Bal 003 en PDF

Operating Manual EN
Type:
BA 280
Serial number:
115 532
ORIGINAL 003 - 27.08.2010 / lwnfim2

INDEX
INDEX
1. Drilling drive 1-1
1.1 General 1-1
1.2 Overview of Drilling Drive 1-3
1.3 Check Oil Level 1-4
1.4 Maintenance 1-5
1.5 Transport 1-6
115 532 (mf) LWN - TD27/8/2010
0-1
INDEX
NOTES:
0-2
1. Drilling drive
1. Drilling drive
1.1 General
CAUTION !
The safety regulations in the operating manual of the basic appliance are applicable!
Technical Data
Type of Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BA 280

Weight drilling gear slide with drilling gear and drilling drive . . . . . . . . . . . . . . . . . 5643 kg [12440 lbs]
Weight Kelly damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521 kg [1148 lbs]
Weight cardan pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562 kg [1239 lbs]
Output torque in slow running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 kNm [206517 lbf ft]
Output torque in fast running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 kNm [103258 lbf ft]
Revolutions per minute in slow running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 13 U/min [13 rpm]
Revolutions per minute in fast running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 26 U/min [26 rpm]
Required quantity of oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 l [50 gal]
Temperature range of the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 20° C to + 80° C [- 4° F to + 176° F]
For the exact specifications of the oil and lubricant to be used see Chapter 7 under "Lubricant
Requirements" of the basic device.
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1-1
1. Drilling drive
Dimensions
Usage
This drilling drive is solely intended to be used for drilling purposes in special excavation engineering
or similar applications. It is only to be operated and put into use in connection with a suitable
supporting device.
This drilling drive is not intended for types of use other than those listed here - this is not deemed to
be use as directed!
Use as directed also includes reading this operating manual and following the instructions contained
herein - particularly the safety instructions. Furthermore, it is also true that all servicing and repair
work is to be carried out in the prescribed time intervals.
If the drilling drive is not used in accordance with this provision, then no safe operation is
guaranteed.
It is not the manufacturer but the operator of the drilling drive that is responsible for any personal
injury or material damage caused by use not as directed!
1-2
1. Drilling drive
1.2 Overview of Drilling Drive
1 Drilling Gear Slide 7 Oil Insert

2 Oil Drain Screw 8 Kelly Damping
3 Cardan Pivot 9 Dipstick
4 Cover Screw and Grease Nipple 10 Hydraulic Engines
5 Drilling Gear
6 Oil Level Indicator
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1-3
1. Drilling drive
1.3 Check Oil Level
NOTE !
Always check the oil level of the drilling drive when cold and stationary.
To check the oil level, the device must be horizontal.
3
The precise filling quantity of the oil is to be determined
using the oil level indicator (Fig 3):
• The oil level must be between the MIN. and MAX.

marking. If the level is under the MIN. marking, top up
the oil.
4
Additionally the filling quantity of the oil is to be deter-
mined using the dipstick (Fig 4):
• Twist the dipstick out in an anticlockwise direction.

• Twist the dipstick out, wipe with a clean cloth and
push in again until it clicks.
• Pull the dipstick out again and check oil level.

marking on the dipstick, top up with oil as needed.
1-4
1. Drilling drive
1.4 Maintenance
Lubricating
This drilling drive must be greased daily via the grease nipple (Fig 2)!
• First twist out the cover screw (Fig 2, No. 4) anticlockwise.

• Then grease the grease nipple underneath until it forms a collar of grease.
• Then turn the drilling drive about 90°.
• Grease the grease nipple again until a grease collar forms
Oil Change
The oil change is to be done for the first time after 200 hours of operation and then every 1000
hours of operation, but at least once a year.
The used oil can be drained using the oil drain screw underneath the drilling gear.
Driver bar wear
5
115 532 (mf) LWN - TD27/8/2010
1 Driver
2 Driver bar
3 Kelly rod
The driver bars (Diagram 5, no. 2) must be replaced when wear equals a = 6mm .
1-5
1. Drilling drive
6
Hydraulic buffer of the Kelly shock absorber
The maintenance of the hydraulic buffer (Fig 6, No. 1) is

described in the "Hydraulic buffer installation and operat-
ing instructions" in the "Technical information" volume.
The measures that are taken when a hydraulic buffer no

longer goes to its output position (b=105 mm) after work
input are also indicated there.
Bearing of the Kelly shock absorber
The bearing (Figure 6, No. 2) must be replaced when it

is worn or has detached from the steel ring.
Check Before Operating the Drilling Drive

Before operating the machine, the general condition of the drilling drive
is to be checked for
- secure bolts.
- fastening screws being tight.
- mechanical damage.
- seal of the hydraulic system.
- other damage.
- damage to the electrical cables.
If there is any damage, the machine must not be operated!
1.5 Transport
Safety Instructions for Transport
• To avoid damage or life-threatening injuries when transporting the drilling drive, the following points
must be followed:
• Transport work must only be carried out by persons qualified to do this while following the safety
instructions.
• This drilling drive must only be lifted at the provided (Fig 7) attachment points.
• When transporting the drilling drive, only the weight of the relevant attachment resource may be
used.
• Protruding sharp edges may lead to cut injuries.
• Suspended loads may drop, resulting in danger of death - do not go underneath suspended loads!
• Parts that are stacked too high may topple.
• In air cargo transport, ensure that the pressure accumulator is unpressurised, otherwise there is
risk of explosion.
1-6
1. Drilling drive
7
Lifting the Drilling Drive
For lifting, the suspension gear must be attached to the
attachment points. (Fig 7, No. 1-4)
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1. Drilling drive
NOTES:
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Operating Manual EN
Type:
LB 28
Serial number:
115 532
ORIGINAL 003 - 27.08.2010 / lwnfim2

115 532
LIEBHERR
INTRODUCTION .................................................1
PRODUCT DESCRIPTION .................................2
SAFETY INSTRUCTIONS ..................................3
CONTROLS ........................................................4
OPERATION .......................................................5
CHAPTER SUMMARY
ASSEMBLY AND DISMANTLING ......................6
MAINTENANCE ..................................................7
REPAIR ...............................................................8
OPTIONS ............................................................9
LB 28_V007 (hsj/mf/es/sh) LWN - TD27/7/2010
APPENDIX ....................................................... 10
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INDEX
INDEX
1. INTRODUCTION 1-1
1.1 Foreword 1-1
1.2 Handling of documentation 1-2
1.2.1 How are the Operating instructions set up? 1-3
1.2.2 System requirements of the computer for use of CD-ROMs 1-3
1.2.3 Storage of documentation 1-3
1.2.4 Current status of documentation 1-4
1.2.5 Danger symbols 1-4
1.3 Legal notice 1-6
1.4 Conversion tables 1-7
1.4.1 Length 1-7
1.4.2 Surface area 1-7
1.4.3 Weight (Mass) 1-8
1.4.4 Volume 1-8
1.4.5 Pressure 1-8
1.4.6 Temperature 1-9
1.4.7 Speed 1-9
1.4.8 Force 1-9
1.4.9 Torque 1-9
1.4.10 Performance 1 - 10
1.5 Conformity declaration 1 - 11
2. PRODUCT DESCRIPTION 2-1

2.1 General 2-1
2.1.1 What should you be aware of when reading the operating manual? 2-1
2.2 Applications of the machine 2-2
2.2.1 Equipment rating 2-2
2.3 Appropriate use 2-3
2.4 Inappropriate use 2-4
2.5 Machine overview 2-5
2.6 Safety and monitoring devices 2-6
2.6.1 Safety devices 2-6

2.6.2 Monitoring devices 2-8
2.7 Drilling unit 2-9
2.8 Superstructure 2 - 15
2.8.1 Central power unit 2 - 18
2.8.2 Counterweight 2 - 20
2.9 Undercarriage 2 - 21
2.10 Overview of the hydraulic cylinders 2 - 24
2.11 Technical data 2 - 25
2.11.1 Dimensions and transport weight 2 - 25
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2.11.2 Machine in operation 2 - 26

2.11.3 Key data 2 - 27
2.11.4 Operating conditions 2 - 28
2.11.5 Emissions 2 - 28
2.11.6 Engine 2 - 29
2.11.7 Hydraulic system 2 - 30
2.11.8 Winches 2 - 30
2.11.9 Slewing gear 2 - 31
2.11.10 Travel gear 2 - 31
2.11.11 Control 2 - 32
2.11.12 Load Capacity Charts 2 - 33
3. SAFETY INSTRUCTIONS 3-1

