnel lift operation is indicated red on the main page of the litronic screen.
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5.13.8. LIGHTING
− Press button Crane lighting at control panel X25.

Working place light fixture is on.
− Press button Flood light boom at control panel X25.

Flood lights of the boom are on.
− Press button Flood light slewing column at control panel X25.

Flood lights of the slewing column are on.
− Press button Cabin light" in the operators cabin.

Cabin lighting is on.
− Turn switch Helicopter warning light" at switch cabinet.

Aircraft warning lights are on.
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5.13.9. WINDSCREEN WIPER OPERATION
1 Screen wiper top window

2 Screen wiper front window
− Press button Screen wiper front/top window interval operation on control panel
screen wiper.
Screen wiper Interval operation is on.
First LED in the button lights up.
screen wiper a second time.
Screen wiper continuous operation is on.
All LEDs in the button lights up.
Screen wiper a third time.
Screen wiper operation is off.
All LEDs in the button darken.
− Press and hold button Screen wiper front/top window pump operation on control panel
screen wiper.
Windscreen wash system is on.
All LEDs in the button lights up.
− Release button Screen wiper front/top window pump operation on control panel
screen wiper.
Windscreen wash system is off and all LEDs in the button darken.
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5.13.10. BYPASS CRANE LIMITS

This function is used to bypass the crane sector limits for the slewing and luffing gear according the load
chart.
CAUTION !
In bypass mode there is no limitation of the crane slewing and luffing
movements. The crane driver acts on his own responsibility.
Improper use leads to machine damages.
− Work with foresight and care.
One of the stop symbols for sector limit is shown on the screen.
− Turn key switch Bypass mode" to position bypass mode on (2).
− Keep pressed button "Bypass sector" (1) on the left control lever.
When a stop gets overridden one peep is to hear.

The stop symbol is crossed out and shown yellow on the screen.
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− After operation, turn key switch Bypass mode" to position bypass mode off (1).
Crane can now moved according the load chart limits.
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5.13.11. BYPASS SLACKROPE OPERATION

The slackrope protection is used to avoid damages of the hoisting rope.
CAUTION!
Risk of damage or possible involvement of the rope.
− After slackrope occurs, check correct guiding of rope in the rope pulleys and correct winding
up of the rope on the hoisting winch.
If the slackrope sensor detects slackrope movement, lowering of hoisting winch will be stopped.
Slackrope in the hoisting system is indicated on the screen.
− Keep pressed button "Bypass hoisting gear" (1) on the right control lever.
Lowering of the hoisting winch is possible again.
− Move the right control lever into direction lowering" until slackrope disappears on the screen.
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5.13.12. OPERATE WARNING HORN
Press button "Warning horn" (1) on the left control lever.

The warning horn sounds.
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5.13.13. CHANGE LOAD CURVE GROUP *

This function is used to change the valid rules and regulations with their corresponding load curve group
(see also load curve tables in operation manual and cabin).
. NOTE !
Check valid rules and regulations to be considered during crane in service condition (e.g. national
requirements etc.).
− .Press button adjustment page" on the litronic screen.
− .Press button load curve" several times, to change between the different load curves.
The actually selected rules and regulations with the corresponding load curve group is indicated on the screen.
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5.13.14. CHANGE LIFT CONDITION *

With the lifting condition the crane operator has the possibility of, or where he wants to lift the load.
− Verify that no load is attached on the hooks.
− Verify that the crane is in parking position.
− .Press button adjustment page" on the litronic screen.
− .Press button lift conditions" on the litronic screen.

The symbol in the button shows the actual selected lifting condition.
.The actual lifting condition is also shown in the status bar on the screen.
Possible lifting conditions and symbols (vary from crane to crane):
Floating unit − supply vessel
Floating unit barge
Floating unit − semi−submersible
Floating unit − fixed structure
Floating unit − harbour area
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Floating unit − Sub Sea
Floating unit seabed
Floating unit − onboard (SWH)
Fixed structure − supply vessel
Fixed structure − barge
Fixed structure − semi−submersible
Fixed structure − fixed structure
Fixed structure − harbour area
Fixed structure − Sub Sea
Fixed structure − seabed
Fixed structure − onboard (SWH)
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5.13.15. CHANGE ROPE REEVING *

MECHANICAL WORK
This procedure is used to change the actual rope reeving of the crane mechanically.
WARNING !
Risk of working at heights and / or dropped objects.
− Only qualified and authorized personnel are allowed to change the rope reeving of the crane.
− Always use adequate safety equipment (safety harness, personal protective equipment).
CAUTION !
Unproper use lead to damages to the rope and increase the risk of accidents.
− Don’t pull the rope over sharp edges.
− Don’t contaminate the rope with dirt.
− For changing rope reeving, refer to the Liebherr drawings rope reeving" and
rope fixing point" (which can be found in the Technical Information folder).
− Carefully read section Ropes" in chapter maintenance (installation, maintenance, inspection, etc.).
. NOTE !
This is a generic description for rope reeving operations and is not considering the relevant platform
/ vessel layout / worksite / specific local rules and requirements. If a more detailed work plan is re
quired contact the Liebherr After Sales Service Department.
PRECONDITIONS:
l Hook cradles (available by Liebherr) positioned underneath boom when in park position.
l Boom in parking position (between 0 − 5 °, not mandatory to be in boom rest), in a location where proper
access to equipment is ensured.
l Suitable guide rope (e.g. nylon rope) in place, has to be evaluated in accordance to the wire rope weight
(height from deck, size of wire rope, etc. ....)
l Suitable hand tools in place.
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PROCEDURE:
− Place two hook cradles underneath the boom tip.
− Place hook block (for requested fall) in one of the hook cradles, to rest it vertically.
− Place the installed hook block in one of the hook cradles, to rest it vertically.
− Give sufficient slack rope (a few meters) in the hoist rope (bypass of slackrope protection may be required).
− Connect a suitable guide rope to the rope end (1) of the hoist rope at the fixing point. (hook block or boom
tip). (refer to pic. 1)
WARNING !
Risk of unintended movement of the hoist rope.
− For safety reasons, additionally a chain hoist maybe required to secure the rope end.
− Tension the guide rope and secure it to the deck or a suitable fixed point.
It prevents the wire rope from moving due to it’s own weight after disconnection of the
rope end at the fixing point.
− Dismantle the rope end from fixing point (2), by removing pin, nut, etc.(refer to pic. 2)
− Unreeve wire rope (3) completely from installed hook block. (refer to pic. 3)
− Use the guide rope to reeve the wire rope, according to the Liebherr rope reeving" plan, through
the requested hook block. (refer to pic. 4)
− Reeve the wire rope to the requested fixing point, under consideration of the Liebherr rope fixing point"
drawing. (refer to pic. 5)
− Assemble the wire rope (4) to the rope fixing point with the pin, nut, etc. (refer to pic. 6)
− Remove the temporary guide rope.
Rope reeving is completed.
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FOR EXAMPLE: UNREEVE HOIST ROPE
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FOR EXAMPLE: REEVE HOIST ROPE
CAUTION !
Unproper use lead to damages to the rope and increase the risk of accidents.
− Before start of normal crane operations ensure there is no slack rope on the hoist winches.
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ADJUST THE CRANE CONTROL SYSTEM

This procedure is used to change the actual rope reeving of the crane electronically.
WARNING !
Incorrect handling leads to serious injuries and partial damages of the crane.
− Only qualified and authorized personnel are allowed to change the rope reeving of the crane.
− After the first test−run of several lifts check all limit switches, rope fix points, rope pulleys and rope
protection devices again.
− The selected rope reeving must be the same as the installed rope reeving at the crane.
− The operator acts on his own responsibility.
− Press button Change rope reeving" on the litronic screen several times,
to change between the different numbers of fall operations.
The actual selected fall is indicated on the main (1) and adjustment page (2).
6 The number in the symbol shows the actual selected rope reeving.
1 2
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5.13.16. SECTOR OPERATION *

The sector limit system defines a restricted working area of the crane.
. IMPORTANT !
Boom outreach must be greater than 10 meters. Sector angle should be between 10° and 160°.
− .Press button Sector limit page" on the litronic screen.
− .Press button select sector range" to select and edit sector range.
Selected sector range is indicated by the number on the symbol.
− Turn the crane to left sector position and move boom to minimum sector outreach.
− .Press button left sector point.

− Slewing angle and boom outreach position will be saved.
− Turn the crane to right sector position and move boom to minimum sector outreach.
− .Press button right sector point.

− Slewing angle and boom outreach position will be saved.
− Sector is now saved and if the crane reach one of the sector limits, an alarm sounds.
− .Press button delete sector to delete a sector range.
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5.13.17. PA−SYSTEM / AMPLIFIER
CAUTION!
Risk of malfunctions.
− Make sure that no objects or liquids get into the amplifier.
− Should the amplifier be overheated due to prolonged exposure to sunlight, let it cool before using it.
− If the unit should emit any strange sounds or smoke, switch it off immediately.
− To prevent stress on the final power stages, do not allow the amplifier to work in distorting for long
periods of time.
− Never use solvents, petrol or other chemical substances to clean the front panel.
− Before using for the first time, set volume controls to their minimum positions.
− .Switch on power supply, verifying that the inserted LED works.
− Press button Enable PA−system" (1) on the right handed control lever to activate the microphone.
The microphone is activated.
− Speak close to the microphone in order to avoid amplification of background noise.

− Adjust the volume to avoid feedback.
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5.13.18. REMOTE ACCESS (LiDAT)*

A remote access must be allowed by the crane driver. The service interval is set by the database.
− Press button adjustment page" on the screen.
− Press button LiDAT" on the screen.
The symbol on the button turns to green.

Remote access is allowed.
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5.13.19. LOAD RECORDING SYSTEM*
CALIBRATION OF THE LOAD RECORDING SYSTEM

Taring must be performed at each exchanging of the load lifting device and each change of the Flash − program
card.
− Lift the load lifting device (hook, traverse, grab etc.) from ground.
− Wait until the load lifting device is in absolute standstill.
The load indication must not change and should indicate a constant value.
− Press button Main operating page" on the litronic screen.
− Press button Tare load" on the litronic screen.

act The indication of the actual load on the ropes is set to zero.
Taring is now finished and the load recorder is now recording for each load cycle considering in the calculations
the correct weight of the new load lifting device.
ACTIVATE AND STOP THE LOAD RECORDING SYSTEM
Conditions for a valid load cycle:

l load recording system active
l button ’pause load recording’ not active
l trigger point must be passed over
l load for min.10 sec. more than e.g. 3 tons
l load must be lowered to ground.
− Press button start record".

The symbol illuminates red when record is activ.
The load recording system is started and a new load file is created on the memory card.
− Press button stop record".

The load recording system is stopped and the opened load file is closed.
. NOTE !
In the case that the crane is switched off during operating the load recording system, the actual load
file stays opened as long as the load file is closed by pressing button Start / stop record" even when
the crane is switched on again.
PAUSE THE LOAD RECORDING
− Press button pause load recording":

The symbol illuminates yellow when pause is active.
The actual load cycle is not recorded.

− Press button pause load recording"again.
The next valid load cycles will be recorded.
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SETTING THE TRIGGER POINT
− Press button for approx. 3 sec. to set the trigger point.
EXAMPLE FOR A VALID LOAD CYCLE
. NOTE !
Before switching on the load recording system, tare the load lifting device !
− Lift the load.

− Move load over the set trigger point.
− Lower load to ground.
Now the load cycle is saved to the memory card.
In the case that one of the emergency stop buttons should be pressed during a load cycle or the crane is shut
down with lifted load, the actual load cycle is not valid and will not recorded by the load recorder.
After releasing the emergency stop button or starting up the crane following steps should be performed to get
a valid load cycle:
− Press button pause load recording":

− Move load to the place where it is lifted from and lower load.
− Press button Pause load recording " again.
− Lift load and proceed as a normal load cycle.
. NOTE !
The figure below shows the principle function of the load recording system. The trigger point can
be set where it is needed depending on the situations on site !
1 Ship 3 Crane
2 Trigger point 1 4 Trigger point 2
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5.13.20. SAVED DATA FILES ON FLASH CARD

The load information is stored on a flash card.
At each startup of the load recorder a directory will be created on the flash card and all the load cycles will
be saved in this directory.
The data on the flash card can be edit on a personal computer (slot for flash card required).
The load records can be viewed on the screen or also printed.
Flash card directories:
LOAD0001
LOAD0002
LOAD0003
..........
Files in the directories :

The data are recorded into two files:
LOAD0001 / Head.txt
Data.txt
In the Head.txt file the general informations are stored: (example of complete directory)
LOAD RECORDER LOAD0001

start date 05.12.2009 date open directory
start time 14:24:35 time open directory
stop date 06.12.2009 date stop directory
stop time 07:06:48 time stop directory
load cycles 10 number of load cycles
sum load [t] 244.0 summation of all average loads
min. time load cycles load hatch 2 00:12:15 time of shortest load cycle
[t]
max. time load cycles load hatch 3 00:25:32 time of longest load cycle
[t]
In the Data.txt file each lift cycle with all informations about the lift are stored:
date time start time stop net load [t] gross load
[t]
05.12.2009 14:24:35 14:30:22 32,7 50.4
05.12.2009 14:31:40 15:00:17 33.7 53.4
05.12.2009 15:01:20 15:34:55 33.3 52.7
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5.13.21. LIFT RECORDING SYSTEM*

The lift recorder is switched on automatically over the database. Each day when the crane is switched on a
new recording file is started.
− Press button lift recorder page" on the screen.
If the load on the hook gets higher than the adjusted load limit, the lift recorder starts recording.
− Lift the load and move it some distance.
Indication record active" illuminates (red) on the screen.
Indication file started" illuminates (white) on the screen when file was started"
123
Indication actual lift identifier" illuminates (white) on the screen."
STOP THE LIFT RECORDING SYSTEM
. NOTE !
The lift recording function should only be stopped, if no lift cycle is active.
− Press button stop record" on the screen.
The actual recording file is stopped.

