Crane Instalation

Item code: 10598372
- Installation Manual Edition: 00
INSTALLATION MANUAL
Crane: BOS 4200-100 LITRONIC
00 12.07.12 Issued Stz/Ha according LIKV workflow

Edition Date Description Prepared Checked Approved
No copying or duplication of this document without the permission of Liebherr.

This document has been issued electronically and is valid without signature.
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CONTENT:
SECTION 1 : Unpacking – Lifting – Handling – Storage 1
1.1 MARKING AND IDENTIFICATION SYSTEM 2

1.2 UNPACKING 2
1.3 LIFTING – HANDLING 3
1.4 STORAGE 4
SECTION 2 : Inspection of “As Delivered Conditions” 1
2.1 INSPECTION 1
2.2 DOCUMENTS 1
SECTION 3 : Crane Installation Instructions 1
3.1 PEDESTAL 2
3.1.1 Erection of the pedestal 2
3.1.2 Dimensional control and tolerances before welding 4
3.1.3 Installation of slip-ring collector 5
3.1.4 Installation of circumferential platform 6
3.1.5 Installation of pedestal on foundation 6
3.1.6 Welding 8
3.2 SLEWING COLUMN 9

3.2.1 Installation of luffing winch 9
3.2.2 Installation of cabin 11
3.2.3 Installation of platforms and walkways 12
3.2.4 Installation of machinery house 12
3.3 A-FRAME 14
3.3.1 Installation of mounting crane frame 14
3.3.2 Mounting of compression bar 15
3.3.3 Installation of mounting crane 17
3.3.4 Installation of tilting-back support 17
3.3.5 Installation of platforms and walkways 18
3.3.6 Mounting of A-Frame on slewing column 19
3.4 BOOM 22
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3.5 COMPLETION OF CRANE INSTALLATION 23

3.5.1 Installation of crane on pedestal 23
3.5.2 Mounting of boom 25
3.5.3 Electrical and electronic equipment 29
3.5.4 Preparation for Start-Up 30
A) Electrical System 30
B) Preparation of prime mover 31
C) Hydraulic drive 32
D) Lubrication 32
3.5.5 Start-Up Procedure 32
3.5.6 Reeving of ropes 33
3.6 HANDING OVER REPORT 34
SECTION 4 : Referenced Drawings 1
SECTION 5 : Referenced Working Instructions and Documents 1
SECTION 6 : Packing List 1

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LEGEND
General Mandatory Sign
Reference to a drawing or document

The referenced drawings are attached in Section 4 of this manual.
The referenced working instructions and documents are attached in the Sections 5 – 6
of this manual.
Up, Hoisting
Slowly
Lowering the boom slowly
Down, Lowering
Attention, Danger!
Attention!

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GENERAL
Scope of work of LIEBHERR Service Engineer is defined in the contract.
In case of any trouble during crane assembly preparation or assembly itself, please
do not hesitate to contact LIEBHERR-Nenzing, AUSTRIA / EUROPE.
LIEBHERR Werk Nenzing GmbH

Dr. Hans Liebherr Str. 1
A-6710 NENZING/AUSTRIA
Tel. No.: + 43 5525 606-0 TELEFAX: + 43 5525 606-200
TELEX: 052141
DEPARTMENT: Sales Administration and Project Management
IMPORTANT:
For start-up please apply for engineer at least three weeks in advance.
GENERAL DISCLAIMER
HOWEVER, LIEBHERR SHALL NOT BE RESPONSIBLE AND / OR LIABLE FOR ANY AND
ALL DAMAGES, LOSSES (INCLUDING LIQUIDATED DAMAGES / LOSSES AS WELL AS
CONSEQUENTIAL DAMAGES / LOSSES), CLAIMS, LIABILITIES, DEMANDS, COSTS,
FEES AND EXPENSES WHATSOEVER ARISING OUT OF PERSONAL INJURY,
INCLUDING FATAL INJURY AND DISEASE, TO ANY PERSON AS WELL AS LOSS OF,
LOSS OF USE OR DAMAGE TO ANYONE´S PROPERTY TO THE EXTENT THAT THE
SAME IS CAUSED DUE TO AN IMPROPER PERFORMANCE OF THE ABOVE
MENTIONED PROCEDURE / WORK.