3.1 Technical condition of the machine 3-1
3.2 Areas of responsibility 3-2
3.2.1 Manufacturer 3-2
3.2.2 Owner 3-2
3.2.3 Machine operator 3-2
3.2.4 Rigger 3-2
3.2.5 Signalman 3-3
3.2.6 Maintenance personnel 3-3
3.3 Requirements of personnel 3-4
3.3.1 Machine operator 3-4
3.3.2 Rigger 3-4
3.3.3 Signalman 3-4
3.3.4 Maintenance personnel 3-5
3.4 Personal protective gear 3-6
3.5 Work area 3-7
3.6 Danger zone 3-8
3.6.1 Danger area during drilling operation 3-8
3.6.2 Danger area in piling mode 3-9
3.6.3 Danger zone when moving the machine 3 - 10
3.6.4 Danger area in the transport position 3 - 11
3.7 Safety signs on the machine 3 - 12
3.8 Safety signs on the USA-version machine 3 - 15
3.9 Meaning of the safety signs 3 - 18
3.9.1 Prohibition signs 3 - 18
3.9.2 Warning signs 3 - 18
3.9.3 Fire protection signs 3 - 20
3.9.4 Mandatory signs 3 - 20
3.10 Meaning of the machine-specific safety signs 3 - 22
3.11 Hazards 3 - 23
3.11.1 Mechanical action 3 - 23
3.11.2 Electrical energy 3 - 24
3.11.3 Hydraulic energy 3 - 25
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3.11.4 Burns 3 - 26
3.11.5 Chemical burns 3 - 27
3.11.6 Fire and explosion 3 - 28
3.11.7 Poisoning and suffocation 3 - 29
3.11.8 Electromagnetic influence 3 - 30
3.11.9 Exposure to wind 3 - 31
3.11.10 Snow and ice loads 3 - 33
3.11.11 Lightning strikes 3 - 34
3.11.12 Overhead power lines 3 - 35
3.11.13 Excavation work 3 - 38
3.11.14 Working in the dark 3 - 40
3.11.15 Environment 3 - 41
3.12 What to do in dangerous situations 3 - 42
3.12.1 How to respond in the event of a current transfer 3 - 42
3.12.2 Procedure in the event of fire 3 - 44
3.12.3 Firefighting 3 - 44
3.13 Hand signals 3 - 48
3.13.1 General hand signals in accordance with BGV A8 3 - 49
3.13.2 Special hand signals for attachment operations 3 - 51
3.13.3 Hand signals for lifting operations in accordance with ASME/ANSI B30.5 3 - 54
3.14 Steps 3 - 58
3.15 Safety harness and fall protection slide * 3 - 59
3.15.1 Putting on the safety harness 3 - 59
3.15.2 How the fall protection slide works 3 - 60
4. CONTROLS 4-1
4.1 General 4-1
4.2 Operational controls on the undercarriage 4-2
4.3 Operational controls on the superstructure 4-3
4.4 Cab 4-4
4.4.1 Cab overview 4-4
4.4.2 Control stand overview 4-6
4.4.3 Overhead view of control stand 4-8
4.5 Joysticks, pedals 4 - 12
4.6 Left control panel (X11) 4 - 14
4.7 Left control panel (X12) 4 - 16

4.8 Right-hand control panel (X23) 4 - 18
4.9 Additional control panel (X25) 4 - 21
4.10 Emergency shut-down button 4 - 26
4.11 Overview of the LCD screen 4 - 27
4.11.1 Main areas of the screen 4 - 27
4.11.2 Description of the main areas of the screen 4 - 28
4.11.3 Screen page sequence 4 - 30
4.12 "Mode screen" page 4 - 32
4.13 "Select operating mode" page 4 - 43
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4.14 "Power unit monitoring" page 4 - 46

4.15 Motor error message 4 - 50
4.15.1 Serious motor error message 4 - 50
4.15.2 General motor error message 4 - 51
4.16 "Fault monitor" page 4 - 52
4.17 "Settings" page 4 - 55
4.18 Litronic service panel on the LCD screen 4 - 57
4.18.1 Menu bar 4 - 57
4.18.2 Keyboard menu 4 - 58
5. OPERATION 5-1
5.1 General 5-1
5.1.1 Safe working with the machine 5-1
5.2 Checks before daily operation 5-2
5.2.1 Tour of inspection 5-2
5.2.2 Checks 5-2
5.3 Daily start up 5-4
5.3.1 Switch on ignition 5-4
5.3.2 Checking the fuel level 5-5
5.3.3 Refueling the machine 5-5
5.3.4 Selecting the operating mode 5-6
5.3.5 Starting the diesel engine 5-8
5.3.6 Adjusting the engine speed 5-9
5.3.7 Lower safety lever (access lever) 5 - 11
5.4 Machine operation - main functions 5 - 12
5.4.1 Checks/activities before starting work 5 - 13
5.4.2 Operating the travel gear 5 - 14
5.4.3 Activating the slewing gear 5 - 19
5.4.4 Positioning the lead with the additional control panel (X25) 5 - 22
5.4.5 Adjusting the lead with the joystick 5 - 26
5.4.6 Lead inclinometer 5 - 30
5.4.7 Automatic tower system 5 - 31
5.4.8 Second tower system 5 - 33
5.4.9 Operating the auxiliary winch* 5 - 34
5.4.10 Actuating the Kelly winch* 5 - 36
5.4.11 Kelly winch rope length metering* 5 - 37
5.4.12 Kelly-winch free-wheel* 5 - 41
5.4.13 Feed operation 5 - 44
5.4.14 Parallel operation * 5 - 47
5.5 Litronic 5 - 50
5.5.1 Properties 5 - 50
5.5.2 General 5 - 50
5.5.3 Starting the Litronic 5 - 51
5.5.4 The menus 5 - 52
5.5.5 Main menu 5 - 52
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5.5.6 INPUT/OUTPUT menu 5 - 53

5.5.7 MEMORY menu 5 - 53
5.5.8 SELECT menu 5 - 54
5.5.9 CORRECTION menu 5 - 57
5.5.10 MESSAGES menu 5 - 58
5.5.11 SPECIAL FUNCTIONS menu 5 - 59
5.6 Operating the machine - auxiliary functions 5 - 64
5.6.1 Driver's seat 5 - 64
5.6.2 Additional control panel (X25) 5 - 65
5.6.3 LCD screen adjustments 5 - 65
5.6.4 Windshield wiper 5 - 66
5.6.5 Lighting 5 - 68
5.6.6 Radio 5 - 69
5.6.7 Hooter 5 - 69
5.6.8 Ashtray 5 - 70
5.6.9 Cigarette lighter and socket in the cab 5 - 70
5.7 Operating instructions 5 - 71
5.7.1 General 5 - 71
5.8 Drilling operation 5 - 72
5.8.1 General 5 - 72
5.8.2 CFA drilling * 5 - 75
5.8.3 Double rotary drilling * 5 - 79
5.8.4 Soil mixing mode * 5 - 85
5.8.5 Kelly drilling * 5 - 89
5.9 Casing oscillator* 5 - 93
5.9.1 General 5 - 93
5.9.2 Connecting the casing oscillator 5 - 93
5.9.3 Adjusting casing oscillator 5 - 94
5.9.4 Switch on the casing oscillator 5 - 96
5.9.5 Operating the casing oscillator 5 - 97
5.9.6 Saver circuit 5 - 98
5.9.7 Switching off the casing oscillator 5 - 98
5.10 Reinforcement vibrator * 5 - 99
5.10.1 General 5 - 99
5.10.2 Pre-selecting vibrator operation 5 - 99
5.10.3 Operating the vibrator 5 - 100

5.11 Shutting down the machine 5 - 102
5.11.1 Parked position 5 - 102
5.11.2 Shutting down the diesel engine 5 - 104
5.11.3 Park position of the ignition starter switch 5 - 105
5.11.4 Checks before leaving the machine 5 - 105
6. ASSEMBLY AND DISMANTLING 6-1

6.1 General 6-1
6.2 Operational planning 6-2
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6.3 Safety regulations for assembly and dismantling 6-3

6.3.1 Requirements for the erecting team 6-3
6.3.2 Requirements for the site 6-3
6.3.3 Rules for executing the work 6-4
6.4 Unloading and preparing the machine 6-5
6.4.1 Prerequisites 6-5
6.4.2 Overview of assembly stages 6-5
6.4.3 Bringing the rotating beacons* into operation position 6-6
6.4.4 Bringing the floodlights* into operation position 6-7
6.4.5 Putting the machine into operation 6-8
6.4.6 Drive the machine off the low-loader. 6 - 11
6.4.7 Removing the superstructure locking 6 - 12
6.4.8 Adjusting crawler carriers on work track 6 - 13
6.4.9 Bringing the jib into the working position 6 - 18
6.4.10 Reeve the ropes 6 - 18
6.4.11 Fit the hoisting limit switch 6 - 19
6.5 Load the counterweight 6 - 21
6.6 Erecting the leader 6 - 23
6.6.1 Prerequisites 6 - 23
6.6.2 Overview of assembly steps 6 - 23
6.6.3 Procedure 6 - 24
6.7 Assembly steps with erected lead 6 - 26
6.7.1 Fitting/removing the foot plate 6 - 26
6.7.2 Fitting/removing the drilling drive 6 - 27
6.7.3 Fitting the Kelly bar 6 - 31
6.8 Lay down the leader 6 - 34
6.8.2 Overview of assembly steps 6 - 34
6.8.3 Procedure 6 - 35
6.9 Dismantling and loading the machine 6 - 40
6.9.1 Place the gibbet in the transport position 6 - 40
6.9.2 Transport lashings 6 - 41
6.9.3 Track adjustment convergence 6 - 42
6.9.4 Fit superstructure locking 6 - 43
6.9.5 Driving the machine onto the low loader 6 - 44
6.9.6 Taking the machine out of operation 6 - 44
6.10 Transport 6 - 45
6.10.1 Safety precautions for loading and unloading 6 - 45
6.10.2 Transporting the machine with a low-loader 6 - 47
6.10.3 Transporting overseas 6 - 49
6.11 Lifting the machine 6 - 50
6.11.2 Procedure 6 - 50
7. MAINTENANCE 7-1
0 - 10
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7.1 General 7-1