A new file is automatically started again.
FLASH CARD
From time to time the data have to be stored from the flash card down to a computer.
MB Free space on the memory card is indicated by symbol flash card space" on the screen.
0 % 100
. NOTE !
Don’t delete the last directory on the flash card. The last directory is always the active recording di
rectory, data can be lost.
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DATA RECORDED ON FLASH CARD

The data are recorded into two files. In the header file the general information are stored. In the data file each
lift cycle with all information about the lift are stored .
Data recorded in header file:

start date date the record started
start time time the record started
stop date date the record stopped
stop time time the record stopped
crane identifier serial number of machine
lift number start total recorded number of lifts when
the record was started
lift number stop: total recorded number of lifts when
this record was stopped
lift rec. in file: lifts recorded from start to stop of
this record
Overload alarm rec.: overload alarms recorded from
start to stop of this record
Data recorded in data file:
Lift identifier: number of the recorded lift cycle

Static load [t]: average load
Peak load [t]: maximum peak load
Max static M [kNm]: maximum static moment
Peak M [kNm]: peak moment
Start radius [m]: radius where lift started
Stop radius [m]: radius where lift ended
Start azimuth [°]: start angle from azimuth
Stop azimuth [°]: stop angle from azimuth
Start sg angle [°]: angle where the lift started
Stop sg angle [°]: angle where the lift ended
Date: date of lift cycle
Cycle start: time lift started
Cycle stop: time lift ended
Lift duration: duration of lift
Operation mode: selected operation mode
Rope reeving: adjusted rope reeving
Max wave height: maximum wave height selected
during lift cycle
Average wind [m/s]: average wind speed during the lift
cycle
Peak wind [m/s]: maximum wind speed during the lift
cycle
90% pre−warning: number of 90% pre]warning
during the lift cycle
Overload alarm: number of overload alarms during
the lift cycle
Overload stop: number of overload stops during
the lift cycle
AOPS activated: number of AOPS activations during
the lift cycle
MOPS activated: number of MOPS activations
during the lift cycle
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5.13.22. DATA EXPORT FROM FLASH CARD

The computer must have a compact flash card (CF) socket in order to use the flash card.
Only the customer card can be removed for evaluating the data.
CAUTION !
Loss of data.
− Do not remove the flash card when in use.
− The crane needs to be shut down and turned off. Only after which, the card can be removed.
− Remove the customer flash card" (3) from the CF2 slot" (2) in the Liebherr CPU" (1) located in the
switch cabinet.
− Plug in the customer flash card" in the compact flash card socket" (4) of the computer.
It will show up as a new hard disc in windows explorer.
− Use a standard text editor to view and edit the file.
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5.14. LITRONIC® TEST SYSTEM
The Litronic® test system is a comprehensive diagnostic and servicing tool, that can be operated on the
Litronic® monitor, a Service Notebook and or via a modem connection*.
It is used to examine in/outputs, flags, internal variables and status.
The Litronic® test system can be called simultaneously and completely independently from several inter
faces (Litronic® monitor, Service Notebook, Modem* etc.).
The Litronic® test system consists of several "menus". It is possible to use the function symbols to switch
between these menus.
Many of the menus have two menu bars, and it is possible to switch between these using the MENU 1/2
function symbol. When the menu is called, the first menu bar always appears.
When the Litronic® test system is called for the first time the main menu is loaded. Whenever the pro
gram is called again, it will load the menu that had been active prior to exiting last time. The remaining
settings also remain intact.
. IMPORTANT !
Only LIEBHERR service personnel are allowed to make changes to the setting and/or corrected values
through the Litronic® service panel.
How to execute the function symbols several times in succession

Some commands can be carried out several times in succession, by entering the number of times it is to
execute (appears on the input bar) and then actuating the function symbol you want. This can include, for
example PREVIOUS and NEXT.
5.14.1. PROPERTIES
The Litronic® test system provides the following functions:

l It displays the identification number and version of the installed software
l It displays all in/outputs of the modules with comments
l It displays the internal memory variables with comments
l It displays a selection list
l It displays the correction values (machine setting values)
l It displays messages (message stack)
l It displays special functions:
Modem configuration*
Memory card control (CF)
CAN configuration/status
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5.14.2. STARTING UP OF THE TEST SYSTEM
CAUTION !
Errors of the LIEBHERR electronic control will not be shown whilst test system is running.
− Press button test system" on the adjustment page"
5.14.3. THE MENUS
The following description of the menu bars describes all available function symbols.
From the main menu you get access to the next menu pages or leave the testsystem by pressing function
symbol BACK" ).
2 −
++
3
−
4
1 Headerline
contains the designation of the current page
2 Main window:
contains the proper information
3 Status line:
Entered values are displayed and modified, messages and input request is also displayed in this line.
4 Function symbols line
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5.14.4. INPUT / OUTPUT PAGE
On this page all in− /outputs of the modules are indicated
function symbol layout

− NEXT CAN LINE changes to the next CAN line
− PREVIOUS−NEXT MODULE changes between the modules of the selected CAN line.
− PREVIOUS−NEXT moves the cursor up and down in order to select a channel of the chosen module
selected channel is shown by an inverse indicated I/Q.
− SELECT loads the selected channel into the select−list". The selected channel is deleted from the se
lect−list, if it was selected before. If a channel is selected, the item is displayed inverse.
− MENU 1/2 changes between the two different function symbol bars.
− DOCUMENT indicates 16 channels (in− / outputs) on one page. Use buttons PREVIOUS/NEXT to
change to the next page at digital modules (32 channels).
− UNDOCUM indicates 16 analog or 32 digital in− / outputs on one page
− IDENTIFY indicates 16 in− / outputs on one page with the identifier.
− BACK returns to main menu page.
5.14.5. MEMORY PAGE
On this page the internal used memories are indicated

− NEXT SECTION changes between the 16 memory−sections: X−B−W−D, 1−2−3−4
− PREVIOUS−NEXT PAGE changes between the pages. One page contains 16 memories of the se
lected SECTION.
− PREVIOUS−NEXT changes between the memories.
Indicates the selected memory with an inverse indicated M.
− SELECT loads the selected memory into the select−list". The selected memory is deleted from the se
lect−list , if already been selected before. If a memory is selected, the item is displayed inverse.
− DOCUMENT indicates the memory with the full text additionally.
− IDENTIFY indicates the memory with the identifier.
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SELECT
It is possible to enter 16 values into the select−list, without permanently changing to the different menu pages.
The entries can be modified and are displayed on the SELECT PAGE.
When adding a new entry to a full select−list, the oldest entry in the select−list is deleted.
The select−list can be saved to the memory card and loaded from the memory card.
Possibility for adding to the select−list
− Select with function symbol SELECT directly on the I/O, MEMORY or CORRECTION VALUE
PAGE required entry (collecting of entries) or
− with function symbol ADD on the SELECT PAGE by entering the IEC address or
− load select−list from a file with function symbol LOAD FROM CARD
Possibility for deleting from the select−list
− Select with function symbol SELECT directly on the I/O, MEMORY or CORRECTION VALUE
PAGE required entry again or
− delete selected entry with function symbol DELETE on the SELECT PAGE

− ADD adds a new entry to the select−list. A menu bar appears (see ADD SELECTION) and the IEC ad
dress can be entered.
− DELETE deletes the selected entry in the select−list.
− PREVIOUS−NEXT changes to each the select−entry. The selected entry is displayed inverse.
− MENU 1/2 changes to the two different function symbol bars.
− IDENTIFY indicates the identifier additionally.
− DOCUMENT indicates the full text additionally.
− LOAD FROM CARD loads a new select−list from a file. A menu bar appears and a filename can be
selected, or a new filename entered.
− SAVE TO CARD saves the current select−list in a file. A menu bar appears and a filename can be se
lected.
ADD SELECTION PAGE
This page is selected by operating ADD out of the SELECTION PAGE. On this page the IEC address of a
new select entry is generated. The IEC address is generated in the input line by operating the function symbols
and the numerical keys.
e.g.: wanted IEC address %QW1.17.1
Q is generated by pressing SELECT
1.17.1 is entered as normal number and can be modified corresponding.
Press button TAKE&BACK to take over the address

− M, I, Q defines the IEC−types memory, input or output. This type is modified at each operation of
the function symbol and is displayed in the input line. The entry can be easily corrected by entering
an other type.
− X, B, W, D defines the size of the IEC entry. The size is modified at each operation of the function
symbol and is displayed in the input line. The entry can be easily corrected by entering an other
type.
− TAKE & BACK returns to the SELECT PAGE.
The IEC address is taken over to the input line.
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SELECT FILE LOAD PAGE
This menu is used to load a stored select−list from the memory card.

− CHARACTER NEXT adds a new sign at the end of the input line. New signs can also be generated
by entering numbers/letters.
− CHARACTER DOWN and CHARACTER UP modify the last sign of the input line.
− PREVIOUS and NEXT moves the cursor up and down in the file−list. When selecting a file, its filename
is taken over to the input line.
− LOAD loads the selected file, which is indicated in the input line and returns to the SELECT PAGE.
− BACK stops the process and returns to the SELECT PAGE.
This menu is used to save a select−list to the memory card.

− CHARACTER NEXT adds a new sign at the end of the input line. New signs can also be generated
by entering numbers/letters.
− CHARACTER DOWN and CHARACTER UP modify the last sign of the input line.
− PREVIOUS and NEXT select the different files in the list. When selecting a file, its filename is taken
over to the input line.
− SAVE saves the select−list in a file (enter file−name in the input line) and returns to the
SELECT PAGE.
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5.14.6. MESSAGES PAGE
On this page displays the saved application messages (sensor errors) and all system errors (CAN bus, mod
ules, central unit etc.) These are buffered internally.

− ALL lists the last 15000 saved messages.
− SINCE START lists only the messages since machine was started.
− LANGUAGE allows another text file for these messages to be loaded and for them to be viewed
in a different language. This language change applies only to the messages page, not to the LI
TRONIC test system (see APPLICATION LANGUAGE SELECTION" page for function symbol
menu.)
− PREVIOUS and NEXT move between the messages
− SAVE TO CARD saves all messages in the buffer to a file. The file name can be selected from
the menu that now appears. A standard file name (created from the current date) is suggested.
This name can, of course, be changed (see SELECT FILE SAVE" page for function symbol
menu).
APPLICATION LANGUAGE SELECTION PAGE
The language in which the messages are displayed is selected on this page.
function symbol assignment

− PREVIOUS and NEXT move between the separate language−files
− SELECT is used to select and load the highlighted language−file
1760_170461 −5.68−
CRANEOPERATION
5.14.7. CORRECTION PAGE
On this page correction values are indicated. This page is similar to the MEMORY PAGE but only correction
values are indicated.

− NEXT SECTION changes between the 4 correction value sections: X−B−W−D
− PREVIOUS−NEXT−PAGE changes between pages. One page contains 16 correction values of the se
lected SECTION.
− PREVIOUS−NEXT changes between the correction values. The selected correction value is indicated
with an inverse displayed M.
− DOCUMENT indicates the correction values with the full text.
− IDENTIFY indicates the correction values with the identifier.
− BASE MIN & MAX indicates the correction values with the base value, the minimum and the maximum
value.
− SAVE TO CARD saves the current correction values in a file. A menu bar appears and a filename can
be selected (function symbol layout refer to SELECT FILE SAVE page)
− SELECT loads the selected entry into the select−list. The selected entry is deleted from the select−list,
if already selected before. If a correction value is selected, the item is displayed inverse.
−5.69− 1760_170461
CRANEOPERATION
5.14.8. SPECIAL FUNCTIONS PAGE
From this page on you can change to further pages or return to the main menu by touching function symbol
BACK. Following pages are subordinated to the special function page

− MODEM − DISPLAY INFO
− DRIVE − SYSTEM LANGUAGE
− TIME − SAMPLE
− LEVEL − SYSTEM STATUS
− CAN CONFIG − MDE
− CAN LINE INFO − CLIENTS
− MENU 1/2 − BACK
MODEM FUNCTIONS PAGE

On this page the modem can be operated and the settings changed
− DIAL dials a entered telephone number
− HANGUP rings off an active modem connection
− RLP ON / OFF switches the radio link protocol for GSM modem connection on resp. off. Switching
on / off is activated at the next machine start up.
− PREVIOUS−NEXT changes between the interfaces. The standard modem client is COM 4.
− PIN INPUT enables the manual input of the PIN code for the GSM modem.
− MODEM CONNECT enables to start the modem−server programme on a non used interface.
− BACK returns to the SPECIAL FUNCTION page.
DRIVE FUNCTIONS PAGE

On this page information about the current drive are indicated
− REMOVE CARD must be operated first before the memory card is removed from the drive. The
system automatically recognizes if a card is plugged into the drive.
− DIR LIST lists all files and directories (no subdirectories) of the current drive.
− PREVIOUS−NEXT DRIVE changes between the drives defined in the system.
− CHECK CARD checks for errors of actual drive
TIME FUNCTIONS PAGE

On this page information about date, time and systemtime are indicated.
− DAYLIGHT SAVING switches over to summer time.
− TIMEZONE MOVE WEST switches timezone setting one hour to the west.
1760_170461 −5.70−
CRANEOPERATION
PRIORITY LEVEL PAGE
On this page you can enter a LICCODE to get into the supervisor level.

− LEVEL CHANGE takes over the value in the input line and checks if it is a valid LICCODE.
CAN CONFIGURATION PAGE
On this page all mounted modules are indicated with their status of use

− NEXT PAGE changes to the next page
− PREVIOUS−NEXT MODULE moves the cursor up an down between the modules
− CAN LINE INFO changes to the CAN LINE INFORMATION page
CAN LINE INFORMATION PAGE
On this page the used CAN lines and their settings are indicated

− IDENT.NO. indicates the ident−, modification− and serialnumber of the CAN bus interface card
CV003.
− VERSION indicates the version of the different installed software components of the CAN bus in
terface card CV003.
− MODULE INFO changes to the CAN CONFIGURATION page.
DISPLAY CONFIGURATION PAGE
On this page the settings for indication of the in−/output page can be changed

− ALL MODULES indicates all modules (used" and not used") on the I/O page.
− ONLY USED MODULES indicates used" modules on the I/O page only.
−5.71− 1760_170461
CRANEOPERATION
SYSTEM LANGUAGE SELECTION PAGE

On this page the system language can be set resp. modified. Depending on the access level the enabled lan
guages or all available languages with release note are displayed.

− PREVIOUS and NEXT select the different files in the list. When selecting a file, its filename is taken
over to the input line.
− SELECT loads the selected file with new system language and returns to the SPECIAL FUNC
TION PAGE.
− USE DEFAULT loads English as new internal system language and returns to the SPECIAL
FUNCTION PAGE.
SAMPLING TRACE PAGE
The SAMPLE TRACE will be used for online data−recording of selected in−/outputs
On this page information about the sampling trace is displayed, the condition of the sampling trace can be
modified and recorded data can be saved to the memory card.

− SAMPLE ACTIVE activates the sampling−trace functionality after setting the options. With this
function recording is started and the trigger conditions are checked.
− TRIGGER MANUAL simulates the trigger conditions.
This function is available only if the sampling is activated and the trigger conditions are not fulfilled
yet.
− END MANUAL stops the recording of the sampling−trace and leads automatically to READY con
dition. This function is available only if the sampling is in active condition.
− LOAD FROM CARD loads a configuration from a existing sample−trace file. A menu bar appears
and a filename can be selected. (function symbol layout refer to SELECT FILE LOAD page)
− SAVE TO CARD saves all recorded data and the sample−trace configuration into a file. A menu
bar appears and a filename can be selected. (function symbol layout refer to SELECT FILE SAVE
page)
− SAVE TO SELECT saves the variables used in the sampling−trace into the select−list. Existing
variables in the select−list will be deleted.
− LOAD FROM SELECT loads the currently selected variables (see SELECT) into the sampling−
list. Existing variables in the sampling−list will be deleted.
− PREVIOUS−NEXT changes between the configuration data. The selected / active entry is dis
played inverse.
− CHANGE modifies the selected entry to the value entered in the input line. This operation is done
only if the value of the input line is in the specified range.
1760_170461 −5.72−
CRANEOPERATION
SYSTEM STATUS PAGE

On this page the current system status (running, stopped, ...) and the timing of the SPS is displayed.
MDE PAGE
On this page the condition of the MDE is displayed.