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INSTALLATION MANUAL
SECTION 1 :
Unpacking – Lifting –
Handling – Storage

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1. UNPACKING – LIFTING – HANDLING - STORAGE
The delivered items and components shall be handled according to their

a) size
b) weight
c) volume
d) nature (i.e. electrical, hydraulic, electronic, mechanical steel, plastic etc.)
For transport, safety and protection reasons, attachment parts (walkways, mounting cranes,
all type of electrical and electronic equipment) are removed and dismantled from the
primary crane parts and are delivered in separate packages.
Preparation, unpacking, lifting and handling operations shall be done by skilled

and experienced operator and according to “good operator’s practice”.

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1.1 MARKING AND IDENTIFICATION SYSTEM
In the shipping document, the following information is given for item identification:
All shipping items are grouped in sections and marked in the “Packing List”, with
their position given in the drawing “Delivered Items”.
Steel made items such as walkways, platforms, railings etc. are grouped and palletised for
easy handling.
All electrical, electronic and other sensitive equipment are packed in suitable boxes
according to working instruction “Preservation for Storage and Shipping”, included in
Section 5 of this manual.
If not otherwise specified and agreed in a contract specification, every package is clearly
marked for easy identification. In each package, one fully complete packing list is included
in a waterproofed envelope.
The packing list includes the following item data:

 Item location number
 Package number for corresponding item
 Part description
 LWN-Identification Number (9-Digit-Number Id.No. xxxxxxxxx)
 Weight
 Item dimensions (L x W x H)
 Volume (if required)
1.2 UNPACKING
Attention shall be paid to package markings, package weight, warning marks and other
standard international signs on the packages. Unpacking is to be done in the storage area
which suits the package size and item nature or in open air according to the environment
atmospherically and weather conditions.

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1.3 LIFTING – HANDLING
The safe and careful handling, especially during lifting up of the delivered packages, must
be observed.
The crane main component lifting points, (pad eyes) weight of the main items and
SWL of main equipment (required for safe lifting and handling) is shown in the
drawing “Delivered Items”.
Lifting must proceed with equipment (hooks, slings, shackles, turnbuckles etc.) of
corresponding safe working load and using pad eyes as shown in the above
mentioned drawing.
The operator is fully responsible for complete lifting preparation and co-ordination
during lifting operation and handling as well as for supervising and during
operation.
Palletised packages, as well as boxes, shall be treated in the same manner.
Important:
The transport conditions, as well as responsibility and insurance, before, during

and after shipping of the goods, are defined in the contract.
LIEBHERR waive any responsibility for any damage, accident or injury caused:
 due to the harsh environment conditions

 unskilled handling, preparation, lifting and handling, or
 due the lack of information in documentation supplied regarding any specific
condition not covered by these instructions, or not known to LIEBHERR at the
time of compilation and preparation of these instructions.
For any further information, required before or during preparation, do not hesitate
to contact LIEBHERR.

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1.4 STORAGE
Storage of the main components of crane and package crates delivered, are to be treated
in different ways:
Crane Main Components: Pedestal Adapter / Slewing Column / Boom /

Crates with steelwork (e.g. platforms)
Crane main components are to be stored in places or areas, which are prepared
as storage areas. Such areas may be sheltered or open air areas but must be
remote from any aggressive source and its environment such as:
 Sandblasting equipment
 Welding or flame-cutting equipment
 Burners, open flame equipment
 Exhaust gases
 Adverse chemicals
The storage area must have an AC current source to enable operation or heating
system. The heating system complies from:
 Stand-still heater of the slip-ring collector