7.1.1 Lubricants 7-2
7.1.2 Welding work 7-2
7.1.3 Cylinder 7-2
7.2 Maintenance chart 7-3
7.2.1 Work to be carried out 7-3
7.3 Diesel engine 7 - 17
7.3.1 Engine; check oil level and oil pressure 7 - 17
7.4 Fuel System 7 - 18
7.4.1 Drain off condensate 7 - 18
7.4.2 Draining condensation and sediments from the fuel tank 7 - 18
7.4.3 Bleeding the fuel system 7 - 19
7.5 Cooling system 7 - 20
7.5.1 Check coolant level, top up if necessary 7 - 20
7.6 Dry air filter 7 - 21
7.6.1 Arrangement on the central power unit 7 - 21
7.6.2 Emptying the dust collection container 7 - 22
7.7 Power divider 7 - 23
7.7.1 Checking the gearbox oil level 7 - 23
7.8 Crawlers 7 - 24
7.8.1 Cleaning and maintaining the crawlers 7 - 24
7.9 Guide wheels 7 - 25
7.9.1 Overview of the crawler tensioning systems 7 - 25
7.10 Checking the chain tension 7 - 27
7.10.1 Tensioning the chain 7 - 27
7.10.2 Floor plates 7 - 28
7.11 Slewing gear transmission/Rotary connection 7 - 31
7.11.1 Slewing gear transmission, checking the oil level 7 - 31
7.11.2 Lubricating the crown gear/pinion 7 - 31
7.11.3 Lubricating the rotary connection bearing races 7 - 32
7.12 Winches 7 - 33
7.12.1 Component check 7 - 33
7.12.2 Check the oil level 7 - 33
7.13 Ropes and pulleys 7 - 34
7.13.1 Checking the rope against end of service life criteria 7 - 34
7.13.2 Check the rope for diameter shrinkage 7 - 35

7.13.3 Check for rope deformations 7 - 36
7.13.4 Check ropes for corrosion 7 - 37
7.13.5 Check ropes for abrasion 7 - 38
7.13.6 Check ropes for the effects of heat 7 - 38
7.13.7 Check the rope for number of permitted wire breaks 7 - 40
7.13.8 Selecting a rope 7 - 42
7.13.9 Storing ropes 7 - 46
7.13.10 Transporting ropes 7 - 47
7.13.11 Checking the rope drive 7 - 47
0 - 11
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7.13.12 Winding ropes 7 - 52

7.13.13 Luffing ropes 7 - 54
7.13.14 Lubricating ropes 7 - 56
7.13.15 Check rope suspension and rope fixation 7 - 56
7.13.16 Checking the pocket locks 7 - 57
7.13.17 Checking the rope fixation and rope thimble 7 - 58
7.14 Hydraulic system 7 - 60
7.14.1 General 7 - 60
7.14.2 Check the oil level 7 - 60
7.14.3 Topping up hydraulic oil 7 - 61
7.14.4 Suction pipe on the hydraulic tank 7 - 62
7.14.5 Shut off valve on hydraulic tank 7 - 62
7.14.6 Cleaning the magnet plug 7 - 63
7.14.7 Check the hydraulic system 7 - 64
7.14.8 Special maintenance activities 7 - 64
7.15 Electrical system 7 - 65
7.15.1 General 7 - 65
7.15.2 Wet cleaning 7 - 65
7.15.3 Batteries 7 - 65
7.15.4 Limit switch 7 - 67
7.15.5 Checking displays, lights etc. 7 - 69
7.16 Heating and ventilation 7 - 70
7.17 Drilling unit 7 - 72
7.18 Lubrication chart 7 - 73
7.19 Hydraulic oil 7 - 77
7.19.1 Initial filling 7 - 77
7.19.2 Mixing 7 - 77
7.20 Diesel fuels 7 - 79
7.21 Diesel engine lubricating oils 7 - 80
7.22 Diesel engine coolant 7 - 82
7.23 Capacities 7 - 85
7.24 Lubrication chart 7 - 86
7.25 Repair welding 7 - 89
7.25.1 General 7 - 89
7.25.2 Requirements for welding 7 - 89
8. REPAIR 8-1
8.1 General 8-1
8.2 Change cables 8-2
8.3 3-windings limit switch * 8-3
8.3.1 General 8-3
8.3.2 Setting the 3-windings limit switch 8-3
8.4 Changing the auxiliary rope 8-4
8.4.1 General 8-4
8.4.2 Procedure 8-4
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8.5 Changing the feed ropes 8-5

8.6 Changing the Kelly rope 8-6
8.6.1 General 8-6
8.6.2 Procedure 8-7
8.7 Diesel engine 8-8
8.8 Fire extinguishers 8 - 11
8.9 Personal protective gear 8 - 11
8.10 Conservation regulations 8 - 11
8.11 Resale – Decommissioning 8 - 11
9. OPTIONS 9-1
9.1 General 9-1
9.2 Orthopaedic driver's seat 9-2
9.3 Heating and air conditioning system 9-3
9.3.1 General 9-3
9.3.2 Air conditioning system units 9-3
9.3.3 Operation 9-4
9.3.4 Information on the use of the heating and air conditioning system 9-5
9.4 Auxiliary heating 9-7
9.4.1 General 9-7
9.5 Cold weather kit 9-8
9.5.1 General 9-8
9.5.2 Auxiliary heating 9-9
9.5.3 Hydraulic oil heating 9 - 10
9.6 Function lock 9 - 11
9.7 Compressor 9 - 12
9.7.1 General 9 - 12
9.7.2 Commissioning 9 - 12
9.7.3 Operating the compressor 9 - 12
9.8 Refueling the machine from a refueling pump 9 - 13
9.9 GSM Service Modem 9 - 16
9.10 Process data acquisition (PDE) 9 - 17
9.10.1 General 9 - 17
9.10.2 PDE monitor 9 - 19
9.10.3 Compact flash card 9 - 28
9.10.4 Recording and printing 9 - 28

9.10.5 Operating modes 9 - 29
9.10.6 Operation 9 - 34
9.10.7 Data organization 9 - 41
9.10.8 Printer 9 - 42
9.10.9 Protocol style 9 - 43
9.11 Central lubrication system for lead runner 9 - 49
9.11.1 General 9 - 49
9.11.2 Filling the grease container 9 - 50
9.11.3 Function 9 - 50
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9.11.4 Maintenance of the central lubrication system 9 - 50

9.12 Central lubrication for the kinematics and rotary connection 9 - 51
9.12.1 General 9 - 51
9.12.2 Filling the grease container 9 - 53
9.12.3 Function 9 - 53
9.12.4 Time interval programming 9 - 54
9.12.5 Maintenance of the central lubrication system 9 - 54
9.13 Counterweight loader 9 - 55
9.13.1 General 9 - 55
9.13.2 Loading/removing the counterweight 9 - 55
9.14 Diesel particle filter 9 - 57
9.14.1 Product description 9 - 57
9.14.2 Controls and operating elements 9 - 59
9.14.3 Operating the monitoring and display unit 9 - 60
9.14.4 Maintenance 9 - 63
9.15 Kelly bar guide 9 - 65
9.15.1 General 9 - 65
9.15.2 Mounting the Kelly bar guide 9 - 65
9.16 Kelly extension 9 - 67
9.16.1 General 9 - 67
9.16.2 Installing the Kelly extension 9 - 67
9.17 Roof railing 9 - 69
9.17.1 General 9 - 69
9.17.2 Mounting 9 - 70
9.18 Noise reduction cover 9 - 71
9.19 Video surveillance system 9 - 72
10. APPENDIX 10 - 1
10.1 General 10 - 1
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1. INTRODUCTION
1. INTRODUCTION
1.1 Foreword
The Liebherr name not only stands for products and services. It has become well known for ideas
and innovations. For progress, which has proven itself in the market.
We continuously expand and improve our wide variety of product and service offering with great
intensity. To do so, the constant cooperation and the experience exchange with our customers and
business partners all over the world is a prerequisite. For that reason we are thankfull for every
suggestion and recommendation for improvement.
Contact:
Liebherr-Werk Nenzing GmbH

P.O. Box 10, A-6710 Nenzing/AUSTRIA
Phone: +43 50809 41-0
Fax: +43 50809 41-500
info.lwn@liebherr.com
www.liebherr.com
The documentation for this machine is handled customer-specific.

Please inform our Service Dept.,
- when you sell your machine,
- when you buy one from a previous owner,
- when you decommission one.
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1. INTRODUCTION
1.2 Handling of documentation

The supplied documentation should make it possible for you
- to safely operate the machine,
- to utilize it in all permissible applications,
- to maintain it regularly.
The prerequisite for that is that you become familiar with the multi-section documentation:
Operating instructions
Here you find information for start up, operation and maintenance of the basic
machine.
Load charts
Here you find the valid load charts for all equipment configurations of your
machine.
Spare parts catalogue

Here you find information for spare parts procurement.
Technical information
Here you find information about the hydraulic and electric system of your ma-
chine.
• The entire documentation is provided in digital form on the CD-ROMs.