− SAVE TO CARD saves the MDE−data (function symbol layout refer to SELECT FILE SAVE page)
CLIENTS PAGE
On this page the condition of the different communication interfaces (clients) is displayed.
− PREVIOUS−NEXT changes between the interfaces.
−5.73− 1760_170461
CRANEOPERATION
5.15. ADDITIONAL FUNCTIONS
5.15.1. AIR CONDITION AND VENTILATION SYSTEM
. NOTE !
For a detailed description refer to volume Technical Information chapter Additional documentation".
1760_170461 −5.74−
CRANEOPERATION
5.15.2. ADJUSTING THE OPERATOR’S SEAT
The driver’s seat can be adjusted for maximum driver comfort.
CAUTION !
Risk of injury from incorrect adjustment of the driver’s seat.
− Adjust the seat position and the position of the control and operating elements so
that the latter are easy to see and reach.
− For security reasons adjust the seat only when the crane is not operated.
− The seat should only be mounted or repaired by trained workers. Alterations can lead to lapse of
operation−permission.
− The seat is maintenance free but check fixations twice a year.
− Press lever upwards

− Moving the operator’s seat horizontally.
− Turn the adjustment wheel.

The seat suspension is suited to your body weight.
−5.75− 1760_170461
CRANEOPERATION
− Press lever upwards.

− Press your back gently against the backrest.
The backrest tilts backwards.
− Press lever downwards.
The seat back automatically tilts forwards.
− Twist adjusting knobs.

− Adjusting the armrest.
− Untwist adjusting knobs.
1760_170461 −5.76−
CRANEOPERATION

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

To adjust the height of the rear of the seat, press on it then release the pressure.
−5.77− 1760_170461
CRANEOPERATION
1760_170461 −5.78−
6
6
EMERGENCYOPERATION
INDEX
6. EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.1. ARRANGEMENT OF EMERGENCY DEVICES . . . . . . . . . . . . . . . . . . . . 6.3
6.2. EMERGENCY POWER PACK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4

6.2.1. HOIST/LOWER THE LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
6.2.2. LIFT/LOWER THE BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
6.2.3. SLEW THE CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
−6.1− 1760_170461
EMERGENCYOPERATION
1760_170461 −6.2−
EMERGENCYOPERATION
6. EMERGENCY OPERATION
With the built−in emergency power pack it is possible to carry out emergency movements or operations at a
total standstill of the crane.
6.1. EMERGENCY POWER PACK SYSTEM
The emergency power pack shall be used only in case of a total standstill of the crane or for testing purposes.
It is possible to carry out all crane movements but only one movement can be executed at the same time.
. NOTE !
When testing the emergency power pack system for correct function, the crane ignition must be
switched on in order not to lose the stored data from the test system (i.e. position of the hook, boom,
slewing column etc.).
6.1.1. LAYOUT OF REMOTE CONTROL
1 Switch control mode"

2 Pilot light remote control on"
3 Control lever
4 Switch remote control on/off"
−6.3− 1760_170461
EMERGENCYOPERATION
6.1.2. CONNECT RECEIVER WITH REMOTE CONTROL
The receiver for the remote control is located in the machinery house.
− Plug remote control box cable (1) into control station (2).
LED operating voltage on" is indicated yellow on the front cover of the receiver.
1760_170461 −6.4−
EMERGENCYOPERATION
6.1.3. TURN ON REMOTE CONTROL
− Ensure that emergency stop buttons on remote control unit and switch cabinet X99 are not released.
− Turn the main switch at switch cabinet X99 to position on.
Pilot light main switch on" is indicated".
− Press button motor on" at control panel X99.

Pilot light motor on "illuminates".
The emergency hydraulic is now running and the crane is ready for emergency operation.
Pilot light remote control on "illuminates".
−6.5− 1760_170461
EMERGENCYOPERATION
6.1.4. HOIST/LOWER THE LOAD MAIN HOIST
WARNING!
In case an emergency operation is carried out, the crane movements are not stopped by limit switches
or other safety devices.
− The movements have to be supervised by additional personnel.
− During emergency operations move crane only in valid limits according the load chart.
− Turn switch control mode to position hoisting gear 1.

Emergency operation for hoisting gear 1 is preselected.
− Move control lever to position hoisting or lowering.

The selected hook(s) starts hoisting or lowering according the movement of the control lever.
− Release control lever to stop the hook motion.
1760_170461 −6.6−
EMERGENCYOPERATION
6.1.5. HOIST/LOWER THE LOAD AUXILIARY HOIST
WARNING!
− Turn switch control mode to position auxiliary gear 1.

Emergency operation for auxiliary gear is preselected.

The hook starts hoisting or lowering according the movement of the control lever.
− Release control lever to stop the hook motion.
−6.7− 1760_170461
EMERGENCYOPERATION
6.1.6. LIFT/LOWER THE BOOM
WARNING!
− Turn switch control mode to position luffing gear.

Emergency operation for luffing gear is preselected.

The boom starts hoisting or lowering according the movement of the control lever.
− Release control lever to stop boom motion .
1760_170461 −6.8−
EMERGENCYOPERATION
6.1.7. SLEW THE CRANE
WARNING!
− Turn switch control mode to position slewing gear.

Emergency operation for slewing gear is preselected.
− Move control lever to position slewing left or slewing right.

The crane starts slewing according the movement of the control lever.
− Release control lever to stop boom motion .
−6.9− 1760_170461
EMERGENCYOPERATION
6.1.8. TURN OFF REMOTE CONTROL
− After each emergency operation turn remote control switch on/off to position off.
Pilot light remote control on "extinguishes".
− Turn the main switch at switch cabinet X99 to position off.

Pilot light main switch on"extinguishes".
− Press button motor off" at control panel X99.
Pilot light motor on "extinguishes".
1760_170461 −6.10−
EMERGENCYOPERATION
6.2. EMERGENCY MANUAL LOWERING SYSTEM
It is possible to release the brakes and to refill the pressure accumulator. Only one movement can be executed
at the same time.
In case of a pressure loss below approx. 20 bar in the pressure accumulator, it is not possible to open the multi
disc brakes. In this case the accumulator can be refilled by the manual operated emergency hand pump.
LAYOUT OF EMERGENCY HAND PUMP
1 Pump lever
2 Pressure port
3 Suction port (connected to hydraulic tank)
4 Pump cylinder
−6.11− 1760_170461
EMERGENCYOPERATION
6.2.1. LOWER THE LOAD / PERSONNEL CAGE
WARNING !
Incorrect use can cause death, severe physical injury or substantial damage to property!
− Emergency operation has to be done by trained personnel only.
− Turn hand valve B9 to emergency position".

− Turn hand valves HA, HB to emergency position".
− Remove safety plate from valve B8, loosen wing nut ,move up the plate and turn sideways.
− Operate slowly hand valve B8 emergency lowering".
If the load / personnel cage will not lower:
− Operate slowly regulation valve H63 emergency lowering" (turn handle).
The personnel cage starts lowering according to the movement of the regulation valve.
(In this way the speed for lowering the load can be variable controlled)
. NOTE !
If not enough hydraulic oil pressure is available, manual emergency operation stops.
The pressure accumulator can be refilled with the emergency hand pump.
AFTER EMERGENCY OPERATION

− To restore "normal position" follow the above sequence backwards.
1760_170461 −6.12−
EMERGENCYOPERATION
6.2.2. LOWER THE BOOM
WARNING !
WARNING !
Danger of droping or jerking load by emergency lowering of the boom if a load is attached on the hook.
− Lower the load to the ground before lowering the boom.
− Turn hand valves EA, EB to emergency position".

− Turn hand valve E62 to emergency position".
− Brakes are now opened and the boom should lower.
If the boom does not move:
− Press button on valve E63 and hold it.
− Additionaly open slowly hand throttle valve E63A.
The lowering speed fo the boom can be variable controlled with this valve.
− Stopp the movement by releasing button E63.
. NOTE !

− To restore "normal position" follow the above sequence backwards.
−6.13− 1760_170461
EMERGENCYOPERATION
6.2.3. OPEN SLEWING BRAKES
WARNING !
− Turn hand valves D62A and D62B to emergency position".

− Turn hand valves D62C to emergency position".
− Multi disc brakes will be released.
− Turn the crane slowly by additional gear (e. g. chain block, emergency slewing device).
. NOTE !
1760_170461 −6.14−
EMERGENCYOPERATION
6.2.4. TURN THE CRANE WITH EMERGENCY SLEWING DEVICE
− Dismount the hydraulic motor of one slewing gear.

− Insert slewing device.
− Turn the crank handle of the emergency slewing device (1).
The crane will be slew with slow−speed.

− turn hand valve D62C to normal position".
− turn hand valve D62B to normal position".
− turn hand valve D62A to normal position".
− Remove slewing device and store it in the provided place in the crane.
−6.15− 1760_170461
EMERGENCYOPERATION
− Mount hydraulic motor of the slewing gear to original position.
1760_170461 −6.16−
EMERGENCYOPERATION
6.2.5. LOADING PRESSURE ACCUMULATOR (H73) WITH HAND PUMP
− Operate hand lever (1) until pressure accumulator is filled.
−6.17− 1760_170461
EMERGENCYOPERATION
1760_170461 −6.18−
7
7
MAINTENANCE
INDEX
7. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
7.1. QUALIFIED PERSONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5

7.1.1. MAINTENANCE PERSONNEL AND AUTHORISED SPECIALISTS . . . . . . . . . . . 7.6
7.1.2. REMARK CONCERNING NATIONAL REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.2. MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.3. MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

7.3.1. GREASING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
7.3.2. OIL FILLING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
7.4. LUBRICANT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15

7.4.1. ORDER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
7.4.2. BLENDING OF LIEBHERR HYDRAULIC OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
7.4.3. UTILITY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
7.5. MAIN DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19

7.5.1. MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
7.6. DISTRIBUTION GEARBOXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21

7.6.1. CHECKING THE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
7.6.2. TOP UP GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
7.6.3. REPLACING THE GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
7.7. SLEWING GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24

7.7.2. TOP UP GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26
7.8. MAIN HOISTING WINCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27

7.8.2. TOP UP GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
7.9. AUXILIARY HOISTING WINCH* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29

7.9.2. TOP UP GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30
7.10. LUFFING WINCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31

7.10.2. TOP UP GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32
7.11. TUGGER WINCHES* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33

7.11.2. TOP UP GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.34
−7.1− 1760_170461
MAINTENANCE
7.12. SLEWING BEARING − WEAR MEASUREMENT . . . . . . . . . . . . . . . . . . . 7.35

7.12.1. TILTING CLEARANCE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35
7.12.2. DIAL GAUGE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35
7.12.3. CRANE CONDITION FOR MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36
7.12.4. MAXIMUM PERMISSIBLE INCREASE OF BEARING CLEARANCE . . . . . . . . . . . 7.37
7.13. EXTERNAL DISC BRAKES * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38

7.13.1. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
7.13.2. CHANGING THE BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
7.14. ROPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.39

7.14.1. CONDITION BEFORE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.39
7.14.2. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40
7.14.3. INSTRUCTIONS FOR UNTWISTING OF HOIST ROPES . . . . . . . . . . . . . . . . . . . . 7.42
7.14.4. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.43
7.14.5. EXAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.44
7.14.6. DISCARD CRITERIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.47
7.14.7. OPERATING PERFORMANCE OF WIRE ROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56
7.14.8. CONDITION OF EQUIPMENT RELATED TO ROPE . . . . . . . . . . . . . . . . . . . . . . . . 7.56
7.14.9. ROPE EXAMINATION RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56
7.14.10. ROPE STORAGE AND IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56
7.15. ROPE PULLEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.57

7.15.1. CHECKING THE ROPE DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.57
7.16. CHECKING HYDRAULIC LINES AND HOSES . . . . . . . . . . . . . . . . . . . . . 7.62

7.16.1. INDICATION OF HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.62
7.16.2. REPLACEMENT AND INSPECTION OF HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.62
7.17. HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.63

7.17.1. CHECKING THE HYDRAULIC OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.64
7.17.2. TOP UP HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.64
7.17.3. REPLACING RETURN FLOW FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.65
7.17.4. VALVE AND FILTER PLATE AGGREGATE ROOM . . . . . . . . . . . . . . . . . . . . . . . . . . 7.66
7.18. LIEBHERR OIL DIAGNOSIS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.67

7.18.1. TAKING AN OIL SAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.67
7.18.2. TAKING AN GREASE SAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.69
7.18.3. DIAGNOSTIC REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.69
7.19. PRESSURE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.70

7.19.1. TESTING THE PRESSURE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.70
7.20. MAINTENANCE OF OIL COOLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.71
7.21. WINDOW CLEANING* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.72
7.22. REPLACEMENT OF BOOM / CHANGE BOOM CONFIGURATION . . . 7.74
7.23. REPLACEMENT OF PRIME MOVERS / GEARBOXES . . . . . . . . . . . . . 7.74
7.24. REPLACEMENT OF WINCHES / WINCH DRUMS . . . . . . . . . . . . . . . . . 7.74
1760_170461 −7.2−
MAINTENANCE
7.25. REPLACEMENT OF SLEW BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.74
7.26. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.75

7.26.1. REPLACING FUSES AND LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.75
7.26.2. REPLACING OF FILTER MAT * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.75
7.26.3. CLEANING THE SLIP RING UNIT * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.76
−7.3− 1760_170461
MAINTENANCE
1760_170461 −7.4−
MAINTENANCE
7. MAINTENANCE
In tables, this chapter lists all maintenance works that have to be carried out on the crane.
. NOTE!
The exchange of the following components must be requested from our after sales service depart
ment: Winches, boom, slew bearing, gearboxes, drive units and all safety−relevant parts.
The operator is responsible for a job safety assessment and safe method of temporary access when
maintenance work is done on difficult to reach areas.
7.1. QUALIFIED PERSONS
Persons responsible for the safety of the crane must ensure that:
l Qualified persons are only delegated to work on the machinery or apparatus.
l These persons must keep the Operating manual provided, and other documents, available when carrying
out the operations to which they refer and to follow that documentation without fail.
l Unauthorized persons are prohibited from working on, or approaching, the machinery or apparatus.
l 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 authorized by those responsible for the safety of the machine to carry
out the particular task required and who are able to recognize and avoid the potential hazards.
l A knowledge of first−aid and local rescue equipment is essential.
l According to regulations, unqualified personnel are forbidden to work for example on power installations
and apparatus.
. NOTE!
The specified maintenance and inspection intervals must not be exceeded. When required, shorten
the intervals.
The safety guidelines in chapter 3 must be observed and strictly adhered to.
Maintenance must be carried out conscientiously within the specified intervals. These maintenance
intervals are indicated in operating hours and calendar days. Apply the maintenance interval that
comes first.
Whenever the crane will not be in use for at least 3 months, all exposed parts must be covered and
protected against the environment. The protective covers have to be removed before restarting the
crane.
The boom should only be inspected (if applicable) when the boom is in the horizontal position.
−7.5− 1760_170461
MAINTENANCE
7.1.1. MAINTENANCE PERSONNEL AND AUTHORISED SPECIALISTS
MAINTENANCE PERSONNEL
Trained personnel who have received qualified training and posses the necessary specialist knowledge and
experience to perform the various maintenance tasks.
AUTHORISED SPECIALISTS
Personnel who have received specialist training, posses in−depth knowledge about the components and sys
tems, and are authorised by LIEBHERR to perform the specified tasks. These persons are primarily LIEB
HERR service engineers, who have been trained and authorised at one of the service centres.
7.1.2. REMARK CONCERNING NATIONAL REGULATIONS
All of the following maintenance tasks are deemed mandatory by the manufacturer. However, they do not in
clude the requirements of any classification bodies or other regulatory authorities.
1760_170461 −7.6−
MAINTENANCE
7.2. MAINTENANCE INTERVALS
The maintenance intervals mentioned in this section are guiding times and should be observed. If due to ex
treme 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 real
ity these intervals should depend on crane usage and therefore − may need to be updated accord
ingly.
. 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 inspec
tions and oil level checks have to be done as well.
7.3. MAINTENANCE CHART