 Space heaters in the Slewing Column
 Stand-still heater of electric motor
Make sure that the heating system is connected to the power source and remain switched
on all the time during crane storage.
Corrosion preservation for shipping will be applied to provide a temporary corrosion
protection for an outdoor storage period of maximum 12 month.
Attention:
If the storage period will exceed 3 month (including time for shipment) there must
be taken specific action regarding the crane system (start of power unit, winches,
motors etc) required. For details contact Liebherr Service Department.
If this measurement will not be taken, this can result in major damages of
components or systems. The complete operation has to be recorded properly.
Check the physical protection (plastic covers, timber covers) and corrosion protection on
weather exposed items and repair or renew it if necessary.
Crates – Packages
All other equipment packed in crates or card-boxes are to be stored in dry, enclosed, fully
sheltered stores/warehouses. Inside the crates/boxes the items are treated by VCI
compounds providing the corrosion protection for a shipping and storage period up to
maximum 12 month.

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INSTALLATION MANUAL
SECTION 2 :
Inspection of
“As Delivered Conditions”

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2. INSPECTION OF DELIVERED ITEMS (“AS DELIVERED CONDITIONS”)
2.1 INSPECTION
The inspection of the delivered items has to be performed by customer, his

operator, operator involved or by a third party involved.
The inspection shall include:
 a comparison of the delivered packages under consideration of the shipping document

 the condition of the delivered items regarding damages, missing parts etc.
Notice:
If any parts are missing or damaged, please contact LIEBHERR – Werk Nenzing under
consideration of the following reference data:
 customer name
 crane type
 series number
 package and LIEBHERR item number
 a short description of the damage occurred if possible documented by help of photos
2.2 DOCUMENTS
Inspection shall be provided using the following documents:
 Shipping documents including packing list

 Installation instructions as given in Section 3 of this manual
 Delivered Items

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INSTALLATION MANUAL
SECTION 3 :
Crane Installation
Instructions

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3. CRANE INSTALLATION INSTRUCTIONS
Important:
 Personnel have to wear appropriate PPE (Personnel protection equipment).

 Local procedures, rules and regulations have to be observed.
 Always refer to the crane instruction manual.
 This procedure is only a guideline and should not be considered as complete.
 Only competent personnel should be allowed to carry out the above mentioned scope of
work.
 LIEBHERR recommends to use a LIEBHERR service engineer to execute overload tests.
 During mounting, wind is taken into account with 10 m/s. If wind is stronger, all free-
standing parts have to be temporarily fixed against tilting.
 The sketches in this manual serve only to show particular crane components and will not
always represent “Your crane one hundred percent”. Look at the drawings in Section 4 if
you need detailed information.
 All deviations from the given installation instructions and sequences (i.e. Single Lift of
crane as a whole) must be clarified with LIEBHERR Service Department.
Bolt fastening by torque wrench pre-tensioning:
For all bolted flange connections the following steps must be done prior the installation and
the bolt fastening:
1. Clean both contact surfaces of the flange connection. The connections must be free of
moisture, grease, oil, painting or any dirt.
2. Install the bolt into the hole, install the washer plates and thread the nuts.
3. Bolts must be properly fastened/pre-tensioned by using torque wrench with torque-wrench
tightening moment.
For data and values regarding required pre-tensioning torque refer always to the
mentioned drawings only. Any other value found in other documents or sketches
may not be valid. In case of doubt revert to LIEBHERR.
If not otherwise mentioned in the contract, torque wrench may be, on client request,
supplied by LIEBHERR for extra cost.
If torque wrench is supplied by a client, it must be of an approved and calibrated
type, equipped with an indication scale.
After pre-tension is completed, a corrosion protection of all bolts exposed to the

environmental conditions must be provided.

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3.1 PEDESTAL
3.1.1 Erection of the pedestal
Image 01:
For the weight of pedestal refer to the
Drawing No.:
2278 995 69 01 000 00X
Image 02:
Image 03:
To put the pedestal into upright position lift the

pedestal by using ...
a) two Cranes with hoist lines

or
b) one Crane with two hoists
of adequate capacity!