• The displayed icons provide iniformation about the contents of the CD.
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1. INTRODUCTION
1.2.1 How are the Operating instructions set up?

The operating instructions consist of individual, continuously numbered chapters. These chapters are
filed in the yellow register of the ring binder.
The chapter overview at the beginning of the Operating instructions provides quick orientation. The
subsequent index provides information about the set up of the individual chapters.
A short description of contents is noted at the beginning of the followings chapters under the General
heading . At the end of each chapter is a page to enter notes.
The numbering of pages, charts and certain, large-sized illustrations contains the actual chapter
number as prefix. For example, the page number 2 - 10 designates the 10th page in chapter 2
PRODUCT DESCRIPTION.
* Optional accessories
A multitude of optional additional equipment is available for the machine. Every description, which
affects such optional additional equipment is marked with a * symbol in the Operating instructions.
1.2.2 System requirements of the computer for use of CD-ROMs

Hardware:
• at least Intel® Pentium II ®
min. 500 MHz
• 128 MB RAM main memory or higher
• CD-ROM drive
• 800x600 pixels minimum resolution, High Color depth
Software:
• Windows 2000, XP operating system
• Internet Explorer 5.5 or newer version
• Acrobat Reader 7.0 or newer version
NOTE !
Popup blockers may not be activated when working with Liebherr Parts. Please also note that the
Popup blocker functionality can be included in certain web browsers as well as in socalled personel
firewalls (Software Firewalls). It can generally be turned off via options in the corresponding program.
1.2.3 Storage of documentation

The Operating instructions must always be readily available in the driver's cab.
The currently required load charts must be kept in the driver's cab. They can be printed out from the
CD-ROM.
Spare parts catalog and Technical Information must be available for maintenance and service
personnel if needed.
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1. INTRODUCTION
1.2.4 Current status of documentation

The supplied documentation has been assembled especially for the listed serial number and can
therefore not be transferred to other machines in the same series.
To keep the documentation complete and current at all times
- do not remove individual documentation,
- request missing, illegible pages from the manufacturer or print them out again from the CD-ROM
and replace them,
- immediately file new documentation, which is supplied for modification work,
- replace changed documentation and dispose of the old version (especially for load charts),
- always replace CD-ROMs with the current version, which is provided, for example with change
documentation (dispose of the old CD-ROMs),
- if the documentation is available in multiple languages, update all languages.
1.2.5 Danger symbols

In the operating manual, dangers and important information appear with special symbols and signal
words. These appears before the relevant work step and are marked as follows:
DANGER!
The safety sign DANGER

- denotes an imminent threat of danger,
- relates to operating and maintenance procedures,
- includes WARNING and CAUTION.
Disregarding this notice will lead to immediate dangers, certainly resulting in severe injuries,
disability or death.
WARNING!
The safety sign WARNING

- denotes a dangerous situation,
- includes CAUTION.
Disregarding this notice will lead to dangers resulting in serious injuries or death.
CAUTION!
The safety sign CAUTION

- denotes a potentially dangerous situation,
Disregarding this notice will lead to dangers resulting in injuries or serious damage to the
machine and/or other serious damage to property and the environment.
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1. INTRODUCTION
NOTE!
The word NOTE
- indicates a potentially damaging situation,
- denotes advice on technical aspects that is helpful and that the user must adhere to.
IMPORTANT!
IMPORTANT is used to highlight usage tips and provide useful information that increases the
availability and service life of the machine or considerably simplifies certain operations.
Symbol Meaning
Requirement must be
met
Carry out task
Outcome of task
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1. INTRODUCTION
1.3 Legal notice

Version
The EU standards used are listed in the conformity declaration as well as in the load chart
forewords.
In the interest of our customers, changes due to technical developmental advancements are
reserved. This documentation therefore conforms to the technical status of the delivered machine
and not the current manufacturer developmental status.
Copyrights
Litronic® is a registered trademark of the LIEBHERR company.

The documentation is protected by copyright. Copying and reproduction of load charts in the context
with the job planning and operation of this machine is explicitly permitted. Otherwise, the documenta-
tion may not be duplicated, reproduced, microfilmed, translated or converted for storage and
processing in EDV systems in whole or in part without the written approval of Liebherr-Werk Nenzing
GmbH.
© 08/2008 Copyright by
Liebherr-Werk Nenzing GmbH
A-6710 Nenzing/AUSTRIA
All rights reserved.
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1. INTRODUCTION
1.4 Conversion tables

The following tables simplify the conversion of all conventional units of measure. Please note that the
accuracy of the conversion factors depends on the size of the unit of measure.
For that reason, avoid size combinations, where the conversion factor in the table takes on a very
small or a very large value. For example, the direct conversion of square inches [in²] into square
kilometers [km²] provides inexact results.
1.4.1 Length
Length conversion Table 1-01
1.4.2 Surface area

Surface area conversion Table 1-02
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1. INTRODUCTION
1.4.3 Weight (Mass)
Weight conversion Table 1-03
1.4.4 Volume
Volume conversion Table 1-04
1.4.5 Pressure
Pressure conversion Table 1-05
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1. INTRODUCTION
1.4.6 Temperature
Temperature conversion Table 1-06
1.4.7 Speed
Speed conversion Table 1-07
1.4.8 Force
Force conversion Table 1-08
1.4.9 Torque
Torque conversion Table 1-09
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1. INTRODUCTION
1.4.10 Performance
Performance conversion Table 1-10
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1. INTRODUCTION
1.5 Conformity declaration

The applicable declaration of conformity for delivery of the machine to a country of the European
Union appears here. Additional documents required for type testing or national acceptance testing
may also be enclosed.
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1. INTRODUCTION
NOTES:
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1. INTRODUCTION
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2. PRODUCT DESCRIPTION
2.1 General
This chapter
- provides information on display conventions in the operating manual,
- provides information on possible uses for the machine,
- describes the assembly and the main components,
- lists important technical data.
2.1.1 What should you be aware of when reading the operating manual?
Text references
The headings in the chapters are numbered sequentially, and the first number always corresponds to
the chapter number. In the case of text references which take you beyond the current chapter you
should therefore take note of the first number and look up the corresponding chapter, where you will
find the point referred to.
See section 1.1 "Foreword", for instance, points you to Chapter 1 "Introduction", which contains
section 1.1 "Foreword".
Schematic diagrams and simplified illustrations
provide general information and may not necessarily reflect the current set-up of the machine.
Illustration captions
The illustrations are numbered sequentially in each chapter, starting with 1
- either with a framed number in the top corner of the illustration,
- or below the border of the illustration with a chapter and figure number, for instance
"Figure 2-01".
Numbering in these two alternative designation systems is independent, which means that this
chapter contains both a Figure 1 and a Figure 2-01.
Figure numbers and associated item numbers
appear in the text enclosed by brackets, e.g. (Figure 2, item 7). In the case of figures with a large
number of items, the item numbers are listed with the associated names. In this case the item
numbers appear in subsequent text with no figure reference, e.g. (7).
Position lines
in a figure end with a
- dot if they are describing visible parts,
-arrow if they are pointing to non-visible, covered parts.
Options
are indicated in the text with a star * and are either described in Chapter 9 or, where more
appropriate, documented in other chapters of this operating manual.
Direction indications
such as"right/left, forward/backward" are always in relation to the sitting position of the driver in the
cabin.
Dimensions
are quoted in the ISO unit system. The US measurements given in square brackets are in some
cases rounded during conversion.
IMPORTANT!
IMPORTANT is used to highlight usage tips and provide useful information that increases the
availability and service life of the machine or considerably simplifies certain operations.
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2.2 Applications of the machine

This drilling rig is suitable for a wide range of civil engineering and construction applications.
Applications:
- Kelly drill (with or without casing oscillator).
- FOW drilling (Front-of-Wall) or double head drilling)
- CFA drilling (Continuous- Flight-Auger drilling)
- Soil mixing mode
2.2.1 Equipment rating

This machine is designed as a drilling rig and is dimensioned accordingly.
The steelwork components are calculated in accordance with DIN 15018, Part 1.
The equipment rating is calculated in accordance with DASt, Part 011.
The machine complies with the standard:

- EN DIN 791 Drilling Equipment
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2.3 Appropriate use

Appropriate use of the machine is a basic requirement of safe operation.
The supplied equipment determines the possible uses and areas of application for the machine in
accordance with section 2.2.
Basically, the machine may only be used for the operations listed and described in this operating
manual. Appropriate use with specially installed options is described in Chapter 9.
Appropriate use of the machine depends
- on adherence to the applicable national safety requirements,
- on observance of all safety information in this operating manual,
- if all the necessary safety devices are present and in good working order,
- if the operating conditions described in Chapter 2 "Technical Data" are adhered to and all the
fuels and lubricants prescribed here are used.
Appropriate use also depends on all maintenance and inspection work being carried out fully and in
good time by qualified and authorized personnel.
Procedure:
- Drilling is carried out with the lead standing vertically with different outreaches.
All systems approved by Liebherr are acceptable as drilling equipment, provided that they do not
exceed the maximum permitted dead weights specified in Chapter 2 "Technical Data".
Special operations not listed in section 2.2 "Applications of the machine"

- have to be cleared with the manufacturer beforehand,
- may only be carried out with the written consent of the manufacturer.
Any other use, or use of the machine beyond these parameters without the manufacturer's written
consent, shall be regarded as inappropriate use.
The operator alone is liable for any resulting damage.
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2.4 Inappropriate use

Inappropriate use of the machine may result in
- life-threatening injuries,
- serious damage to the machine and major damage to property,
- invalidation of the guarantee.
Examples of inappropriate use of the machine include the following:

• Any structural modification of the machine which influences operational safety and has been
carried out without the written consent of the manufacturer.
• The commissioning of the machine
- without an acceptance test, if one is stipulated by national legislation,
- by persons who are not authorized by the operator,
- without the requisite training and knowledge of the operating manual,
- where the operating manual is incomplete (pages missing or illegible) or not in the local
language,
- below ground (mining).
• Any manner of working which endangers operational safety.