Different symbols (circle, box, asterisk − filled; circle, box, asterisk − empty) divide the maintenance operations
into two groups.
Meaning of symbols
q m ¶ Symbols without colour fill:

− These maintenance and inspection tasks are to be carried out by authorized
maintenance staff of LIEBHERR or its authorized dealers.
n l « Symbols with colour fill:

− In these cases the machine operator or its maintenance staff carry out the
maintenance tasks under its own responsibility.
Special intervals are maintenance intervals that must be carried out in addition to the stipulated maintenance
intervals.
The spare parts required for maintenance and inspection work can be found in the spare parts catalogue.
. NOTE !
l Use the mechanical service hours counter on the left control panel in the cab to determine
the service intervals.
l If necessary, carry out the maintenance and inspection tasks before the specified intervals.
l All filters must be changed at least every two years.
l Clean or replace dirty filters before the specified intervals.
−7.7− 1760_170461
MAINTENANCE
Service/Inspection at
Work to be carried out
Operating hours
by maintenance personnel by authorized maintenance

1000 h / 6 months
500 h / 3 months
6000 h / 4 years
Special intervals
4000 h / 2 years
2000 h or yearly
personnel
40 h or weekly
n one−off task q one−off task

8 h or daily
l repetition interval m repetition interval

« when necessary ¶ when necessary
Overall machine
l Check function and correct indication of all control devices
l Check function of emergency stop(s) without load on the hook and
with running crane control system and drive.
l Visual check of all brackets, ladders, platforms
l Check complete crane for loose objects
l Keep crane, boom, platforms and ladders snow and ice free
l Operate all functions and check correct function of limit switches
l Execute brake test procedure (if personnel transport is installed)
l Execute MOPS test (if installed)
l Execute Standard AOPS test (if installed)
l Visual inspection according inspection report (refer to Technical In
formation)
m All 4 years inspection according inspection report (refer to Technical
Information) or prescribe proofs from the class regulations
l Check function of mechanical boom angle indicator (if installed)

l Visual check of fire damper(s) (if installed)
¶ Visual check of complete crane after extreme incidents (e.g. storm,
overload, emergency stop with load..)
¶ Check after AOPS or MOPS release: visual inspection of all weld
ing seams, inspection of hydraulic system especially motors, visual
inspection of all holding breaks, pulleys and winch support
m Check rated capacity indication
l Check function of emergency lowering/ power pack according
emergency operation (if installed)
l Visual check of cpl painting system on crane against mechanical
damage or corrosion
l l Check rubber backstop at fall back support, replace every five
years (if installed)
Diesel driven cranes
l Refer to original engine manual(s)
Electric driven cranes
l Engine(s) maintenance and lubrication of bearings in accordance to
lubrication plate on motor
l Check insulation resistance after longer down time.
1760_170461 −7.8−
MAINTENANCE
Operating hours

1000 h / 6 months
500 h / 3 months
Special intervals
6000 h / 4 years
2000 h or yearly
4000 h / 2 years
personnel
40 h or weekly

8 h or daily

Distribution gearbox(es) (if installed)

l Check oil level(s)
l Drive up to working temperature, take oil sample, if required ex
change oil
l Check air breather
l Visual check of fastening bolts
Hydraulic System
l Visual check of tightness and condition of hoses, fittings, valves,
blocks, motor(s), pump(s), cylinder(s)
l Visual check of hard piping (if installed)
l Check oil level
l Replace filter elements of all hydraulic filters
l Replace air breather of hydraulic oil tank
l l Clean magnet at return flow filter (weekly at the first 250 hours)
m Check pressure setting, adjust if required
l Drive system to working temperature, take oil sample 10 h after
each hydraulic oil change (reference measurement)
n Drive system to working temperature, take oil sample each 500 h
l Drive system to working temperature, take oil sample each 1000 h /
yearly
l Renew hydraulic oil each 2000h/ 2 years when using NO Liebherr
hydraulic oil
l Renew hydraulic oil each 4000h/ 4 years when using Liebherr Hy
draulic 37
l Renew hydraulic oil each 6000h/ 6 years when using Liebherr Hy
draulic Plus or Liebherr Hydraulic Plus Arctic
n l Check pressure accumulators
m Replace pressure accumulators
l Check oil cooler for contamination, clean if required
m Visual check wear of tooth profile of hydraulic motors and pumps
m Check feed pressure switches for correct function (if installed)
−7.9− 1760_170461
MAINTENANCE
Operating hours

1000 h / 6 months
500 h / 3 months
Special intervals
6000 h / 4 years
2000 h or yearly
4000 h / 2 years
personnel
40 h or weekly

8 h or daily

Winches
l Check gear oil level(s)
n Once after 100 h − take oil sample, if required renew oil
l Drive system to working temperature, take oil sample, if required
change oil
l Check air breather(s)
l Check lower−limit−switch for correct mounting
l Check lower−limit−switch for correct function (if possible)
l Check every installed winch for correct installation to crane main
structure
m Check function of holding break
l Check condition and wear of external disc brake for personal trans
port (if installed)
l Change ATF oil at additional disk brake (Crane type RL, if personal
transport is installed)
l Check condition and wear of rope kicker (if installed)
l Check overhaul mechanical condition of winch(es) like drum
groove, etc.
l Check correct spooling of ropes on the winch drum(s)
l Check correct installation of rope on rope fixing point and fixing
point itself
Slewing gear
l Check oil level(s)
l Check air breather(s)
l Drive system to working temperature, take oil sample, if required
change oil
l Visual check of tightness
l Visual check of gear rim pinion for wear and pittings
l Visual check of fastening bolts
m Check function of holding break(s)
Slewing bearing (not valid for MTC)
l All 250 h, check slewing bearing for sufficient lubrication, regrease
as required
l Check gear rim for sufficient lubrication, regrease if required
m Visual check of gear rim pinion for wear and pittings
l Take grease sample of slewing bearing
m Check correct torque of bolts of slewing bearing
l n Execute tilt measurement procedure incl. zero measuring after
handover
m Replace slewing bearing bolts every 10 years
1760_170461 −7.10−
MAINTENANCE
Operating hours

1000 h / 6 months
500 h / 3 months
Special intervals
6000 h / 4 years
2000 h or yearly
4000 h / 2 years
personnel
40 h or weekly

8 h or daily

n Grease gear rim and gear rim bearing before longer expected
standstill
Slewing system (MTC only)
l Inspection wear of upper and lower slewing bearing
l Check gear rim for sufficient lubrication, regrease as required
m Visual check of gear rim pinion for wear and pittings
Rope(s) and rope sheave pulley(s)
l Check condition, lubrication and spool behavior of rope(s)
l Check condition rope end fitting(s)
l Check rope sheave pulley(s) for damage or wear
¶ To compensate rope wear, shorten rope by 1/3 of drum circumfer
ence
Lifting equipment
l Check hook for corrosion, wear, damages
l Check swivel for correct function
l Check safety latch for correct function and corrosion
Boom
m Check torque and corrosion bolts of boom flange connections (if
installed)
m Replace bolts of boom flange connections every 10 years (if
installed)
l Visual check of boom pivot bearing

Lubrication
l Check mechanical condition and tightness of all lubrication points
and lines
l Lubricate all lubrication points after every 250 h
l Regrease telescopic boom surface (if installed)
Electric system
l Replace air filter of the switch cabinet(s)
l Check all terminals and ventilation of switch cabinet
m Check all terminals for correct fixing in switch cabinet
l Inspect all junction boxes for mechanical and electrical condition
l Check all cable glands to correct installation
l Check correct fit and function of instrumentation (e.g. cables, sen
sors)
l Visual check of all instrumentation against corrosion, damage
l Check correct function of lighting and heating
l Clean battery terminal, grease if necessary (if installed)
−7.11− 1760_170461
MAINTENANCE
Operating hours

1000 h / 6 months
500 h / 3 months
Special intervals
6000 h / 4 years
2000 h or yearly
4000 h / 2 years
personnel
40 h or weekly

8 h or daily

l Check distilled water level of battery, refill with distilled water if nec
essary (if installed)
l Check potential equalization lines (bonding) between moving com
ponents (e. g. boom− slewing−platform)
Slip ring unit (if installed)
l Check bolt connections, brushes of slipring unit
l Tightness test of a random sample of the terminal clamp bolt
l All 1500 h or latest every 6 months, check wear of carbon brushes
l Check tightness by random sample of the bolt connections of the
copper bus bars
l Clean the insulating barriers between the slipring ways of metal par
ticles
Electric cable loop system (if installed)
l Check proper mechanical function of cable loop system
Cabin
« Replace wiper blades
Air condition system see original manual of manufacturer
l Check emergency rope device for damage or wear
If equipment for use in hazardous areas is installed
l Check bronze coating on lifting equipment (if installed)
l Check rubber stopper of drop latches or gates
l Check all electric equipment in accordance to (local) regulations or
site rules
l Visual check of coupling at diesel engine against cracks each
10000 h, change if required
l Replace rubber elements of coupling at diesel engine each 10000 h
l Check torque of all bolts of coupling at diesel engine each 10000 h
1760_170461 −7.12−
MAINTENANCE
7.3.1. GREASING SCHEMATIC
Lubricants and service fluids should be selected from the specifications of service products of lieb
herr
1 Rope pulleys
2 Main hoisting winch
3 Auxiliary hoisting winch
4 Ropes
5 Rope pulleys
6 Slewing bearing
7 Slewing ring gear rim
8 Slewing gears (inside)
9 Luffing winch
−7.13− 1760_170461
MAINTENANCE
7.3.2. OIL FILLING SCHEMATIC
1 Distribution gear box (inside)

2 Main hoisting winch
3 Auxiliary hoisting winch
4 Hydraulic oil tank (inside)
5 Slewing gearboxes (inside)
6 Luffing winch
1760_170461 −7.14−
MAINTENANCE
7.4. LUBRICANT TABLE
No. Lubrication Outside temperature Model Specification Liebherr

points ISO VG / SAE Lubricants
throughout the year SAE 10W−40 ACEA E4 Liebherr Motoroil
to −20°C API CF 10W−40
below −20°C with
preheating
throughout the year SAE 10W−40 ACEA E4 / E6 / E7 Liebherr Motoroil
Engine, oil bath to −20°C API CF−4 / CG−4 10W−40 low ash required
1. when using a soot particle
air filter below −20°C with CH−4 / CI−4 filter
preheating
throughout the year SAE 5W−30 ACEA E4 Liebherr Motoroil 5W−30
to −30°C API CF
below −30°C with
preheating
2. Mechanical to −20°C SAE 85W−90 API GL 5 Liebherr Hypoid EP 90
gearboxes,
winches
Drive shafts to −40°C SAE 75W−90 API GL 4; GL 5; Liebherr Syntogear Plus
MT 1 75W−90
to −25°C + 50°C B) ISO VG 32−46 DIN 51 524 / T3 Liebherr Hydraulic 37
SAE 10W−20 HVLP
ATF A) 1.DEXRON II D/E
to −25°C + 50°C B) ISO VG 46 DIN 51 524 / T3 Liebherr Hydraulic Plus
(32−68)
SAE 10W−20 HVLPD HC
Hydrostatic drive
3. unit, hydraulic biodegradable in
steering accordance with
CEC−L−33−A−93
to −50°C + 30°C ISO VG 15−46 DIN 51 524 / T3 Liebherr Hydraulic Plus
SAE 10W−20 HVLPD HC Arcitc
biodegradable in
accordance with
CEC−L−33−A−93
to −25°C + 150°C DIN 51 502 Liebherr universal
Roller bearing,
For lubrication system KP 2 K−30 grease 9900
friction bearing,
ball/rollerbearing to −20°C + 150°C Lubricating KPF 2 N−25
4
4. swing rings,
rings grease lithium
grease,
cardan pivots, to −60°C + 140°C saponified DIN 51 502 Liebherr universal
other grease For lubrication system KPFHC 1 N−60 grease Arcitc
lubrication to −55°C + 140°C
to −25°C + 150°C DIN 51 502 Liebherr universal
For lubrication system OGPF 2 grease 9900
Open gear to −20°C + 150°C Lubrication and
5
5. wheels and
to −60°C + 140°C preservation OGPF 1 Liebherr universal
crown gears
For lubrication system grease Arcitc
to −55°C + 140°C
6. Ropes to −40°C + 50°C Liebherr WR−Lube SC
All areas Special regula DIN 51 502 Liebherr grease for tele
Telescopic
7. tion KP 2 K−30 scopic components
boom
9613 Plus
to −37°C DIN 51 757/4 Liebherr Antifreeze Mix
8. Coolant
DIN 51 432/2
Screenwash to −80°C Rala Klirr
9.
fluid
A) If Liebherr oil is not being used, ATF oil is compulsory for disc brakes.
B) When the oil preheater is activated, the outside temperature may be about 10 °C lower.
−7.15− 1760_170461
MAINTENANCE
. NOTE !
The familiar specifications listed above are minimum oil grades only.
High−quality Liebherr products have been developed and tested for compatibility. The correct func
tion of the machine can only be guaranteed with original Liebherr products. Products of other grades
do not carry this guarantee.
For more information contact the Liebherr Lubricant Hotline (+49 (0) 7354 806060 or lubri
cants@liebherr.com).
7.4.1. ORDER INFORMATION
Engine oil
5 l canister 20 l canister 210 l drum 1000 l container
Liebherr Motoroil 10W−40 10 29 05 06 10 33 02 39 10 33 02 46 10 28 62 79
Liebherr Motoroil 10W−40 low ash 10 32 61 13 10 32 61 12 10 32 61 11 10 32 61 10
Liebherr Motoroil 5W−30 10 42 57 12 10 42 57 13 10 42 57 15 10 42 57 19
Gear oil
Liebherr Hypoid 90 EP 10 66 48 74 10 66 48 75 10 66 48 76 10 44 16 36
Liebherr Syntogear Plus 75W−90 10 33 02 85 10 33 02 87 10 33 02 88 10 29 64 77
Hydraulic oil
Liebherr Hydraulic 37 10 66 48 65 10 66 48 67 10 66 47 12 10 66 48 56
Liebherr Hydraulic Plus 10 29 64 80 10 33 02 72 10 33 02 76 10 29 64 81
Liebherr Hydraulic Plus Arctic 10 29 64 79 10 33 02 77 10 33 02 78 10 29 64 78
Grease
400 g cartridge 5 kg tub 10 kg tub 25 kg tub
Liebherr universal grease 9900 10 29 68 16 10 29 68 13 10 29 68 12
Liebherr universal grease Arctic 10 29 68 28 10 29 68 25 10 29 68 24
Liebherr paste spray 10 33 03 08 10 33 03 11
(950 g)
Liebherr grease for telescopic 86 13 036 08
components 9613 Plus
Liebherr WR − Lube SC 600 ml spray
10 17 33 71
Coolant
Liebherr Antifreeze Mix 10 65 18 38 10 30 12 13 10 45 54 46 10 35 90 77
Screenwash fluid
Windscreen wash −80 °C 89 03 108 14
Oil analysis kit