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Image 04:
Image 05:
Image 06:

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Image 07:
Image 08:
3.1.2 Dimensional control and tolerances before welding
Image 09:
1. Visual control of welding bevel preparation (no

damages allowed)
2. Control roundness of pedestal at interface
level
3. Control flange flatness according to Working
instruction “Flatness Control”
Drawing No.:
2278 060 17 00 000 00X
2278 061 17 00 000 00X

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3.1.3 Installation of slip-ring collector
Image 10:
Installation of slip ring collector

according to Drawing No.
2278 541 05 00 000 00X
Image 11:
Image 12:

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3.1.4 Installation of circumferential platform
Image 13:
Installation of circumferential platform

2276 006 34 00 000 00X
3.1.5 Installation of pedestal on foundation
Image 14:
Image 15:

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Image 16:
Image 17:
In order to be able to put the boom

onto the boom rest during installation
of the boom, be sure that the pedestal
is put on in the right orientation
Orientation according to Drawing No.

2278 061 17 00 000 00X
Image 18:

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3.1.6 Welding
Image 19:
The welding preparation is shown in

Drawing No.
2278 060 17 00 000 00X
The welding must be performed according to

Working instruction
“weld assembly 10225362”.
Dimensional control and tolerances after welding
Image 20:
Control flange flatness according to Working

instruction “Flatness Control”
Control inclination of the pedestal’s

centre line (maximum allowed
tolerance ± 0,5°)

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3.2 SLEWING COLUMN
For the required hooking arrangements as well as required site crane capacities refer to the
following technical documents:
Delivered Items 2278 995 69 01 000 00X

Packing List
3.2.1 Installation of luffing winch
Image 21:
Installation of luffing winch

2276 304 05 01 000 00X
Image 22:

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Image 23:
Image 24:

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3.2.2 Installation of cabin
Image 25:
Installation of cabin according to

Drawing No.
2267 491 12 01 000 00X
Image 26:
Image 27:

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3.2.3 Installation of platforms and walkways
Image 28:
Installation of platforms and

walkways according to Drawing No.
2278 516 04 00 000 00X
3.2.4 Installation of machinery house
Image 29:
For the weight of the machinery

house see Drawing No.
2278 995 69 01 000 00X

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Image 30:
Installation of machinery house

2276 440 01 02 000 00X
2277 440 01 01 000 00X
2277 440 01 02 000 00X
Image 31:

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3.3 A-FRAME
3.3.1 Installation of mounting crane frame
Image 32:
Image 33:
Installation of mounting crane

frame according to Drawing No.
2278 516 03 00 000 00X
Image 34:
Insert the bolts

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Image 35:
Fix the frame with slings against falling

down.
Image 36:
3.3.2 Mounting of compression bar
Image 37:
Installation of compression bar

2278 125 01 00 000 00X

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Image 38:
Image 39:
Remove the fixing slings of the

mounting crane frame.
Image 40:

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3.3.3 Installation of mounting crane
Image 41:
Installation of mounting crane

according to Drawing No.:
2278 543 01 00 000 00X
3.3.4 Installation of tilting-back support
Image 42:
Installation of tilting-back support

2278 126 01 00 000 00X

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Image 43:
Image 44:
3.3.5 Installation of platforms and walkways
Image 45:
Installation of platforms and

walkways according to
Drawing No.
2278 516 03 00 000 00X
2278 125 02 00 000 00X

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3.3.6 Mounting of A-Frame on slewing column
Image 46:
For the weight of the complete A-Frame

see Drawing No.:
2278 995 69 01 000 00X
Be sure that you hoist the A-

Frame with the correct lifting
lugs like shown in the image
(upper lugs).
Lift the A-Frame with a cross

bar to avoid transversal force
onto the lifting lugs.