• Operation of the machine with
- faulty safety equipment
- incorrectly attached or non-functioning safety and protection equipment
• Working operations in assembly mode.
• Operation when the maximum permitted wind speed is exceeded.
• Operation while persons are standing on the machine, other than in the cab.
• Any transport of personnel, particularly with the winches.
• Hoisting operations, use as an auxiliary crane.
• Hoisting of loads with cylinders of the drilling unit.
• Earth moving operations (leveling etc.).
• The tearing loose of stuck loads with the winches or with the slewing gear.
• Dragging a load on the ground. with the slewing gear or the travel gear.
• Installation of spare parts and use of media not approved and authorized by the manufacturer.
• Commissioning and working in locations subject to explosion hazards. This also includes locations
where the atmosphere is only rarely or briefly subject to explosion hazards.
• Pulling up loads with the auxiliary winch.
• Realigning pipes with the slewing/travel gear.
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2.5 Machine overview

Main components Figure 2-01
1 Drilling unit 3 Counterweight

2 Superstructure 4 Undercarriage
The main components of the machine are described in detail in the following pages.
The superstructure, counterweight and undercarriage are referred to as the basic machine.
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2.6 Safety and monitoring devices

2.6.1 Safety devices
Safety devices Figure 3-01
1 Hoisting limit switch * 8 Hooter

2 Warning light on cab roof 9 Door lock
3 Roof grill * or stone guard * 10 Fire extinguishers (2x)
4 Work floodlights (4x on superstructure) 11 Acoustic signaling device *
5 Emergency shut-down buttons (2x) 12 Battery main switch
6 Ignition starter switch 13 Outreach limit switch
7 Safety lever for control system
- Shut-off valve on hydraulic tank (see Moni-
toring devices)
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Functions of the signaling devices:

• The warning light (2) indicates that
- the traveling or slewing gear is in operation,
- the machine is in assembly mode
• The hooter (8) can be operated by the machine operator.
• The acoustic signaling device (11) * on the ballast indicates a travel movement or slewing of the
superstructure (optional).
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2.6.2 Monitoring devices
Monitoring devices Figure 3-02
1 LCD screen 4 Sight glasses on the hydraulic tank (3x)

2 Oil dipstick of diesel engine 5 Shut off valve on hydraulic tank
3 Outside rear view mirrors (2x) and inside 6 Oil dipstick of power divider
rear view mirror (not illustrated)
- Angle indicator
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2.7 Drilling unit

Drilling unit Figure 2-02
1 Jib 7 Support boom

2 Auxiliary jib 8 Base arm
3 Lead 9 Base arm positioning cylinder
4 Roll holder 10 Kelly winch
5 Backstay or lead support cylinder 11 Auxiliary winch
6 Triangular support 12 Reversing winch
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1
Jib
The Jib (Figure 1, item 2),
- is bolted (Figure 2, items 4-6) to the top of the lead
(Figure 1, item 1),
- is folded downwards for the purpose of transportation
using a jib adjustment cylinder (Figure 2, item 2).
The auxiliary rope will be fed over the left rope pulleys
(Figure 1, item 3) and the Kelly rope over the right
(Figure 1, item 2).
A boom force measuring axle can be installed in place
of the bolt on the foremost Kelly rope pulley (option).
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3
Lead
The lead
- guides the universal slide
- is composed of three parts,
- the parts are screwed and bolted together.
Lead upper part (Figure 3)

On the lead upper there is:
- the tensioning cylinder (Figure 3, item 3), for the feed
system
- the jib adjustment cylinder (Figure 3, item 2). for the
transportation position of the jib and
- rope pulleys for the rope guide
(Figure 3, item 1, item 4, item 5).
4
Lead mid section
The lead mid section
- is connected to the triangular support through the two
backstay cylinders (Figure 4, item 1)
and the turntable (Figure 4, item 2)
- carries the reversing, auxiliary and Kelly winches.
The turntable enables transverse adjustment of the lead.
An inclinometer measures the current inclination of the

lead.
The Litronic control system therefore offers the following
functions:
- displays the currently inclination (analog and digital)
- automatic inclination adjustment (automatic tower
system).
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5
Lead lower part
On the lead lower part is the hook fixing point (Figure 5,
item 1) for fixing the auxiliary rope.
The lead support cylinder * and the lead foot plate * are
optionally mounted (Figure 5, item 2)
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6
Feed system
The feed system moves the universal slide (Figure 6,
item 5) and thus the working unit (drilling rig) up and
down the lead.
Assembly:
The two feed ropes are reeved between
- the reversing winch (Figure 7, item 4).
- the universal slide (5), and
- the rope pulleys on the lead (1).
The tensioning cylinder (Figure 6, item 3) provides the
required tension for the feed system
Adjustments are made by operating the reversing winch.
The following can optionally be installed:
- a force measuring axle for the load capacity display
- a sensor for the rope length metering feed
7
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8
Triangular support, support boom, base arm
The base arm (Figure 8, item 2) and the support boom
(3) are coupled to the superstructure. Together with the
triangular support (4) they form a parallelogram. Adjust-
ment is carried out with the base arm adjustment cyl-
inder Z4 (1).
The lead inclination adjustment is performed using the
two backstay cylinders Z2 (5)
An angle indicator (6) is mounted on the base arm. The
outreach and permissible load capacity can be deter-
mined from the displayed angle and the load capacity
charts in Chapter 2.
9
Lead foot plate *
The lead foot plate makes it possible to set up the lead
for pulling the auger.
The lead foot plate (Figure 9, item 1) is bolted to the
support cylinder with the two bolts (2). These must be
secured with the two retaining pins (3) as shown in the
picture 9
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2.8 Superstructure
10
Superstructure, from the front
1 Optional xenon floodlight *, superstructure 7 Rotating beacon*

2 Pivot points 8 Central power unit
Drilling unit
3 Bulkhead plate 9 Surrounding platform *
4 Optional floodlight *, superstructure 10 Sliding window on cab
5 Hose support 11 Outside mirror
6 Lead support 12 Cab platforms
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11
Superstructure, rear view
1 Ballast 9 Pivot points

Drilling unit
2 Additional counterweight * 10 Optional floodlight, superstructure
3 Fuel tank 11 Compressor *
4 Hydraulic tank 12 Slewing gear transmission
5 Exhaust system 13 Refueling pump *
6 Access ladder 14 Surrounding platform *
7 Stone guard *, cab 15 Cooler
8 Access ladder
The superstructure is
- a torsion-resistant welded construction,
- fitted to the undercarriage by means of a rotary connection.
The cab (Figure 11, item 8)
- contains all the necessary controls,
- is fitted with safety glass,
- has a roof guard *, searchlight and a warning light.
The platform (Figure 10, item 1) on the left of the cab is folded in during transportation.
The two slewing gear transmissions (Figure 11, item 11) are part of the standard equipment and slew
the superstructure through 360°.
The access ladder (Figure 11, item 6)
- allows personnel to climb on to the superstructure for checking, maintenance and assembly
purposes.
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The cooler (Figure 11, item 14) is made up of four sections:

- the hydraulic oil cooler,
- the combined water and charge air cooler,
- the fuel cooler and
- the gearbox oil cooler.
The hydraulically operated cooling motor is temperature controlled.
The hydraulic tank (Figure 11, item 4)
- has a return and aeration filter to protect it against
possible fouling,
- has sight glasses for checking the fill level and
an electrical level sensor.
The fuel tank (Figure 11, item 3).
- supplies the diesel engine and the optional
auxiliary heating system with fuel,
- is optionally equipped with a refueling pump (Figure 11, item 12) and
a level monitor.
The additional counterweight (Figure 11, item 2) and the basic counterweight (Figure 11, item 1),
together with the associated assembly and retaining equipment, are at the rear of the superstructure.
The central power unit (Figure 10, item 6)
, - consists of the diesel engine, power divider and the
hydraulic system,
- supplies all the drives on the machine through
the hydraulic system.
The drilling unit