Oil analysis kit: 88 56 018 14
1760_170461 −7.16−
MAINTENANCE
7.4.2. BLENDING OF LIEBHERR HYDRAULIC OILS
Liebherr oils with Liebherr oils

Mixable in any conditions
Liebherr oils with biologically degradable Liebherr oils

In order to ensure the biological degradability, a mixture of more than 2% is not permitted.
Liebherr oils with third party oils

In order not to change the properties of the oils, a mixture of more than 10% is not permitted.
−7.17− 1760_170461
MAINTENANCE
7.4.3. UTILITY REQUIREMENTS
The chart with the utility requirements is located directly behind the cover page of this operating manual.
1760_170461 −7.18−
MAINTENANCE
7.5. MAIN DRIVE MOTOR

The electric motor is intended to be installed and used by qualified personnel who are familiar with relevant
safety requirements. Safety equipment necessary for the prevention of accidents at the mounting and operat
ing site shall be provided in accordance with t he regulations prevailing in the local country.
INFORMATIONS ON NAME PLATE (EXAMPLE)
7.5.1. MAINTENANCE AND LUBRICATION

F Inspect the machine at regular intervals.
F Keep the machine clean and ensure free ventilation air−flow.
F Check the condition of connections and mounting and assembly bolts.
F Check the bearing condition by listening for unusual noise, vibration measurement, bearing tem
perature, inspection of spent grease
. NOTE !
When changes of condition occur, dismantle the machine, check the parts and replace if necessary.
LUBRICANTS
When regreasing, use only special ball bearing grease with the following properties:
F good quality lithium base or lithium complex grease
F base oil viscosity 100−140 cST at 40 °C
F consistency NLGI grade 2 or 3
F temperature range −30 °C − +120 °C, continuously
. IMPORTANT !
The machine is fitted with a lubrication information plate. Follow the given values.
The grease amount is used if small quantities of fresh grease are replaced at regular intervals as above. As
an alternative, when the machine is fitted with grease escape valves, fresh grease may be pressed into the
bearings until the old grease is totally replaced.
Greases with the correct properties are available from all the major lubricant manufacturers. If the make of
grease is changed and compatibility is uncertain, lubricate several times at short intervals in order to displace
the old grease.
Highly loaded and / or slowly rotating bearings require EP−grease. If lubrication intervals are short due to bear
ing temperatures above 80 °C or above, use high temperature greases which normally permit approximately
15° C higher bearing temperatures.
−7.19− 1760_170461
MAINTENANCE
LUBRICATION
CAUTION !
Destruction of the electric motor and risk of burns caused by hot temperature of the outer casing of the
machinery
− The machine shall not be used to step on.
− Wear protective clothing.
− Some special machine applications require special instructions
(e.g. using frequency converter supplies).
− Lifting lugs shall be used for lifting the motor alone.
− Open grease outlet with greasing bar (2).

− Lubricate the machine while running.
− Re−grease machine by fitted grease nipples (1).
. NOTE !
For a detailed description of the motor refer to volume motor documentation.
1760_170461 −7.20−
MAINTENANCE
7.6. DISTRIBUTION GEARBOXES
1 Oil level sight glass

2 Vent filter
3 Oil filler inlet
−7.21− 1760_170461
MAINTENANCE
7.6.1. CHECKING THE OIL LEVEL
WARNING !
Hot engine parts and hot gear oil can cause injuries.
− Shut down the crane before making an oil change or oil level inspection.
− Never touch a leak point or the distribution gearboxes itself without body protection.
− Check the oil level at the oil level sight glass.

If you cannot see the oil level, or it does not reach the MIN mark.
− Top up the gear oil.
1760_170461 −7.22−
MAINTENANCE
7.6.2. TOP UP GEAR OIL
CAUTION !
Danger caused by contaminated or unsuitable gear oil! The distribution gear will be de
stroyed!
− Make sure that no dirt or foreign bodies can get inside the opening.
− Use only gear oil as shown on the lubricant table.
− Do not overfill the gear with oil.
− Remove the vent filter on the distribution gearbox.

− Top up with suitable gear oil through the oil filler inlet.
The oil film must be clearly visible between the MIN and MAX markings.
− Reattach the vent filter.
7.6.3. REPLACING THE GEAR OIL
Make sure that the following requirements are in place:

l The engine has been switched off, and secured from unauthorised operation.
l The oil is at a normal operation temperature.
l You are wearing protective clothing (special protective gloves).
l A container and a suitable oil drain hose are available.
l Suitable oil is available as shown on the lubricant table.
CAUTION !
Danger caused by contaminated or unsuitable gear oil! The distribution gear will be destroyed!
− Place the container for the used oil underneath the distribution gearbox.
− Remove the vent filter on the distribution gearbox.
− Unscrew the protective cap from the oil drain (snap−lock fastener) and put the oil drain hose in place.
− Allow the oil to drain into the container.
− Remove the oil drain hose and screw the cap back on.
− Top up with suitable gear oil as per the lubricant table, through the oil filler inlet.
− After about 5 minutes check the oil level.
DISPOSAL !
Used materials must be properly disposed of in accordance with the relevant state regulations !
−7.23− 1760_170461
MAINTENANCE
7.7. SLEWING GEARBOX
1 Oil sight glass

2 Multi disc brake
3 Hydraulic motor
4 Gear oil filling and air release of gear
5 Slewing gear box
6 Drainage plug
7 Slewing pinion
1760_170461 −7.24−
MAINTENANCE
WARNING !
− Never touch a leak point or the winch gearboxes itself without body protection.
− Check oil level at the oil sight glass.

If the oil level is clearly visible between the MIN and MAX markings.The oil level is OK.
If you cannot see the oil level, or it does not reach the MIN mark.
−7.25− 1760_170461
MAINTENANCE
CAUTION !
Danger caused by contaminated or unsuitable gear oil! The slewing gear will be destroyed!
− Remove the vent filter on the slewing gearbox.

− Top up with suitable gear oil through the oil filter inlet.
− After about 5 minutes check the oil level at the oil sight glass.

CAUTION !
Danger caused by contaminated or unsuitable gear oil! The slewing gear will be destroyed!
− Place the container for the used oil underneath the slewing gear.
− Remove the vent filter on the slewing gearbox.
− After about 5 minutes check the oil level at the oil sight glass.
DISPOSAL !
1760_170461 −7.26−
MAINTENANCE
7.8. MAIN HOISTING WINCHES
1 Venting plug (2 x)
2 Oil dip stick, oil filler inlet (2 x)
3 Oil outlet (2 x)
WARNING !
− Shut down the engine and secure it from unauthorised operation.

− Twist the dipstick, pull it out, and clean with a lint−free, clean cloth.
− Reinsert the dipstick as far as it will go and wait for a moment.
− Withdraw the dipstick again and hold it in a horizontal position, as far as is possible.
If the oil film is clearly visible between the MIN and MAX markings the oil level is OK.
− Put the oil dipstick back in and turn to secure.
If you cannot see the oil film, or it does not reach the MIN mark.
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CAUTION !
Danger caused by contaminated or unsuitable gear oil! The winch gear will be destroyed!
− Remove the vent filter on the winch gearbox.

− After about 5 minutes use the oil dipstick to check the oil level.

CAUTION !
− Place the container for the used oil underneath the winch gearbox.
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7.9. AUXILIARY HOISTING WINCH*
3 Oil outlet (2 x)
WARNING !

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CAUTION !


CAUTION !
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7.10. LUFFING WINCH
3 Oil outlet (2 x)
WARNING !
−Never touch a leak point or the winch gearboxes itself without body protection.

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CAUTION !


CAUTION !
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7.11. TUGGER WINCHES*
1 Oil dip stick, oil filler inlet

2 Venting plug
3 Oil outlet
WARNING !

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CAUTION !


CAUTION !
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7.12. SLEWING BEARING − WEAR MEASUREMENT
For assessing the condition of a bearing, the wear rate is to be determined. The wear present in the raceway
system shows itself by a change in the axial motion of the bearing. Depending on the individual conditions,
wear is to be determined by measuring the tilting clearance.
7.12.1. TILTING CLEARANCE MEASUREMENT
The first measurement (base measurement) is to be performed,

F whe the crane is comissioned (put into operation for the first time)
F after a slew bearing overhaul
F after a slew bearing replacement
in order to obtain a base value for subsequent repeat measurement.
PRECONDITIONS
F 2 Dial gauges with an accuracy (resolution) of ±0.01 mm.
F 2 Magnetic stands
7.12.2. DIAL GAUGE LOCATIONS
Ball bearing type Roller bearing type
1 Base column (non−slewing) 4 Slewing unit (slewing)

2 Recommended measure position 5 Alternative measure position
3 Slew bearing
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7.12.3. CRANE CONDITION FOR MEASUREMENT
. NOTE !
The Boom positions should be as close as possible to the bearing, to prevent further influences
due to elastic deformations.
Crane positions
Mark permanently four boom positions (directions) on the circumference of the slewing bearing each 90°.
Boom position 1 (e.g. Aft), Boom position 2 (e.g. Fore), Boom position 3 (e.g. port), Boom Position 4 (e.g. Stb)
90° (pos. 3)
180° (pos. 1) 0° (pos. 2)
270° (pos. 4)
− Raise the boom without load to min. radius with boom in one of the four positions.
− Fix the magnetic stands with the dial gauges at front and rear of crane and set the dial gauges to 0.
− Raise the max. allowed load with the main hoist at max. radius according to load chart.
− Write down the shown values on the gauges in the chart.
− Remove the magnetic stands with the dial gauges and turn the crane 90° clockwise.
− Repeat Step 1 to 5 three times for Boom positions 2, 3, 4.
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Measuring table Base Test Test Test Test

Measurement Measurement Measurement Measurement Measurement
Boom pos. 1 front of crane
back of crane
back of crane
back of crane
back of crane
SWL [t]
Name of Test
Person
Signature
Date
The measured differnece between the Base Measurement and the actual Test Measurement shows the in
crease of bearing clearance.
The measured difference must not be higher than the values in the tables below.
Contact LIEBHERR, if values exceed the Maximum permissible increase of bearing clearance.
7.12.4. MAXIMUM PERMISSIBLE INCREASE OF BEARING CLEARANCE
Manufacturer: LIEBHERR − Werk Biberach (LBC)

Measurement repeated every 1000 operating hours / 6 months (to be given in intervall table)
Max. wear
Ball slew bearings with external diameter of up to 2500mm 1,5
Ball slew bearings with external diameter greater than 2,5
2500mm
All roller slew bearings 1
If, when measurements are taken, the tilting play limit value is reached:
− Replace the ball slew bearing or roller slew bearing.
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7.13. EXTERNAL DISC BRAKES *
1 Venting screw
2 Brake pad
3 Piston
4 Dust seal
5 Piston support ring
6 Piston seal
. NOTE !
l The oil quantity for operation continuously increases up to 200 ml at the maximum pad wear.
l The mounting plate between the 2 modules has to be of the same thickness as the brake disc.
7.13.1. MAINTENANCE
WARNING !
Incorrect usage can cause serious injuries to the operator.
− Switch off the hydraulic supply and secure against switching on during work on the brakes.
− Periodically check correct tightness of the screws.
7.13.2. CHANGING THE BRAKE PADS
Latest when the stroke per pad side reaches 7 mm, the brake pads have to be changed.
WARNING !
The screws for piston retraction are spring loaded.
− Work with care.
WARNING !
Incorrect usage can cause serious injuries to the operator.
− Switch off the hydraulic supply and secure against switching on during work on the brakes.
− Remove the retaining plate at one side of the calliper.