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Image 47:
Image 48:

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Image 49:
Mounting of A-Frame
2278 125 01 00 000 00X
Image 50:

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Image 51:
3.4 BOOM
The boom as a whole is completely assembled (inclusive walkway, platforms, winches etc),
before it is connected to the slewing platform.
To assembly the boom sections refer to the drawings:
Gangway Pivot Piece – left 2277 544 05 17 000 00X 10516104

Mounting Material – Pivot Piece - left 2278 544 33 01 000 00X 10576067
Gangway Intermediate Section – 12m 2277 544 05 15 000 00X 10517042
Mounting Material – Interm. Section 12m 2278 544 33 04 000 00X 10594251
Gangway Head Section 2278 544 02 03 000 00X 10516549
Mounting Material – Head Section 2278 544 33 05 000 00X 10594252
Gangway Pivot Piece – right 2277 544 05 18 000 00X 10516105
Mounting Material – Pivot Piece - right 2278 544 33 07 000 00X 10594261
Bolting Pivot 2276 514 01 00 000 00X 990274414
Mounting Material – Pivot Piece 2277 215 01 00 000 00X 990284214
Mounting Material – Boom Sections 2272 235 01 00 000 00X 919933614
For the completion of the boom assembly also refer to the drawings:
General Arrangement 2278 001 69 01 000 00X

Delivered Items 2278 995 69 01 000 00X
Packing List

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3.5 COMPLETION OF CRANE INSTALLATION
3.5.1 Installation of crane on pedestal
Image 52:
For the weight of the complete slewing

column with A-Frame see Drawing No.
2278 001 69 01 000 00X
Be sure that you hoist the crane with

the correct lifting lugs like shown in the
image (lower lugs).
Lift the crane with a cross bar to avoid

transversal force onto the lifting lugs.
Image 53:

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Image 54:
Installation of crane on pedestal

2278 551 02 00 000 00X
For bolt fastening also refer to working

instruction “Pre-Tensioning of Bolts via
Hyrd. Tensioning Tool”.
Image 55:

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3.5.2 Mounting of boom
Image 56:
For weight of boom see

Drawing No.
2278 995 69 01 000 00X
Image 57:
Provide boom slings or

Ropes for hoisting. Assure
that the Ropes don’t
damage the paint work.
Image 58:

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Image 59:
Image 60:
Image 61:

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Image 62:
For pin connection of boom

refer to Drawing No.:
2276 514 01 00 000 00X
Installation remark:
Pins, bushings and bores
must be cleaned,
dried and shall not be
greased or oiled before
installation !
Image 63:
Image 64:

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Image 65:
Image 66:

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3.5.3 Electrical and electronic equipment
Due to transport reasons a number of items of electrical and electronic equipment

such as lighting, warning lights, alarm devices, junction boxes, limit switches etc.
were disconnected and are delivered as separate packages.
To locate, install and connect electrical equipment in appropriate position, refer to

the drawings:
Outline Power Supply 2278 600 69 00 031 00X 10597929

Search Light Installation – Cabin Platform 2276 528 04 00 000 00X 992032814
Search Light Installation – A-Frame 2278 530 02 00 000 00X 919648014
Search Light Installation – Boom Head 2276 529 08 00 000 00X 992937214
Search Light Installation – Boom 2276 531 07 00 000 00X 993820314
Helicopter Lamp Instal. – Aux. Hoist Boom 2276 537 01 01 000 00X 990695314
Helicopter Lamp Instal. – Boom 2276 537 02 01 200 00X 990844514
Helicopter Lamp Instal. – A-Frame 2276 537 01 02 000 00X 990695414
Helicopter Lamp Instal. – A-Frame add. 2276 537 02 02 200 00X 990844714
Wind Transmitter Installation 2265 526 01 00 000 00X 919332214
Camera Equipment – Boom Head 2289 552 03 02 000 00X 994546214
Camera Equipment – Luffing Winch not in this crane not in this crane
Wind Sock Installation not in this crane not in this crane
Fire Extinguisher System not in this crane not in this crane
All adjustments of the limit switches and potentiometers shall be carried out or
checked by a LIEBHERR Engineer.