- lies on the lead support (Figure 10, item 6) in the transport position,
- is bolted to the superstructure via pivot points (Figure 10, item 2 and Figure 11, item 9).
- is lubricated by the central lubrication system (Figure 11, item 12) (only applies to bearing races).
The optional compressor (Figure 11, item 10) (2)
- is mounted on the right hand side in the middle of the cab.
The compressed air supply is mounted

- on the front of bulkhead plate (Figure 10, item 3) on the cab.
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2.8.1 Central power unit
12
Central power unit, viewed from front left
1 Dipstick for motor oil 8 Hydraulic oil cooler

2 Oil filler neck 9 Cooling water equalizing reservoir
3 Gearbox oil cooler 10 Fuel cooler
4 Water separator 11 Shut-off valve, hydraulic tank
5 Oil filter 12 Hydraulic suction pipe
6 Exhaust system and soot particle filter * 13 Air filter, suction unit
7 Water cooler (with charge air cooler) 14 Oil filler neck with dipstick for gearbox oil
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The suction pipe (Figure 12, item 12) connects the hydraulic tank to the hydraulic pumps.
The shut-off valve (11) allows the hydraulic tank to be shut off for maintenance and repair.
The cooling system equalizing reservoir (9) has
- an overpressure valve for venting purposes,
- a filler neck for adding coolant and
- a sight glass for checking the coolant level.
The water cooler (7) cools the cooling water in the diesel engine.
The charge air cooler cools the charge air of the two exhaust gas turbochargers.
The hydraulic oil cooler (8) cools the oil in the whole system.
The gearbox oil cooler (3) cools the gearbox oil in the power divider.
The air filters (13) supply filtered fresh air to the diesel engine.
The oil level in the diesel engine can be topped up through the oil filler neck (2). The oil level is
checked using the dipstick (1).
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2.8.2 Counterweight
13
Counterweight
1 Counterweight
2 Eyebolts (2x)
3 Additional counterweight(s)
The entire counterweight, consisting of a counterweight and one or two additional counterweight(s)
- is essential to the stability of the machine,
- is hoisted by the eyebolts (2) for assembly/dismantling,
- is bolted on to the rear of the superstructure from below,
IMPORTANT!
All counterweights can be removed when the machine is being transported.
The eyebolts (2) must neither be used to hoist the whole machine nor for lashing!
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2.9 Undercarriage
14
Undercarriage viewed from front left
1 3-bar track pad 7 Central section

2 Superstructure locking 8 Left crawler carrier
3 Right guide wheel 9 Travel drive of left crawler carrier
4 Cover for external bolt holes 10 Tumbler
5 Rotary connection 11 Running roller
6 Right crawler carrier 12 Step (2 x)
The undercarriage central section (7)

- has a torsion-resistant welded construction,
- supports the swiveling superstructure and the two crawler carriers.
The rotary transmission (5) makes the hydraulic connections between the superstructure and the
undercarriage.
The telescopic outriggers of the two crawler carriers (6) and (8)
- are bolted to the undercarriage central section,
- can be moved between the transport track and the wide track using the track adjustment
cylinders.
The transport track (narrow) is used exclusively for transporting the machine.
The steps (12) allow access to the superstructure and to the cab. The steps are folded up when the
machine is being transported.
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The low-maintenance and dirt-protected drive system of the crawler carrier consists of:
- a guide wheel (3),
- running rollers (11),
- a travel drive (9) with axial piston motor, planetary gear and multi-disc brake,
- the tumbler (10)
- a pre-tensioned crawler chain and 3-bar track pads (1).
The superstructure locking (2) must be fitted during transport, decommissioning and maintenance
and repair operations. It prevents the superstructure from slewing accidentally.
15
Track adjustment cylinder, sectional drawing
1 Track adjustment cylinder 3 Bolting the track adjustment, transport po-

sition
2 Bolting the track adjustment, working posi- 4 Track adjustment lever
tion
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16
The undercarriage is prepared for use with a casing
oscillator *. The adapter * (Figure 16, item 1) or The
adapter * (Figure 17, item 1) is fitted for this purpose on
the front of the center section. The necessary hydraulic
connections (2) and additional hydraulics are available
as an option.
17
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2.10 Overview of the hydraulic cylinders
Hydraulic cylinders Figure 2-03
1 Gibbet adjustment cylinder 5 Base arm adjustment cylinder (Z4)

2 Tensioning cylinder 6 Lead foot cylinder (Z8)
3 Lead support cylinder, left (Z2L) 7 Track adjustment cylinder
4 Lead support cylinder, right (Z2R)
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2.11 Technical data

2.11.1 Dimensions and transport weight
18
Transport weight with telescopic undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68,2 t [150355 lbs]

- basic machine with lead (and winches), without working tools:
- without ballast 10,2 t [22487 lbs]
- without additional ballast 5,2 t [11464 lbs]
- without drilling drive 6,0 t [13227 lbs]
- without Kelly bar (incl. kardanische Aufhängung) 6,0 t [13227 lbs]
- without special equipment (options)
A Overhang in front of travel gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6681 mm [21 ft 11 inch]

B Length of travel gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5895 mm [19 ft 4 inch]
C Overhang behind the travel gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11770 mm [38 ft 7 inch]
D Additional Overhang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 mm [1ft]
E Length without lead foot plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24345 mm [79 ft 10 inch]
F Height of travel gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112 mm [3 ft 8 inch]
G Height to underside of superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1252 mm [4 ft 1 inch]
H Transport height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3599 mm [11 ft 10 inch]
I Overall length in transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24657 mm [80 ft 11 inch]
19
J Superstructure (radius) - only swivel with with set up lead . . . . . . . . . . . . . . . . . . . . . 4264 mm [13 ft 12 inch]
K Transport width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3500 mm [11 ft 6 inch]
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2.11.2 Machine in operation
20
A Maximum height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25634 [84 ft 1 inch]

B Length of lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22030 mm [72 ft 3 inch]
C Vorschubweg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18500 mm [60 ft 8 inch]
D Lead over corridor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1637 mm [5 ft 4 inch]
E Drilling drive over corridor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2582 mm [8 ft 6 in]
F Distance from axis of drilling to front edge of lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 mm [4 ft 3 inch]
G Outreach from axis of rotation to front edge of lead
minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3112 mm [10 ft 2 inch]
maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4365 mm [14 ft 4 inch]
H Outreach from axis of rotation to tail ballast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4190 mm [13 ft 9 inch]
I Track pad width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 mm [2 ft 7 inch] / 900 mm [2 ft 11 inch]
J Track width of the undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3800 mm [12 ft 6 inch]
Width of the undercarriage with 800 mm [31.5 inch] track pad . . . . . . . . . . . . . . . . . . . 4600 mm [15 ft 1 inch]
Width of the undercarriage with 900 mm [39.4 inch] track pad . . . . . . . . . . . . . . . . . . . 4700 mm [15 ft 5 inch]
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2.11.3 Key data

Machine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LB 28
Lead type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Box lead
Lead length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 m [72 ft]
Maximum pulling force/pressing force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 kN [89924 lbf]
Maximum torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 kNm [206517 lbf ft]
Continuously adjustable inclination of lead

Transverse inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +/- 5°
Forward inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5°
Backward inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15°
Permitted angle of inclination (driving along slope) ** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10°
Permitted angle of inclination (driving across slope) ** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5°

** Set lead vertically!
Permitted wind speed when working with the machine * . . . . . . . . . . . . . . . . . . . . . . . 20 m/s [45 mph]
Permitted wind speed when not working * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 m/s [81 mph]
* Windspeed based on the spoil in each case!
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Operating weight
Telescopic under carriage
3-bar track pads in Operating weight in t [lbs]

mm [in]
800 [31.5 inch] 95,6 [210762]
900 [36 inch] 95,6 [210762]
2.11.4 Operating conditions

Ambient temperatures
- for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 20 °C to + 40 °C [- 4° F to + 104° F]
- with optional cold weather kit to . . . . . . . . . . . . . . . . . . . . . . . - 25 °C or - 40 °C [- 13° F or - 40° F]
- for storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 40 °C to + 40°C [- 40° F to + 104° F]
Altitude
The exhaust turbo charger lessens the influence of reduced air pressure at high altitudes on the
power output of the diesel engine.
Nevertheless, some reduction in performance is to be expected if the machine is used at high
altitudes and at high air temperatures.
2.11.5 Emissions
Exhaust emissions
Engine exhaust emission limits . . . . . . . . . . . . . . . . according to 97/68/EG step 3A, EPA/CARB Tier III
Noise emissions
Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . according to Directive 2000/14/EC
Acoustic pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 dB(A)
Acoustic pressure in cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 dB(A)
With use of the machine in restrained environments the sound values stated above can rise around
5 to 10 dB(A) due to reflections.
Vibrations:
- Vibrations on the upper limbs of the driver: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ‹ 2,5m/s²
- Vibrations on the entire body of the driver: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ‹ 0,5m/s²
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2.11.6 Engine
Diesel engine with
- exhaust turbocharger,
- charge air cooler,
- electronic engine control,
- automatic load limiter to adjust power requirements of the auxiliary units to the current engine
speed.
Engine data
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D 846 A7
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIEBHERR
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . electronic (EDC)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 1050 kg
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-line engine
Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . four stroke, electronic diesel injection
No. of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Nominal power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 kW to ISO/DIN 9249
Nominal speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1900 rpm
Engine idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 rpm
Fuel consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 220 g/kWh
Engine oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 g/kWh
Electrical system
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V, 6,5 kW
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 V, 110 A
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 batteries connected in series, each 12 V / 170 Ah
Consumables
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial diesel fuel for vehicles
Tank capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 l [185 gal]
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended engine oil according to lubrication chart
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 l [8.7 gal]
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water with anti-corrosive and anti-freeze agents added
Capacity (complete cooling system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 70 l [18.5 gal]
Chapter 7 "Maintenance" contains detailed information on the appropriate fuels.