− Remove the screws for piston retraction.
− Pull the brake pad out of the calliper.
− Install a new brake pad.
− Insert the springs and screws for piston retraction.
− Install the retaining plate.
− Repeat steps on the second module.
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7.14. ROPES
7.14.1. CONDITION BEFORE INSTALLATION
Rope replacement
Only a rope of the correct length, diameter, construction and breaking force as specified by the
cranemanufacturer shall be installed on the crane, unless an alternative rope has been approved by the
crane manufacturer. Only rope terminations specified by the crane manufacturer, or alternatives similarly
approved, shall be used to attach a rope to a drum, hook block or crane structure.
Instructions from the crane manufacturer and the rope manufacturer

The instructions in the crane manual and those given by the manufacturer shall be followed.
Before re−equipping the crane, all grooves in drums and sheaves shall be checked to ensure that they will
correctly accept the replacement rope.
Offloading and storage

To avoid accidents, ropes shall be offloaded with care. The rope reels or coils shall not be dropped, nei
ther shall the rope be struck by a metal hook or fork of a fork−lift truck.
Ropes shall be stored in a cool, dry building and shall not be in contact with the floor. Ropes shall never
be stored where they are liable to be affected by chemical fumes, steam or other corrosive agents. Ropes
in storage shall be examined periodically and if necessary, a rope dressing applied. If outdoor storage
cannot be avoided, the ropes should be covered so that moisture cannot induce corrosion.
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7.14.2. INSTALLATION
Uncoiling and installing

When uncoiling the wire rope from a reel or coil, every precaution shall be taken to avoid the inducement
of turn into, or loss of turn out of, the rope. Allowing such a condition can result in formation of loops, kinks
or bends in the rope. To prevent this condition, the rope shall be paid out without slack and in a straight
line.
A revolving reel of rope can have a high inertia, in which case it needs to be controlled in order to slowly
pay out the rope.
Rope in coil should be paid out from a turntable. Alternatively, where a coil is of short length, the outer end
of the coil may be made free and the remainder rolled along the ground. For ease of handling, the inside
end shall first be secured to an adjacent wrap. A rope shall never be paid out by throwing off wraps with
the coil or reel flat on the ground.
. NOTE !
The rope must not be pulled over the ground as it will get dirty.
Particular care shall be taken with rotation−resistant ropes to ensure that they are installed without induc
ing or losing turn, and that any cut is secure and prevented from unlaying.
. NOTE !
If the strands are disturbed, deformation of the rope is likely to occur during subsequent use and
the service life of the rope may be reduced.
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. NOTE !
Introducing or losing turn during installation can result in additional twisting of the hook block.
The lay of the rope shall not be disturbed during installation, i.e. turn should not be put in nor taken out of
the rope. During installation, the rope shall always bend in the same direction: i.e. pay out from the top of
the reel to the top of the drum, or from the bottom of the reel to the bottom of the drum.
Care shall be taken to ensure that termination anchorages are made and secured in accordance with the
given instruction. If the rope rubs against any part of the crane during installation, then the points of con
tact shall be suitably protected.
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 layer 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.
If wear mainly occurs if rope is multi−layer reeved on the Lebus drum, rope life may be increased by cutting−off
one length according to 1/3 of drum circumference. This procedure can be repeated up to three times per rope.
Non−rotation free ropes may be used with fixed points at both ends only.
For luffing winches, the rope lenght must be appropriate shorten.
In park position or lowest boom position for service (lowest boom angle) 5−6 saftey windings must be on
the luffing rope drum to avoid damges of the lower layers.
Running in
Before bringing the rope into operation on the crane, the crane operator has to:
F check load lifting devices.
F check the spooling condition of the winch and the rope pulleys.
To ensure correct winch spooling condition min. 3 operational cycles have to be carried out with reduced
speed and reduced load.
F Reduced speed: ~30% of v(max)
F Reduced load: ~10% of SWL(max)
additional:
F 2 operating cycles with 1/3 SWL(max)
F 2 operating cycles with SWL(max) stated for max. outreach acc. to load chart
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7.14.3. INSTRUCTIONS FOR UNTWISTING OF HOIST ROPES
The direction of untwist can be determined also by simulating this situation by simply using a string.
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
sufficient in most cases.
If this procedure proves to be ineffective refer to the instructions given for compensation 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
possible 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 occurrence of multiple twist. The respective direction of twist is indica
ted by a continuously 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 continues arrow. It is important that
the correct reference point is selected i.e. the crane operator must hold the rope in front of himself.
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 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.
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7.14.4. MAINTENANCE
Maintenance of the wire rope shall be carried out relative to the crane, its use, the environment and the
type of rope involved.
Subsequently the wire rope shall be cleaned where necessary, and the rope dressing re−applied at regular
intervals and before the rope shows signs of dryness or corrosion, particularly on the lengths which pass
over sheaves.
Lubricating ropes
Regular rope maintenance ensures safe operation of the crane and increases the service life of the rope.
Only a lubricant equivalent to the original rope lubricant may be used (see chart).
. NOTE !
A shorter working life of the rope will result from lack of maintenance, particularly if the crane is used
in a corrosive environment and, in certain cases for reasons connected with the operation, if no rope
dressing can be used. In such cases the period between rope examinations shall be reduced accor
dingly.
The rope must be regularly lubricated, particularly where it flexes around the winch drums and
the rope pulleys. Grease is normally applied using a brush. In exceptional cases, high pressure
lubricating devices are used (if these are used, the manufacturer’s instructions must be fol
lowed). An alternative is to use solvent−based lubricants that can be sprayed on the rope.
. NOTE !
The rope dressing shall be compatible with the original lubricant used by the manufacturer, and shall
have penetrating characteristics. If the rope dressing is not identified in the crane manual, the user
shall seek advice from the service department.
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7.14.5. EXAMINATION
Frequency
Daily visual inspection

As far as possible, all visible parts of any rope shall be observed each working day with the objective of
detecting general deterioration and deformation. Particular attention shall be paid to the rope at points of
attachment to the crane. Any appreciable change suspected in the rope condition shall be reported, and
the rope examined by a competent person.
sheave
sheave hook block
load
drum
Type of examination
1) Examine termination of rope at drum
2) Examine for defective coiling, which causes deformations (flattened portions) and wear, which can
be severe at crossover positions
3) Examine for wire breaks
4) Examine for corrosion
5) Look for deformations caused by snatch loading
6) Examine portion which winds over sheave for wire breaks and wear
7) Points of attachment:
check for wire breaks and corrosion;
similarly, check section of rope which lies on or adjacent to compensating sheaves.
8) Look for deformation
9) Check rope diameter
10) Examine carefully length which runs through sheave block, particularly that length which lies on the
sheave when the appliance is in a loaded condition
11) Examine for wire breaks and surface wear
12) Examine for corrosion
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Periodic examination
Periodic examination shall be carried out by competent persons
In order to determine the frequency of a periodic examination, consideration shall be given to
a) the statutory requirements covering the application in the country of use,
b) the type of crane and the environmental conditions in which it operates,
c) the classification group of the crane,
d) the results of previous examination,
e) the length of time the rope has been in service.
Ropes should be examined at least once per month or more often, in accordance with the instructions of
the competent person.
. NOTE !
Depending on the condition of the rope, the competent person may deem it necessary to reduce
the time interval between examinations.
Special examination
The rope shall be examined if an incident has occurred which could have caused damage to the rope
and/or its termination, or if a rope has been brought back into operation after dismantling followed by re−
assembly.
If the crane has been out of operation for three months or more, the ropes should be examined prior to
recommencement of work.
. NOTE !
Inspection of ropes operating on synthetic sheaves or metal sheaves having synthetic lining
If a rope operates either solely or partially over synthetic sheaves or over metal sheaves having a syn
thetic lining, wire breaks can occur internally in large numbers before there is any external visible evi
dence of wire breaks or of substantial wear on the periphery of the rope. In these conditions, consider
ation shall be given to the establishment of a specific inspection schedule period based on past rope
performance data, taking into account the results from regular inspection in service and information gained
from detailed examination of ropes following retirement from service.
Particular attention shall be paid to any localized area which exhibits a dryness or denaturing of the lubri
cant.
Information for the criteria for discard of wire rope for specific lifting appliances shall be based on an ex
change of information between the crane manufacturer and the wire rope manufacturer.
. NOTE !
Points to be covered by examination
General
Although the wire rope shall be examined throughout its length, particular care shall be taken at the follow
ing
locations:
a) the termination points of both moving and stationary ropes;
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b) that part of the rope which passes through the block or over sheaves;
c) in the case of cranes performing a repetitive operation, any part of the rope which lies over
sheave(s) while the crane is in a loaded condition );
d) that part of the rope which lies over a compensating sheave;
e) any part of the rope which may be subject to abrasion by external features (e.g. hatch coamings);
f) internals of the rope, for corrosion and fatigue;
g) any part of the rope exposed to heat.
The results of the examination shall be recorded in the examination record for the crane.
Terminations, excluding slings

The rope shall be examined in the area where it passes out from the termination, as this position is critical
for the onset of fatigue (wire breaks) and corrosion. The terminal fittings themselves shall also be ex
amined for signs of distortion or wear.
Terminations involving pressed or swaged ferrules shall be similarly examined, and the ferrule checked for
cracks in the material and possible slippage between the ferrule and the rope.
Detachable terminations (e.g. wedge sockets, grips) shall be examined for broken wires within and under
the termination, and for tightness of wedges and screwed grips. The examination should also include an
assessment that the standards and codes of practice specified for the termination of the rope have been
met.
Eye splices made by hand shall be examined to check that they are served only over the tail of the splice
(so as to protect the hands from protruding wire), while at all times allowing the remainder of the splice to
be visually inspected for wire breaks.
When broken wires are evident close to, or within, the termination, it may be possible to shorten the rope
and re−fit the terminal fittings. However, the resulting length of the wire rope shall be sufficient to allow for
the minimum required number of rope wraps on the drum.
Non−destructive testing
Non−destructive testing by electromagnetic techniques may be used as an aid to visual inspection to de
termine areas and levels of rope deterioration.
When it is the intention to use electromagnetic means of NDT as an aid to visual examination, the rope
should be subject to an initial electromagnetic NDT examination as soon as possible after the rope has
been installed.
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7.14.6. DISCARD CRITERIA
General
The safe use of wire rope is qualified by the following criteria:
a) the nature and number of broken wires;
b) broken wires at the termination;
c) localized grouping of wire breaks;
d) the rate of increase of wire breaks;
e) the fracture of strands;
f) reduction of rope diameter, including that resulting from core deterioration;
g) decreased elasticity;
h) external and internal wear;
i) external and internal corrosion;
j) deformation;
k) damage due to heat or electric arcing;
l) rate of increase of permanent elongation.
All examinations shall take into account these individual factors, recognizing the particular criteria. How
ever, deterioration frequently results from a combination of factors, giving a cumulative effect which should
be recognized by the competent person, and which reflects the decision to discard the rope or to allow it
to remain in service.
In all cases, the examiner shall investigate whether the deterioration has been caused by an abnormality
in the crane; if so, he should recommend action to overcome that abnormality before installing a new
rope.
The individual degrees of deterioration should be assessed, and expressed as a percentage of the partic
ular discard criteria. The cumulative degree of deterioration at any given position is determined by adding
together the individual values that are recorded at that position in the rope. When the cumulative value at
any position reaches 100 %, the rope should be discarded.
Nature and number of broken wires
The overall design of a crane is such that it does not permit indefinite rope life. In the case of 6− and
8−strand ropes, broken wires usually occur at the external surface. In the case of rotation−resistant ropes,
there is a probability that the majority of broken wires will occur internally and are non−visible" fractures.
Tables 1 and 2 take these factors into account when considered in conjunction with the factors.
One valley break may indicate internal rope deterioration, requiring closer inspection of this section of
rope. When two or more valley breaks are found in one lay length, the rope should be considered for dis
card.
When establishing rejection criteria for rotation−resistant ropes, consideration shall be given to the rope
construction, length of service and the way in which the rope is being used. Guidance relating the number
of visible broken wires and their rejection is given in Table 2.
Particular attention shall be paid to any localized area which exhibits a dryness or denaturing of the lubri
cation.
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Table 1 Number, reached or exceeded, of visible broken wires in single−layer and parallel−
closed ropes working in steel sheaves, signalling mandatory discard of rope
Broken wires at termination
Broken wires at, or adjacent to, the termination, even if few in number, are indicative of high stresses at
this position and can be caused by incorrect fitting of the termination. The cause of this deterioration shall
be investigated and, where possible, the termination shall be remade, shortening the rope if sufficient
length remains for further use, otherwise the rope shall be discarded.
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Localized grouping of broken wires

Where broken wires are very close together, constituting a localized grouping of such breaks, the rope
shall be discarded. If the grouping of such breaks occurs in a length less than 6d or is concentrated in any
one strand, it may be necessary to discard the rope even if the number of wire breaks is smaller than the
maximum number shown in Tables 1 and 2.
Table 2 Number, reached or exceeded, of visible broken wires in rotation−resistant ropes work
ing in steel sheaves, signalling mandatory discard of rope
Rate of increase of broken wires

In applications where the predominant cause of rope deterioration is fatigue, broken wires will appear after
a certain period of use, and the number of breaks will progressively increase over time.
In these cases, it is recommended that careful periodic examination and recording of the number of bro
ken wires be undertaken, with a view to establishing the rate of increase in the number of breaks. This
premise may be used to propose a future date for rope discard.
Fracture of strands
If a complete strand fracture occurs, the rope shall be immediately discarded.
Reduction of rope diameter resulting from core deterioration

Reduction of rope diameter resulting from deterioration of the core can be caused by
a) internal wear and wire indentation,
b) internal wear caused by friction between individual strands and wires in the rope, particularly when it is
subject to bending,
c) deterioration of a fibre core,
d) fracture of a steel core,
e) fracture of internal layers in a rotation−resistant rope.
If these factors cause the actual rope diameter to decrease by 3 % of the nominal rope diameter for rota
tionresistant ropes, or by 10 % for other ropes, the rope shall be discarded even if no broken wires are
visible.
. NOTE !
New ropes will normally have an actual diameter greater than the nominal diameter.
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Low values of deterioration might not be so apparent from normal examination, particularly if the rope
stresses are well balanced throughout the individual strands. However, the condition can result in a high
loss of rope strength, so any suggestion of such internal deterioration shall be verified by internal ex
amination procedures. If such deterioration is confirmed, the rope shall be discarded.
External wear
Abrasion of the crown wires of outer strands in the rope results from rubbing contact, under pressure, with
the grooves in the sheaves and drums. The condition is particularly evident on moving ropes at points of
sheave contact when the load is being accelerated or decelerated, and is revealed by flat surfaces on the
outer wires.
Wear is promoted by lack of lubrication, or incorrect lubrication, and also by the presence of dust and grit.
Wear reduces the strength of ropes by reducing the cross−sectional area of the steel strands.
If, due to external wear, the actual rope diameter has decreased by 7 % or more of the nominal rope di
ameter, the rope shall be discarded even if no wire breaks are visible.
Decreased elasticity
Under certain circumstances usually associated with the working environment, a rope can sustain a sub
stantial decrease in elasticity and is thus unsafe for further use.
Decreased elasticity is difficult to detect. If the examiner has any doubt, advice shall be obtained from a
specialist in wire ropes. However, it is usually associated with the following:
a) reduction in rope diameter;
b) elongation of the rope lay length;
c) lack of clearance between individual wires and between strands, caused by the compression of the
component parts against each other;
d) appearance of fine, brown powder between or within the strands;
e) increased stiffness.
While no wire breaks may be visible, the wire rope will be noticeably stiffer to handle and will certainly
have a reduction in diameter greater than that related purely to wear of individual wires. This condition can
lead to abrupt failure under dynamic loading and is sufficient justification for immediate discard.
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External and internal corrosion
General
Corrosion occurs particularly in marine and polluted industrial atmospheres. It will diminish the breaking
strength of the rope by reducing the metallic cross−sectional area, and it will accelerate fatigue by causing
surface irregularities which lead to stress cracking. Severe corrosion can cause decreased elasticity of the
rope.
Check for: Photographs of damage:
Pockets: can occur when the outer layer of wires

loosens or the outer wire braids are longer than the
inner ones. Movement of the outer wires or strands
in relation to the inner ones causes movement of
the excess length at a particular location.
Loop formation: single wires or groups of wires

emerge from the rope structure. The loops usually
lie in a series of braids.
Contractions: are reductions in the diameter of

the wire rope over short lengths. Rope sections
immediately before the end attachment must be
checked for contractions with particular care. Con
tractions are often difficult to recognize at these
points.
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Knots: are deformations of the wire rope that are

formed when a eyelet−shaped rope loop is pulled
straight without the wire rope being able to com
pensate by turning on its axis.
Corkscrews: with this type of deformation, the

axis of the unloaded wire rope becomes helical.
This does not weaken the wire rope initially, though
it might prevent the rope drive from running
smoothly. The resultant damage can include in
creased abrasion and more wire breaks. The rope
must be withdrawn from service if the area of
greatest deformation exceeds 1/3 of the nominal
rope diameter.
. TROUBLESHOOTING !
If the rope meets one of the criteria above or exhibits specific damage:
F Stop using the machine and if possible determine the cause of the damage.
F Change the rope or pair of ropes immediately.
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Checking ropes for corrosion
Corrosion: occurs mostly in corrosive and salt

water atmospheres (e.g. prolonged storage of
ropes in the open air, salt water atmospheres,
etc.). Two types of corrosion occur: atmospheric
corrosion (causes "even" rust) and localized corro
sion, such as pitting (forms deep holes in places
where the protective sheath is missing or dam
aged). The photographs both show atmospheric
corrosion.
The diameter of the rope has reduced as a result

of corrosion. If the rope diameter has reduced by
10% or more relative to the nominal dimension, the
rope must be changed regardless of whether or not
wire breaks have occurred.
Checking ropes for abrasion
Abrasion: abrasion reduces not only the static

breaking force of the rope due to reduction of the
metallic cross−section, but also its fatigue limit as a
result of wear notches. If the rope diameter has
reduced by 10% or more relative to the nominal
dimension, the rope must be changed regardless
of whether or not wire breaks have occurred.
. TROUBLESHOOTING !
If the rope meets one of the criteria above or exhibits specific damage:
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Checking ropes for the effects of heat
Heat damage: if the temperature rises above

300°C, the tensile fiber structure of the wire rope
caused by cold deformation recrystallizes and the
wire loses around 2/3 of its original strength.
An extreme form of heat damage is caused by

lightning strike. The rope may heat up at the point
of the strike to such an extent that the steel starts
to melt. In all cases of exposure to high tempera
tures, the rope must be changed regardless of
whether or not wire breaks have occurred.
. TROUBLESHOOTING !
If there is evidence of external heat damage, such as recrystallization, localized melting of steel, etc.:
External corrosion
Corrosion of the outer wires can often be detected visually.