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3.5.4 Preparation for Start-Up
Refer to the drawings:
Drive Unit 2267 410 06 00 000 00X

Central Power Unit Cpl. 1 2267 412 04 00 000 00X
Central Power Unit Cpl. 2 not in this crane
The crane is usually delivered with dry tanks and piping systems and with equipment
temporary protected for transport.
A) Electrical System
 Connect electrical cables from platform/ship main supply to the junction box, located in
the pedestal adapter. Refer to the drawing:
Outline Power Supply 2278 600 69 00 031 00X
 Connect all electrical cables

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B) Preparation of prime mover
Electric motor
In general, electric motors are ready for the start when the main power is connected. Before
you run the power pack or start-up the crane, the following steps are necessary for electrical
system start-up:
 Remove all transport protection from the equipment (the power pack frame is fastened to
the supporting structure by means of bolts as transport safety).
 Before the initial start-up of the electric-motor or in case that the electric-motor was out of
service for a longer period, the insulation resistance of motor is to be checked in order to
prevent short circuit damage of rotor and stator due to residual humidity, moisture, oil or
dirt between rotor and stator  please contact LIEBHERR Service Department.
Diesel power pack
When you fill the storage tanks with fuel, observe the appropriate safety
instructions. Fire or explosion may be dangerous and can kill.
To minimise system faults, make sure the fuel system is clean. Use the necessary
filters to prevent ingress of dirt and moisture into the system.
 remove all transport protections from the equipment.
 clean the fuel storage tank and fuel filters if necessary. Moisture is not allowed in the
fuel tank or in the pipes.
 fill the fuel tank according to “Utility Requirements” included in Section 5 of this
manual.
 fill the engine (oil pan and oil filters) according to “Utility Requirements” and “Table of
Lubricants” included in Section 5 of this manual.
 fill the cooling system with coolant containing the recommended additives for summer
or winter seasons according to “Utility Requirements” and “Table of Lubricants”
included in Section 5 of this manual. Use a strainer to remove dirt.
 check the batteries. Add electrolyte if necessary.

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C) Hydraulic drive
Refer to the drawing:
Hydraulic 2278 970 28 00 001 00X
Before start-up of the hydraulic-system the following steps are necessary:
 remove all transport protections from hydraulic components
 check and clean hydraulic oil tank if necessary. The tank must be dry and free of
moisture.
 fill hydraulic oil tank with hydraulic oil provided. Use a strainer to keep oil free from dirt.
For oil quantities and for oil-types refer to “Utility Requirements” and “Table of Lubricants”
included in Section 5 of this manual.
 remove blind plugs at hydraulic gears, check oil level and replace blind plugs with vent
plugs.
 connect hydraulic hoses which were disconnected for transport.
D) Lubrication
Before the start-up of the crane, it is necessary

 to check the oil level off all equipment provided (winches, hydraulic driving
motors, gears etc.)
 to check if all blind plugs are exchanged to vent plugs
 to check if all mechanical, electrical, hydraulic or other equipment which are
provided with grease nipples are fully greased.
For information about oil types and quantities please refer to “Utility Requirements” and
“Table of Lubricants” included in Section 5 of this manual.
3.5.5 Start-Up Procedure
For start up of the Power Pack please contact LIEBHERR service department.

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3.5.6 Reeving of ropes
In order to avoid torsion / twisting of the rope during handling and spooling,
please refer to the attached “Instruction for handling of crane ropes” (see Section
5 of this manual).
Read the instructions prior to the rope reeving carefully!
Image 67:
The reeving of the wire rope shall be carried out according to Drawing No.
2278 700 35 00 000 00X

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Image 68:
3.6 HANDING OVER REPORT
After completion of the installation the crane shall be checked according to the requirements
specified in the handing over report. The service engineer is responsible for completion of
this document. If not otherwise specified the tests have to be witnessed by the client and
surveyor of the nominated Certifying Authority. The scope of crane test has also to meet the
requirements of the Certifying Authorities rules for lifting appliances.
Finally the handing over report shall be signed by the
 Service Engineer
 Client representative
 Surveyor of the Certifying Authority (if applicable)
In case of findings they have to be reported in a punchlist.