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2.11.7 Hydraulic system

The hydraulic unit
- is driven by the diesel engine via a power divider,
- consists of three flow piston pumps, one axial piston pump and 3 (optionally 4) gear pumps,
- works with open hydraulic circuits,
- is equipped with an energy-saving "current-on-demand" system that is also easy on the hydraulic
pumps.
In the hydraulic system
- a pressure cut-off limits any pressure peaks,
- electronically monitored filters clean the hydraulic oil.
The LUDV block is the central distribution block in the hydraulic system and allows pressure-
independent flow distribution.
The hydraulic system must be specially adapted in order to connect hydraulically operated options.
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . approved hydraulic oils (see Chapter 7, Maintenance)
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 l [211 gal]
Working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 350 bar [5076 psi]
2.11.8 Winches
Reversing winch
The Reversing winch is mounted on the middle of the lead. It moves the universal slide along the
lead.
The following additional equipment is provided:
- limit switches (top and bottom)
- rope length metering *
The Reversing winch is fitted with
- an internal planetary gear,
- axial piston motors to drive it,
- hydraulic, spring-loaded multi-disc brakes (stopping brake).
Rope pull (nominal load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 kN [44962 lbf]
Feed force (pulling/pressing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 kN [[89920 lbf]]
Rope diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 mm
Rope speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 88 m/min [0 - 288 ft/min]
Universal slide speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 44 m/min [0 - 144 ft/min]
Auxiliary winch *
The auxiliary winch is mounted on the middle piece of the lead. It is used to hold the pile, for
mounting cages etc.
- hoisting limit switch on lead head
- 3-windings limit switch *
The auxiliary winch is fitted with
- an internal planetary gear,
- axial piston motor (constant motor) as drive unit,
- a hydraulic, spring-loaded multi-disc brake (stopping brake).
Rope diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 mm
Rope speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 126 m/min [0 - 413 ft/min]
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Kelly winch *
The Kelly winch is mounted on the middle piece of the lead. When drilling the Kelly bar is moved by
the Kelly winch.
- hoisting limit switch on the Kelly jib
- 3-windings limit switch *
- rope length metering *
Outstanding features of the Kelly winch include

- compact, low-maintenance design,
- load stabilized by the hydraulic system,
- a spring-loaded multiple disc brake (stopping brake).
Rope diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 mm
Rope speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 81 m/min [0 - 265 ft/min]
The drive system of the Kelly winch
- is implemented by high-pressure-controlled axial flow piston motors,
- utilizes the full motor power even during partial load operation, by adjusting the speed to the
appropriate rope pull.
2.11.9 Slewing gear

The slewing gear consists of a roller-bearing mounted slewing ring that is toothed on the inside and
two transmissions.
The slewing gear consists of
- an axial piston motor,
- a planetary gear,
- a hydraulic, ventilated spring-loaded multi-disc brake,
- a slewing gear pinion.
Slewing speed of the superstructure
(continuously adjustable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 2 U/min [rpm]
2.11.10 Travel gear

The two crawler carriers of the travel gear can be steered independently of each other and in
opposite directions.
Preferred traveling and working direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guide wheel forward
Telescopic undercarriage
Speed of travel (continuously adjustable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 1,9 km/h [0 - 1.2 mph]
Travel gear pulling force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622 kN [139831 lbf]
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2.11.11 Control
The Litronic control system of the machine
- is an electro-hydraulic proportional controller,
- enables simultaneous execution of all movements,
- is designed for extreme temperatures and heavy-duty operation on construction sites,
- is designed in-house and subject to ongoing development.
The Litronic control system is
- located in the switch cabinet in the cab,
- connected via a CAN bus system to the engine controller and to all sensors, transmitters and
limit switches.
Machinery and Component Data

In some cases machinery and component-specific data will be recorded by the electronic system.
These data serve the manufacturer for the ongoing improvement of function and reliability.
Controls in the cab

• The LCD screen in the cab shows
- all necessary information for the operation,
- error messages as error text.
• Two joysticks for controlling all main functions.
• Two pedals for controlling the travel gear (can be adapted with two levers to allow hand lever
control).
• A safety lever
- prevents operational errors,
- disables the joysticks and foot pedals while the operator is getting in or out.
• Different control desks for control, operation and service functions.
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2.11.12 Load Capacity Charts

Lead supported on ground
The driver can pull with full traction, independent of the outreach of the lead.
Lead not supported on ground

The loads permissible in accordance with the load capacity chart apply depending on the outreach of
the lead.
WARNING!
The machine is liable to be damaged if these loads are exceeded. Danger: the machine may
topple over!
No torque shutdown
The stated loads must not be exceeded, as no torque shutdown will take place.
Special uses
It is imperative to discuss special uses with the manufacturer.
The load capacity chart to be used depends on the type of use:

• Load capacity chart for drilling rigs to EN791
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NOTES:
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3. SAFETY INSTRUCTIONS
This section:
- warns the user about hazards.
- informs them about hazards arising in normal use.
- tells them about how to avoid hazards.
3.1 Technical condition of the machine

For the machine to be operated safely, the following requirements in terms of its technical condition
must be met:
- The machine must be in perfect condition
- Unauthorised conversion or modification is not permitted
- Maintenance must be performed regularly
- Safety devices must be in good working order
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3.2 Areas of responsibility

3.2.1 Manufacturer
The manufacturer:
- is responsible for the technically safe condition of the machine supplied, together with acces-
sories and documentation.
- must comply with their duty to monitor product performance and document all maintenance and
repair work carried out by LIEBHERR personnel.
- must ensure that the machine is kept operational by a worldwide maintenance and repair service.
- must run a training centre and provide training for the owner's operating and maintenance
personnel as a service.
3.2.2 Owner
The owner:
- must ensure that the machine is operated and maintained by qualified personnel only.
- must check that all individuals who come into contact with the machine are fully qualified and
authorise them to carry out their work.
- must specify the skills and responsibilities of all those working with or near the machine.
- must provide all necessary protective equipment to individuals working with or near the machine.
- must check regularly that personnel carry out their work in a safety-conscious manner.
- is responsible for ensuring the safe condition of the machine.
- must take the machine out of service if any faults that may affect safety are discovered.
- must perform inspections on the machine in line with national regulations in addition to the
inspections stipulated by LIEBHERR.
- must inform the manufacturer of any accident involving the machine leading to serious injury or
severe damage to property.
- must allow LIEBHERR personnel unlimited access to the machine in order that they may fulfil
their duty to monitor the product.
- must carefully and conscientiously carry out work planning for the machine.
- must not carry out any alterations on the machine without first consulting the manufacturer.
- must only use original LIEBHERR spare parts.
3.2.3 Machine operator

The machine operator:
- must have read and understood the operating manual.
- must use the machine for the intended purpose within the limits specified in the load capacity
chart and in accordance with the set-up and the operating manual.
- must wear protective clothing.
- must report to the owner any alteration to the machine that affects safety.
- must cease operations immediately if safe operation is no longer possible.
3.2.4 Rigger
The rigger:
- is responsible for the correct selection and fitting/removal of the slinging equipment on the load
or rigging material.
- gives the approval to move and/or accompany the load.
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3.2.5 Signalman
The signalman:
- conveys signals from the rigger to the machine operator.
- gives signals to the machine operator if he is the only person responsible.
3.2.6 Maintenance personnel

Maintenance personnel:
- maintain the machine to ensure that it remains in a safe and reliable condition.
- must have read and understood the operating manual.
- must perform all specified maintenance tasks.
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3.3 Requirements of personnel

3.3.1 Machine operator
The machine operator
- has reached the statutory minimum age.
- is physically capable (adequate eyesight and hearing, quick reactions) of safely operating the
machine.
- is authorised to operate the machine.
- can accurately estimate distances, heights and clearances.
- is trained:
• to operate this type of machine
• in attaching and signalling
• to operate fire extinguishing equipment
- is aware of the escape routes in the event of an emergency.
- is not suffering from any physical or psychological ailments that lower any of the specified
requirements.
- is not under the influence of alcohol or drugs.
3.3.2 Rigger
The rigger
- is physically capable (adequate eyesight and hearing, quick reactions) of safely using/moving the
slinging equipment.
- is authorised to rig loads.
- 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
- 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
requirements.
3.3.3 Signalman
The signalman
- is physically capable (adequate eyesight and hearing, quick reactions).
- is authorised to give signal signs.
- 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
- is trained in signalling and knows the signal signs.
requirements.
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3.3.4 Maintenance personnel