Wire slackness due to corrosion attack/steel loss is justification for immediate rope discard.
Internal corrosion
This condition is more difficult to detect than the external corrosion which frequently accompanies it, but
the following indications can be recognized:
a) variation in rope diameter;
In locations where the rope bends around sheaves, a reduction in diameter usually occurs. However, in
stationary ropes it is not uncommon for an increase in diameter to occur due to the build−up of rust under
the outer layer of strands.
b) loss of clearance between the strands in the outer layer of the rope, frequently combined with wire
breaks between or within the strands.
If there is any indication of internal corrosion, the rope should be subjected to internal examination. This
shall be carried out by a competent person.
Confirmation of severe internal corrosion is justification for immediate rope discard.
1760_170461 −7.54−
MAINTENANCE
Deformation
Visible distortion of the rope from its normal shape is termed deformation" and can create a change at the
deformation position which results in an uneven stress distribution in the rope.
Waviness
Waviness is a deformation in which the longitudinal axis of the wire rope takes the shape of a helix under
either a loaded or unloaded condition. While not necessarily resulting in any loss of strength, such a de
formation, if severe, can transmit a pulsation resulting in irregular rope drive. After prolonged working, this
will give rise to wear and wire breaks.
In the case of waviness, the wire rope shall be discarded if, under any load condition on a straight portion
of rope that does not bend around a sheave or drum, the following condition is met:
d1 > 4d/3
or, on a portion of rope that bends around a sheave or drum, the following condition is met:
d1 > 1,1d
d is the nominal diameter of the rope;

d1 is the diameter corresponding to the envelope of the deformed rope.
Basket or lantern deformation

Basket or lantern deformation, also called birdcage", is a result of a difference in length between the rope
core and the outer layer of strands. Different mechanisms can produce this deformation.
If, for example, a rope is running over a sheave or onto the drum under a great fleet angle, it will touch the
flange of the sheave or the drum groove first and then roll down into the bottom of the groove. This char
acteristic will unlay the outer layer of strands to a greater extent than the rope core, producing a difference
in length between these rope elements.
When running over a tight sheave", i.e. a sheave with a groove radius that is too small, the wire rope will
be compressed. This reduction in diameter will at the same time result in an increase in rope length. As
the outer layer of strands will be compressed and lengthened to a greater extent than the rope core, this
mechanism again will produce a difference in length between these rope elements.
In both cases, the sheaves and the drum will then be able to displace the loose outer strands and bring
the length difference to one location in the reeving system where it will appear as a basket or lantern de
formation. Ropes with a basket or lantern deformation shall be immediately discarded.
Core or strand protrusion/distortion

This feature is a special type of basket or lantern deformation in which the rope imbalance is indicated by
protrusion of the core (or centre of the rope, in the case of a rotation−resistant rope) between the outer
strands, or protrusion of an outer strand of the rope or strand from the core.
Rope with core or strand protrusion/distortion shall be immediately discarded.
Wire protrusion
In wire protrusion, certain wires or groups of wires rise up, on the side of the rope opposite to the sheave
groove, in the form of loops. Rope with wire protrusion shall be immediatly discarded.
−7.55− 1760_170461
MAINTENANCE
Local increase in diameter of rope

A local increase in rope diameter can occur and might affect a relatively long length of the rope. This con
dition usually relates to a deformation of the core (in particular environments, a fibre core can swell up ow
ing to the effect of moisture) and consequently creates imbalance in the outer strands, which become in
correctly oriented. If this condition causes the actual rope diameter to increase by 5 % or more, the rope
shall be immediately discarded.
Flattened portions
Flattened portions of rope which pass through a sheave will quickly deteriorate, exhibiting broken wires
and may damage the sheave. In such cases the rope shall be discarded immediately.
Flattened portions of rope in standing rigging can be exposed to accelerated corrosion, and shall be sub
ject to inspection at a prescribed shortened frequency if retained in service.
Kinks or tightened loops

A kink or tightened loop is a deformation created by a loop in the rope which has been tightened without
allowing for rotation about its axis. Imbalance of lay length occurs, which will cause excessive wear, and in
severe cases the rope will be so distorted that it will have only a small proportion of its strength remaining.
Rope with a kink or tightened loop shall be immediately discarded.
Bends
Bends are angular deformations of the rope caused by external influence.
Damage due to heat or electric arcing

Ropes that have been subjected to exceptional thermal effects, externally recognized by the colours pro
duced in the rope, shall be immediately discarded.
7.14.7. OPERATING PERFORMANCE OF WIRE ROPE
Accurate recording of information by the examiner can be used to predict the performance of a particular
type rope on a crane. Such information is useful in regulating maintenance procedures and also control of
replacement rope stock. If such forecasting is used, it shall not have the effect of relaxing examinations or
prolonging operating period beyond that indicated by the criteria specified in the preceding clauses of this
International Standard.
7.14.8. CONDITION OF EQUIPMENT RELATED TO ROPE
Winding drums and sheaves shall be checked periodically to ensure that all these components rotate cor
rectly their bearings.
Stiff or jammed sheaves or rollers wear heavily and unevenly, causing severe abrasion of the rope. Inef
fective compensating of sheaves can give rise to unequal loading in the rope reeving.
The radius at the bottom of the groove in all sheaves shall be appropriate to the nominal diameter of the
supplied (see ISO 4308−1 for further information). If the radius has become too large or too small, the
groove should be remachined or the sheave replaced.
7.14.9. ROPE EXAMINATION RECORD
For each periodic or special examination, the examiner shall provide a record containing information relat
ing the examination.
7.14.10. ROPE STORAGE AND IDENTIFICATION
Clean, dry and non−polluted storage shall be provided to prevent deterioration of rope not in use.
Means shall be provided to enable ropes to be clearly identified with respect to their examination records.
1760_170461 −7.56−
MAINTENANCE
7.15. ROPE PULLEYS
7.15.1. CHECKING THE ROPE DRIVE
The service life of the rope depends to a large extent on checking of the rope drive. Any fault on the rope
drive will damage the rope. The rope will reach the end of its service life more quickly due to increased
wear.
The grooves of the winching drums and the rope pulleys are therefore checked for wear using a test tem
plate. In addition, the condition of the rope pulley bearings, the draw rolls on the winch drums, etc. is
checked to ensure the rope drive works correctly.
. NOTE !
Test templates are available in many different shapes. The best are round templates manufactured
on a lathe.
Checking winch drum groove base for wear
Make sure that the following requirements are met:

F The engine has been switched off and secured against unauthorized starting
F A suitable test gauge is available
Fig. Checking the groove base using the test template − the result is OK
1 Test gauge
2 Winch drum
− Check each individual groove on the winch drum.

F If the test template fits easily into each groove, the diameter of the measuring device more or less
coincides with the groove base. If the diameter of the grooves on the winch drum is 4 − 8 % larger than
the diameter of the measuring device, the test is OK and no further action is required.
. TROUBLESHOOTING !
If the diameter of the test gauge does not coincide with the winch drum groove base, or a crescent−
shaped gap is visible between the test template and the groove base:
The rope has become thinner through use over time and must be withdrawn from service. Before
using a new rope, the worn grooves must be machined to ensure that the groove base returns to
specification.
F Inform LIEBHERR Customer Service and seek advice on the precise action to be taken.
−7.57− 1760_170461
MAINTENANCE
. NOTE !
The grooves of the winch drum often become patterned as a result of marks on the rope. When
changing the rope, smooth the surface of the grooves.
If installed, check the winch drum contact rollers

F Check the contact rollers for wear
F If the contact roller is evenly worn and does not show any extreme grooving, etc., the result is OK and
no further action is required.
. TROUBLESHOOTING !
If the contact roller is unevenly worn or is affecting the rope in the rope guide to a significant extent:
F The rope drive cannot function correctly, replace the contact roller.
1760_170461 −7.58−
MAINTENANCE
Checking for wear and, if necessary, replacing steel rope pulleys
The steel rope pulleys are checked in exactly the same way as the winch drum groove base, in other
words the radius of the grooves is checked using a test template.
. NOTE !
The rope grooves often become patterned as a result of marks in the rope. The impressions of the
individual braids in the rope grooves are normal and not undesirable, since these produce a greater
rope supporting surface which increases the service life of the rope. When the rope is changed, the
ridges must be removed and any sharp edges on the surface of the rope pulley smoothed.

F A suitable test template is available
− Use the test template to check the grooves in the rope pulleys
− If the radius of the grooves is 4% larger than the half rope diameter, the result is OK and no further
action is required.
. TROUBLESHOOTING !
If the tolerance is exceeded, in other words the radius of the grooves is greater than the rope
diameter by more than 4%:
F Replace the rope pulley.
F Contact LIEBHERR Customer Service.
Checking for wear and, if necessary, replacing plastic rope pulleys
. NOTE !
The rope grooves often become patterned as a result of marks in the rope. The impressions of the
individual braids in the rope grooves are normal and not undesirable, since these produce a greater
rope supporting surface which increases the service life of the rope. When the rope is changed, the
ridges must be removed and any sharp edges on the surface of the rope pulley smoothed.

F Check the groove base of the rope pulley for wear
− If the rope groove base is worn by less than half the rope diameter, the result is OK and no further ac
tion is required.
. TROUBLESHOOTING !
If the rope groove base is worn by more than half of the rope diameter:
F Replace the rope pulley.
. NOTE !
The tolerance of the groove radius is relatively unimportant, the main thing is the that groove radius
is greater than the rope diameter.
−7.59− 1760_170461
MAINTENANCE
Checking rope pulleys for damage
. NOTE !
Rope pulley are very susceptible to external damage. Chafing must be avoided at all times and rope
pulleys must not be placed on the ground without protective equipment.
Fig. Damaged rope pulley
F Check rope pulleys for all types of damage, such as nicks, wobble, etc.
F If the rope pulleys are aligned with the direction in which the rope is running and there is no evidence
of wobble or other damage, the result is OK and no further action is required.
. TROUBLESHOOTING !
If the rope pulley shows any sign of damage:
F Replace the rope pulley immediately.
1760_170461 −7.60−
MAINTENANCE
Lubricating rope pulley bearings
Rope pulleys must turn easily to provide optimum rope drive. If rope pulleys are not lubricated by the cen
tral lubrication system, the rope pulley bearings must be lubricated manually using a grease gun.

F A lever−type grease gun filled with the appropriate grease type as stated on the lubrication chart is
available
F The boom is lowered
Manually lubricating rope pulleys:

F Use the grease gun to lubricate the grease nipples on the rope sheave bearings on the tower head.
F Use the grease gun to lubricate the grease nipples on the rope sheave bearings on the boom head.
. NOTE !
The grease must not leak from between the rope pulleys.
Cleaning plastic rope pulleys
When in use, plastic rope pulleys in particular can become very dirty, resulting in excessive wear. It is
therefore important to clean gum, etc. off plastic rope pulleys.
. NOTE !
Only clean plastic rope pulleys with suitable cleaning agents.
Plastic rope pulleys are resistant to:

− Mineral oil
− Petrol
− Kerosene
− Diesel
Plastic rope pulleys are not resistant or not fully resistant to:
− concentrated mineral acids (e.g. sulfuric acid, hydrochloric acid, nitric acid)
− concentrated organic acids (e.g. formic acid)
− concentrated bases (e.g. sodium, caustic potash solution or corrosive potassium salts)
− alcohol apart from ethyl alcohol, methyl alcohol and propyl alcohol
− inorganic chlorides, e.g. calcium, lithium chloride, magnesium chloride and zinc chloride
Clean plastic rope pulleys using a cleaning cloth and suitable cleaning agents.
−7.61− 1760_170461
MAINTENANCE
7.16. CHECKING HYDRAULIC LINES AND HOSES
CAUTION !
Pressurized oil can cause body injuries or fires.
− Hydraulic lines, hoses and fittings may never be repaired any damaged sections
must be replaced immediately.
− 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.
Even when hoses and lines are installed, stored and used according to specification they undergo a natural
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 !
We suggest that the service life of a hydraulic hose shouldn’t 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.
7.16.1. 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 operation or round the
clock operations).
7.16.2. REPLACEMENT AND INSPECTION OF HOSES
Hoses and lines must be replaced if any of the following points are found during an inspection:
l Damage on the external layer into the inner layer (such as chaffing, cuts and rips).
l Brittleness of the outer layer (crack formation of the hose material).
l 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.
l Leakages
l Non observance of installation requirements.
l Damage or deformation of hose fittings, which might reduce the strengths of the fitting or the
connection between hose and fitting.
l Any movement of the hose away from the fitting.
l Corrosion on fittings, which might reduce the function or the strength of the fitting.
l Storage or service life has been exceeded.
. NOTE !
To avoid excessive leaks a vacuum−pump could be connected to the hydraulic oil tank.
Route or install the hoses and lines properly, do not mix up connections!
DISPOSAL !
1760_170461 −7.62−
MAINTENANCE
7.17. HYDRAULIC OIL TANK
CAUTION !
Destruction of the Hydraulic system.
− Close suction shut off valve only for inspection or service purpose.
− Before start−up of main motor check open position of shut off valve.
1 Oil level and temperature sensor 5 Oil drain screw

2 Breather filter 6 Standstill heater
3 Oil level sight glass 7 Suction line with suction shut−off valve
4 Inspection cover 8 Return flow filter
−7.63− 1760_170461
MAINTENANCE
7.17.1. CHECKING THE HYDRAULIC OIL LEVEL
WARNING !
Hot hydraulic oil emerging at high pressure can cause burns and open wounds!
− Secure crane from unauthorised operation.
− Never touch a leak point on the hydraulic system with your unprotected body.
− Use the inspection glass to check the oil level in the hydraulic tank.
If the inspection glass is completely covered with hydraulic oil, oil level is OK.
If the level of hydraulic oil is only partially on view, or cannot be seen:
− Top up with hydraulic oil according lubricant table.
7.17.2. TOP UP HYDRAULIC OIL
CAUTION !
If the correct procedure is not followed when topping up the hydraulic oil:
Risk of damage to the hydraulic system.
− Only top up with hydraulic oil through the return filter.
. NOTE !
If replacing "mineral oil−base hydraulic oil" with synthetic oil−base hydraulic oil", please contact Lieb
herr after sales service.
CAUTION !
By using contaminated or unsuitable hydraulic oil, the hydraulic oil will be destroyed!
− Unscrew the screws on the return−flow filter.