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INSTALLATION MANUAL
SECTION 4 :
Referenced Drawings

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4. REFERENCED (DESIGN and FUNCTIONAL) DRAWINGS
Drawings Number System: (e.g.) xxxx 000 00 00 000 00X
Drawing Master Number

Crane Main Assembly
Sub-Assembly
Drawing Alteration Index
Caption Drawing No. Item Code
General Arrangement 2278 001 69 01 000 00X 10598370

Delivered Items 2278 995 69 01 000 00X 10598371
PEDESTAL ADAPTER
BS Weld. Constr. 2278 061 17 00 000 00X 993598914
BC Top Section Weld. Constr. Cpl. 2278 060 17 00 000 00X 993598814
Slip Ring Carrier Installation 2278 541 05 00 000 00X 10550150
BS Add-On 2278 551 02 00 000 00X 991421314
All-Around Platform RFK 2276 006 34 00 000 00X 10545380
SLEWING COLUMN
Standard Constr. Unit Instal. 2278 516 04 00 000 00X 10524546
Mounting Material - Standard Constr. Unit 2278 517 04 01 000 00X 10524547
Luffing Winch Cpl. 2276 304 05 01 000 00X 10533414
Drivers Cabin Install. Cpl. 2267 491 12 01 000 00X 10521415
MACHINARY HOUSE
Drive Unit 2267 410 06 00 000 00X 10598437
Central Power Unit Cpl. 1 2267 412 04 00 000 00X 10579451
Central Power Unit Cpl. 2 not in this crane not in this crane
Machinery House Add-On 2276 440 01 02 000 00X 990277514
Railing Cpl 2277 440 01 01 000 00X 10519998
Mounting Material – Machinary House 2277 440 01 02 000 00X 10520082
A-FRAME
Pressure Profile Weld. Constr. Cpl. 2278 126 01 00 000 00X 990288014
Mounting Material A-Frame 2278 125 01 00 000 00X 990288514
Standard Constr. Unit Instal. 2278 516 03 00 000 00X 10520968
Mounting Material Standard Constr. Unit 2278 125 02 00 000 00X 10521682
Mounting Crane Installation – 5 to 2278 543 01 00 000 00X 990289014
Mounting Crane Installation – 0.5 to 2276 543 02 00 000 00X 990817614

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Item code: 10598372
BOOM
Gangway Pivot Piece – left 2277 544 05 17 000 00X 10516104
Mounting Material – Pivot Piece - left 2278 544 33 01 000 00X 10576067
Gangway Intermediate Section – 12m 2277 544 05 15 000 00X 10517042
Mounting Material – Interm. Section 12m 2278 544 33 04 000 00X 10594251
Gangway Pivot Piece – right 2277 544 05 18 000 00X 10516105
Mounting Material – Pivot Piece - right 2278 544 33 07 000 00X 10594261
Bolting Pivot 2276 514 01 00 000 00X 990274414
Mounting Material – Pivot Piece 2277 215 01 00 000 00X 990284214
Mounting Material – Boom Sections 2272 235 01 00 000 00X 919933614
ELECTRIC
Outline Power Supply 2278 600 69 00 031 00X 10597929
Search Light Installation – Cabin Platform 2276 528 04 00 000 00X 992032814
Search Light Installation – Boom Head 2276 529 08 00 000 00X 992937214
Search Light Installation – Boom 2276 531 07 00 000 00X 993820314
Helicopter Lamp Instal. – Aux. Hoist Boom 2276 537 01 01 000 00X 990695314
Helicopter Lamp Instal. – Boom 2276 537 02 01 200 00X 990844514
Helicopter Lamp Instal. – A-Frame 2276 537 01 02 000 00X 990695414
Helicopter Lamp Instal. – A-Frame add. 2276 537 02 02 200 00X 990844714
Wind Transmitter Installation 2265 526 01 00 000 00X 919332214
Camera Equipment – Boom Head 2289 552 03 02 000 00X 994546214
Camera Equipment – Luffing Winch not in this crane not in this crane
Wind Sock Installation not in this crane not in this crane
Fire Extinguisher System not in this crane not in this crane
HYDRAULIC
Diagram Hydraulic 2278 970 28 00 001 00X 11216463
ROPES
Ropes 2278 700 35 00 000 00X 10598584
BALLAST
Ballast RFK not in this crane not in this crane
Notice:
 “-00X” means the latest drawing alteration index.

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Item code: 10598372
 Item numbers i.e. positions in the Packing List corresponding with the positions
indicated in the drawing: Delivered Items 2278 995 69 01 000 00X. The Packing List
can be found in Section 6 of this manual.

3/3
Item code: 10598372
INSTALLATION MANUAL
SECTION 5 :
Referenced Working Instructions

and Documents

1/1
Item code: 10598372
5. REFERENCED WORKING INSTRUCTIONS AND DOCUMENTS
Document Content:
Caption Item Code
 Preservation for Storage and Shipping 982607114
 Repair Instructions of 2-Pack Paint System 982603614
 Welding 10225362
 Flatness Control 10225363
 Pre-Tensioning of Bolts via Hydr. Tensioning Tool 982608414
 Instructions for handling of Crane Ropes 10227247
 Utility requirements 10598373
 Table of lubricants 809950914

1/1
Item code: 10598372
INSTALLATION MANUAL
SECTION 6 :
Packing List

1/1
Item code: 10598372
6. PACKING LIST
Document Content:
Caption Item Code
 Packing List 10598371

1/1

Crane Instalation

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Item code: 10598372

- Installation Manual Edition: 00

Crane: BOS 4200-100 LITRONIC

00 12.07.12 Issued Stz/Ha according LIKV workflow

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

SECTION 1 : Unpacking – Lifting – Handling – Storage 1

1.1 MARKING AND IDENTIFICATION SYSTEM 2

SECTION 2 : Inspection of “As Delivered Conditions” 1

SECTION 3 : Crane Installation Instructions 1

3.2 SLEWING COLUMN 9

3.5 COMPLETION OF CRANE INSTALLATION 23

3.6 HANDING OVER REPORT 34

SECTION 4 : Referenced Drawings 1

SECTION 5 : Referenced Working Instructions and Documents 1

SECTION 6 : Packing List 1

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

General Mandatory Sign

Reference to a drawing or document

Lowering the boom slowly

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

Scope of work of LIEBHERR Service Engineer is defined in the contract.

LIEBHERR Werk Nenzing GmbH

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

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

1. UNPACKING – LIFTING – HANDLING - STORAGE

The delivered items and components shall be handled according to their

Preparation, unpacking, lifting and handling operations shall be done by skilled

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

1.1 MARKING AND IDENTIFICATION SYSTEM

The packing list includes the following item data:

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

1.3 LIFTING – HANDLING

Palletised packages, as well as boxes, shall be treated in the same manner.

The transport conditions, as well as responsibility and insurance, before, during

 due to the harsh environment conditions

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

Crane Main Components: Pedestal Adapter / Slewing Column / Boom /

 Stand-still heater of the slip-ring collector

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

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

2. INSPECTION OF DELIVERED ITEMS (“AS DELIVERED CONDITIONS”)

The inspection of the delivered items has to be performed by customer, his

The inspection shall include:

 a comparison of the delivered packages under consideration of the shipping document

Inspection shall be provided using the following documents:

 Shipping documents including packing list

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

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

3. CRANE INSTALLATION INSTRUCTIONS

 Personnel have to wear appropriate PPE (Personnel protection equipment).

Bolt fastening by torque wrench pre-tensioning:

After pre-tension is completed, a corrosion protection of all bolts exposed to the

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

3.1.1 Erection of the pedestal

For the weight of pedestal refer to the

To put the pedestal into upright position lift the

a) two Cranes with hoist lines

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

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

3.1.2 Dimensional control and tolerances before welding

1. Visual control of welding bevel preparation (no

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