− Carefully remove the cover and the sealing ring underneath.
− Fill with suitable hydraulic oil until the oil level is visible in the inspection glass.
The oil level should be visible about half way up the upper inspection glass.
− Carefully replace return−flow filter cover, make sure that sealing ring and cover are correctly positioned.
− Manually screw the screws until the stop point is reached.
− Tighten the screws to maximum 69 Nm.
− Start the and allow it to run at idle.
− Check the hydraulic system for leaks.
− Switch off the main motor and after about 5 minutes check again for leaks.
1760_170461 −7.64−
MAINTENANCE
7.17.3. REPLACING RETURN FLOW FILTER
During operation of the crane the return flow filter is monitored by the LITRONIC Control (sensors connected
to filters).
1 Screw, washer
2 Cover
3 Sealing ring
4 magnet stick
5 Tension spring
6 Pressure piece
7 O−ring
8 Filter element
9 Filter housing
WARNING !
Hot hydraulic oil emerging at high pressure can cause burns and open wounds!
− Prior replacing the filter element (insert), wait until the pressure reads 0 bar, all parts and
the hydraulic oil are down to low temperature.
− Check leaktightness, tight fit of sensor at appropriate intervals.

− Should the symbol flowback filter clogged" appear on the screen and the buzzer sound, check the filter
element (insert) and to replaced immediately (latest at next working brake).
− Lower the load / auxiliary equipment safe to ground and shut off the motor. Wait a few minutes till the
pressure is reduced to 0 bar.
− Remove plug of sensor and unscrew the cover ( 2 ) gently by using a spanner for the screws (1) of ade
quate size.
− Pull out gently magnet piece (4) and tension spring (5), pressure piece (6), O−ring (7) and used filter
element (8) of the filter housing
− Clean all parts carefully (1 − 7, 9), check Sealing ring (3) and O−ring (7) for good condition (replace dam
aged 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, connect the plug of the filter sensor 4A−S16.
− Start main motor and run on idle speed first − watch indications on the screen − check for tightness of
cover after 5 minutes again.
DISPOSAL !
−7.65− 1760_170461
MAINTENANCE
7.17.4. VALVE AND FILTER PLATE AGGREGATE ROOM
During operation of the crane the filter is monitored by the LITRONIC Control (sensors connected to filters).
WARNING !
Highly pressurized oil can cause injuries.
− Prior replacing the filter element (insert), wait until the pressure reads 0 bar all parts and
the hydraulic oil are down to low temperature.
− Check leaktightness, tight fit of sensor ( 5 ) and clean the oil tray if required at appropriate intervals.
− Should one of the symbols pressure filter clogged" appear on the screen and the buzzer sounds, the
Filter element (insert) has to be checked and to be replaced immediately (latest at next working brake).
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.
− 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.
− Clean all parts carefully, check O−ring (4) for good condition.
− If required replace the O−ring (4).
− Insert new filter element,
− Check correct seat of O−rings ( 3, 4 ).
− Fill up the lower housing (1) with new hydraulic oil.
− 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 and watch indications on the screen.
− Check for tightness of housing after 5 minutes again.
DISPOSAL !
1760_170461 −7.66−
MAINTENANCE
7.18. LIEBHERR OIL DIAGNOSIS SYSTEM
. NOTE !
Perform the first oil change for the relevant unit as scheduled, since increased levels of contamina
tion are to be expected during the running−in phase.
The LIEBHERR oil diagnostic system is a preventative maintenance system for the main components of the
machine. It is based on an analysis of the oil and has the following objectives:
l to prevent machine failures
l to reduce downtime
l to minimise repair costs
l to indicate abnormal wear
l to detect possible causes of damage at an early stage
7.18.1. TAKING AN OIL SAMPLE
Ensure that the following conditions are satisfied:

l The Liebherr analysis kit available.
l The machine is switched off.
l The machine is secured to prevent unauthorised operation.
l The relevant module/component has been warmed up for approx. 15 minutes.
− Take the oil samples either directly from the housing of the relevant module / component or from the oil that
is being drained out when the oil is changed.
− Drain of at least a quarter of a liter of oil before taking the sample and then fill the container with well−mixed
oil.
1 Plastic syringe container cap 5 Plastic hose

2 Plastic syringe container 6 Dispatch box
3 Syringe neck 7 Sample data sheet
4 Adapter
−7.67− 1760_170461
MAINTENANCE
HOW TO TAKE A REPRESENTATIVE OIL SAMPLE

− Screw the plastic hose (5) with adapter (4) onto the plastic syringe container (2).
− Drain approx. 200 ml. of oil into the sampling vessel.
− Complete all sections of the sample data sheet.
− Place the oil sample and the sample data sheet into the dispatch box.
− Send the box to the pre−printed address.
1760_170461 −7.68−
MAINTENANCE
7.18.2. TAKING AN GREASE SAMPLE
Where available, the grease sample should be taken externally from the rotating assembly via the grease
extraction drill holes. This point is not accessible for all cranes, in which case removal should take place via
the lip seal of the rotating assembly.
For taking an grease sample the same special plastic syringe−cum−bottle−kit as for the oil sample can be used:
How to take a representative grease sample

− Ensure the main motor or other units has been working for at least 15 minutes just prior to taking the sample.
− Clean the lip seal on the rotating assembly thoroughly of old grease and other deposits.
− Grease all lubrication points of the rotating assembly with fresh grease whilst slowly rotating the crane.
− As soon as old grease appears on the lip seals, use this as a grease sample. 2 − 4 samples should be taken
(i.e. every 180° or every 90°)
. NOTE !
It is necessary to ensure that the grease samples are not additionally contaminated on extraction.
− Complete all sections of the sample data sheet.

− Place the grease sample and the sample data sheet into the dispatch box.
− Send the box to the pre−printed address.
7.18.3. DIAGNOSTIC REPORT

The oil diagnostic report contains the detailed results of the oil sample analysis and provides information about
any measures that need to be taken. Four symbols are used for this purpose.
Symbol Meaning
Normal
High result reading obtained, submit second sample for recheck
Change oil as indicated
Action required as indicated
−7.69− 1760_170461
MAINTENANCE
7.19. PRESSURE ACCUMULATORS
For hydraulic accumulators, the relevant regulations at the place of installation must be adhered to prior to
commissioning and during operation.
WARNING !
Danger of explosion and bad injuries.
− 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.
− Always use oxygen free" nitrogen.
− 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.
. IMPORTANT !
To ensure the safety of the lifting appliance the pressure accumulators have to be checked or re
placed every two years.
7.19.1. TESTING THE PRESSURE ACCUMULATOR
By arrangement of the accumulator according the below drawing the gas side fill pressure can also be checked
on the liquid side.
1 Safety valve
2 Pressure gauge
3 Shut off valve
4 Drain cock
5 Plug for control gauge
− Operate shut off valve (3) to disconnect the hydraulically filled

diaphragm accumulator from the system.
− Slowly drain the liquid side of the diaphragm accumulator
through drain cock (4).
− Observe pressure gauge (2).
The pressure initially drops slowly.
. NOTE !
The pressure only drops suddenly once the accumulator has fully drained. This pressure is the
same as the fill pressure of the diaphragm accumulator.
− If the read−off fill pressure deviates from the expected pressure refill the accumulator.
1760_170461 −7.70−
MAINTENANCE
7.20. MAINTENANCE OF OIL COOLERS

The cooling lamella 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 lamella have to be inspected visually at least every week and cleaned if necessary.
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 !
−7.71− 1760_170461
MAINTENANCE
7.21. WINDOW CLEANING*
. NOTE !
The operator is responsible for a job safety assessment and safe method of temporary access when
maintenance work is done on difficult to reach areas.
For a clear view out of the cabin:

− Clean the windows in regular intervals or if it is necessary.
For cleaning the window of the cabin roof there is an optional maintenance ladder available.
WARNING !
Risk of falling down!
− Secure yourself against falling down.
− Hook the ladder (6) onto the provided bracket (5) of the cabin roof.
− Clean the roof window (4) by use of a window cleaning tool with telescopic arm.
1 Left side window

2 Front window
3 Right side window
4 Roof window
5 Bracket
6 Maintenance ladder
1760_170461 −7.72−
MAINTENANCE
After cleaning the window:

− Hook off the ladder from the bracket.
− Rest the maintenance ladder in the provided place (1) for safe keeping.
−7.73− 1760_170461
MAINTENANCE
7.22. REPLACEMENT OF BOOM / CHANGE BOOM CONFIGURATION
. NOTE!
The exchange of this components must be requested from our after sales service department.
7.23. REPLACEMENT OF PRIME MOVERS / GEARBOXES
. NOTE!
7.24. REPLACEMENT OF WINCHES / WINCH DRUMS
. NOTE!
7.25. REPLACEMENT OF SLEW BEARING
. NOTE!
The exchange of this component must be requested from our after sales service department.
1760_170461 −7.74−
MAINTENANCE
7.26. ELECTRICAL SYSTEM
All electric safety equipment (e.g. limit switches, emergency stop buttons etc.) should be checked in regular
intervals as well to ensure a safe operation of the crane (see maintenance list).
7.26.1. REPLACING FUSES AND LAMPS
Ensure the the following conditions are satisfied:

l The power supply has been switched off.
l The crane is secured to prevent unauthorised operation.
l Original Liebherr spare parts are available.
− Replace faulty fuses and lamps.

− Check that the new part is correctly seated.
7.26.2. REPLACING OF FILTER MAT *
Ensure the the following conditions are satisfied:

l The power supply has been switched off.
l The crane is secured to prevent unauthorised operation.
l Original Liebherr filter mat is available.
− Loosen the screws and remove the filter mat cover (1).
− Replace the used filter pad with a new original filter pad.
− Reattach the filter mat cover and fasten with screws.
−7.75− 1760_170461
MAINTENANCE
7.26.3. CLEANING THE SLIP RING UNIT *
The slip ring is installed between base column and slewing column.
l A supply of compressed air or a vacuum cleaner is available.
CAUTION !
Swirling dust and dirt particles could injure your eyes.
− Wear protective clothing (especially safety goggles and breathing mask)
CAUTION !
Danger if not cleaned properly!
The slip ring transmission could become damaged.
− The slip ring transmission must be cleaned by a dry method (vacuum cleaner, compressed air)
− Do not lift the brush holder (it could break).
− −Undo
Do not
theuse
screwanyon
contact sprays
the cover andetc.
remove the cover
− Blow compressed air over the slip ring transmission, or clean with a vacuum cleaner
− Check brushes for wear and correct position.
− Check tightening torque of cable lug fastening screws.
− Reattach the cover and check that it is correctly sealed.
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.
1760_170461 −7.76−

190 MAIN Operation &amp; Maintenance Manual Rev 00

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Vendor Document Front Page

GULF PIPING CO. W.L.L.

Equipment: BOS 7500-300 Litronic (170461)

Purchase Order: 4510041129 (Rev.2)

Suppliers Name: Liebherr Werk Nenzing GmbH (LWN)

Document Title: Operation and Maintenance Manual

Document Number: 170 MAIN 190

Revision Rev. Status

25.09.2013 00 Issued for Information

ORIGINAL 001 − 14.05.2013 / lwnbar3

Serial No.: 170461 Name: GPC JU 125/300

Manufacturer : LIEBHERR-MCCtec GmbH

Ambient temperature: min -10 [°C] Design temperature: -10 [°C]

max +45 [°C]

Crane location: Type of installation, in general fix supported or floating installation

undeformed crane system.

SWH: Significant Wave Height = H1/3 = HSignificant

LCN: Load curve number

OPL: Operational Limitation (see user manual)

Method Main characteristic

or by help of a motion analysis of the involved installations.

n.a. not applicable

Seabed or Subsea lift:

Execution of Marine Operations, Part 2, Chapter 6 Sub Sea Operations", 1996

Item code: 10597063 Revision / Index: 01

LOAD DIAGRAM AND LOAD TABLE - BOS 7500-300 LITRONIC

50 LCN 3 = Offboard, up to SWH 1.0m

Lift mode [-] Onboard Offboard Offboard

Design code: ABS, "Guide for Certification of Lifting Appliances", 2006

Minimum elevation: [m] 34

Boom length: [m] 42.00

1. Operational limitations due to low hoisting velocity: for underlined figures

Item code: 10597063 Revision / Index: 01

LOAD DIAGRAM AND LOAD TABLE - BOS 7500-300 LITRONIC

Lift mode [-] Onboard Offboard Offboard Offboard Offboard

Design code: ABS, "Guide for Certification of Lifting Appliances", 2006

Minimum elevation: [m] 34

Boom length: [m] 42.00

1. Operational limitations due to low hoisting velocity: none

Item code: 10597063 Revision / Index: 01

Crane: BOS 7500-300 LITRONIC

Unit Req. / Unit No. of Units Total Type

2. Slewing Gear: 31 l 6 186 l Gear oil

5. Distribution Gearbox 3l 2 6l Gear oil

7. Electric Power Consumption:

08.10.2012 LWN Idt according LIKV workflow

Crane utility quantity data sheet rev007.xls

2. PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

3. SAFETY GUIDELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

4. CONTROL AND OPERATING ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

5. CRANE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.4. CHECKS PRIOR TO STARTING OPERATION . . . . . . . . . . . . . . . . . . . . . 5.4

6. EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

7.25. REPLACEMENT OF SLEW BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.74

1.1. FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.2. HANDLING OF DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

1.3. LEGAL NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

BOS −1.1− 1760_170461

1760_170461 −1.2− BOS

LIEBHERR−WERK NENZING GMBH

Tel: +43 50809 41−0

BOS −1.3− 1760_170461

1.2. HANDLING OF DOCUMENTATION

The documents supplied should enable you to

190 MAIN Operation & Maintenance Manual Rev 00

190 MAIN Operation & Maintenance Manual Rev 00