Maintenance personnel
- have reached the statutory minimum age.
- are physically capable (adequate eyesight and hearing, quick reactions).
- are familiar with the machine and the dangers.
- are familiar with all maintenance procedures and measures.
- are trained to perform maintenance duties, including on specialist equipment.
- are not suffering from any physical or psychological ailments that lower any of the specified
requirements.
- are not under the influence of alcohol or drugs.
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3.4 Personal protective gear

The machine operator and maintenance personnel must take personal responsibility for:
- wearing the required personal protective gear.
- regular cleaning and care of the protective equipment.
- replacing any defective items of protective equipment promptly.
The personal protective gear comprises:

- Safety helmet, if head injuries are possible due to
• collision
• swinging, falling, toppling or flying objects
- Safety goggles, if eye injuries are possible due to
• corrosive or pressurised liquids
• loose flying parts
- Ear protectors, if the sound level is likely to be excessive
- Breathing mask, where there is danger from noxious gases, vapour, smoke or dust in the
working environment
- Protective gloves, if injuries to the hand are possible due to:
• burns
• pointed or sharp objects
- Wear reflective, boldly-coloured clothing, if prompt recognition by other personnel is required
- Wear safety boots, if injuries to the feet are possible due to:
• collision or trapping
• pointed or sharp objects
• swinging or falling objects
- Wear special protective clothing, where there is a risk of burns, hypothermia, chemical burns,
stabbing or cutting injuries to the body
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3.5 Work area

In accordance with the EU Machinery Directive, the machine must be operated by a machine
operator.
The workplace is the cab on the uppercarriage.
Make sure that the following conditions are satisfied when operating the machine:
- no one other than the machine operator is on the machine or within the danger zone around the
machine.
- the machine operator is in the cab at all times.
The operating elements may only be operated from the driver's seat. Operating any operating
elements through the open cab door is prohibited.
Requirements for a safe working environment:
- keep the operator's cab clean.
- do not place any articles on the control panels.
- do not keep tools in the cab.
- hang any clothing on the hook provided for this purpose.
- keep the entrance to the cab clean and free of snow and ice; do not obstruct the entrance or
block the escape routes.
- keep the screens and mirrors (internal and external) clean and free of condensation and ice.
NOTE!
All sterile items and plasters are to be replaced after use or as required.
• Familiarise yourself with the first-aid measures and national regulations.
1
The first-aid box supplied with the machine (see Fig. 1,
item 1) is equipped in accordance with ÖNORM V 5101.
If it is no longer possible to open the operator's cab

doors by hand, the emergency hammer (Fig. 1, item 2)
can be used to break one of the windows to create an
emergency exit.
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3.6 Danger zone
DANGER
Machine in operation!
- Leave the danger area.
Definition of danger area (EN 791:1995, 3.1):

Any area in the vicinity of a drilling rig in which personnel are exposed to risk of injury or health
impairment.
Definition of working range (EN 791:1995, 3.2):

An area close to the rig in which its tools are moved in order to carry out their work.
3.6.1 Danger area during drilling operation
Drilling operation
1 Additional danger area: Danger area extended by the working range
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3.6.2 Danger area in piling mode
Piling mode
x Length of impact driven element (pile)

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3.6.3 Danger zone when moving the machine
Moving the machine
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3.6.4 Danger area in the transport position
Transport position
NOTE!
Observe the following safety instructions:
- Take into account the overhead power lines and follow the safety precautions in EN 50110-1 and
regulations on operating electrical systems.
- EN 50110-2 also lists the nationally applicable safety distances for EU member states.
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3.7 Safety signs on the machine
WARNING
Missing, damaged or illegible safety signs!

- Check safety signs to ensure they are complete and legible.
- Replace missing or illegible safety signs with new, original ones.
Safety signs on the left-hand side of the machine
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Safety signs on the right-hand side of the machine

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Safety signs at the rear
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3.8 Safety signs on the USA-version machine
WARNING
Missing, damaged or illegible safety signs!

- Check safety signs to ensure they are complete and legible.
- Replace missing or illegible safety signs with new, original ones.
Safety signs on the left-hand side of the machine

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10
Safety signs on the right-hand side of the machine
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11
Safety signs at the rear

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3.9 Meaning of the safety signs

Safety signs are divided into different groups with different shapes and colours.
3.9.1 Prohibition signs

Prohibition signs are round with a red border and have a diagonal line through them. The symbol is
black. Prohibition signs are located wherever a potentially dangerous action is prohibited.
No fire, naked flames or smoking
No access for unauthorised personnel
No access for persons with pacemakers
Do not step on this surface
Pedestrians forbidden
Do not operate
3.9.2 Warning signs

Warning signs are triangles with a yellow background and a black border. The symbol is black.
Warning signs are located to warn of risks or hazards.
Danger zone
Risk from high voltages
Danger from swinging loads
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Danger of being drawn in
Danger from hot surface
Slipping hazard
Risk of falling
Risk of tripping
Crushing hazard
Crushing hazard
Crushing hazard
Crushing hazard
Crushing hazard
Risk of running over
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Risk of running over
Danger from ropes
Risk from electromagnetic waves
Risk from pressure vessel
Risk from batteries
3.9.3 Fire protection signs

Fire protection signs are square and have a white symbol on a red background. Fire protection signs
are affixed to indicate the location of fire extinguishers or fire alarms.
Fire extinguisher
Fire extinguisher
Fire alarm
3.9.4 Mandatory signs

Mandatory signs are round and have a white symbol on a blue background. Mandatory signs are
located where certain actions are required.
General mandatory signs
Wear a safety helmet
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Wear ear protection
Wear protective gloves
Wear face protection
Wear foot protection
Use a safety belt
Wear a safety harness

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3.10 Meaning of the machine-specific safety signs
Warning indicating rotating machine parts
Warning indicating crushing hazard
Lifting load forbidden
No access for unauthorised personnel
Warning of dangerous electrical voltage
Constructed and tested in accordance with ANSI B 30.5
Guaranteed sound power level
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3.11 Hazards
3.11.1 Mechanical action
WARNING!
Mechanical actions due to moving machinery!

When operating the machine, numerous hazards and situations can arise that can cause life-
threatening injuries.
- Observe situation-specific safety instructions and those concerned with handling.
NOTE!
- wear the requisite personal protective equipment.
- only work on non-moving parts.
Examples of mechanical actions:
Standing under a suspended load.
Danger of being drawn in by moving drives or machinery.
Risk of falling when working without safety gear.
Danger of crushing if parts, such as doors or windows, are not secured.

First aid
1. Protection/personal safety
• Identify - what is the nature of the emergency?
• Think - what are the dangers for the injured party or the helper?
• Act - make the situation safe.
2. Emergency call
3. Emergency life-saving measures
• Recovery position
• Cardiac massage, artificial respiration and defibrillation
• Staunch bleeding, deal with shock
4. Additional first aid
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3.11.2 Electrical energy
WARNING!
Electricity in conductive machine parts!

NOTE!
- only carry out work when the electrical supply is switched off.
- secure the machine to prevent unauthorised startup.
Examples of electrical energy:

- external power supply
WARNING!
Live machine parts!

Electric shock.
- Before recovering an injured party ensure that there is no further risk of electrocution.
First aid
2. Emergency call
NOTE!
- Seek medical attention after electrical accidents. The person affected may experience symptoms of
an irregular heartbeat some time after the accident.
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3.11.3 Hydraulic energy
WARNING!
Escaping hydraulic oil under high pressure.

Leakages in hydraulic lines can cause injuries to skin, destroy tissue and can cause blood poisoning
due to the high pressures involved.
NOTE!
- repairs to hydraulic systems may only be carried out by qualified technicians with specialised
knowledge and experience of hydraulics.
- before starting work, ensure that the whole system has been depressurised.
- never attempt to locate a leak with your hand or other parts of the body.
- damaged hydraulic components must be replaced immediately with original LIEBHERR parts.
Examples of hydraulic energy:

Tissue damage from leaks.
Blood poisoning from hydraulic oil entering bloodstream.
First aid
2. Emergency call

• Cover injured area(s) with a sterile anti-bacterial bandage. Do not apply
pressure.
• Rinse eyes with fresh drinking water.
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3.11.4 Burns
CAUTION!
Contact with hot surfaces and equipment!

High surface and equipment temperatures can lead to burns or scalding.
NOTE!
- always wear suitable protective gloves when working on hot components.
- allow the machine to stop and cool down before carrying out any work on it.
Examples of burns and scalding:

Burns through contact with the entire drive system.
Scalding from steam exiting from the cooling system or hydraulic oil from the
drive system.
First aid
2. Emergency call
With first-degree burns (redness of the skin):
• Cool the affected body part by rinsing with cold fresh water.
• Cover injured area(s) with a sterile anti-bacterial bandage. Do not apply
pressure.
With second-degree burns (blisters on the skin):
• Cool the affected body part by rinsing with cold fresh water.
• Cover the area using a sterile anti-bacterial bandage. Do not apply pressure.
With third-degree burns (charring of the skin and tissue):
• Cover the area using a sterile anti-bacterial bandage. Do not apply pressure.
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3.11.5 Chemical burns
CAUTION!
Contact with corrosive materials!

Acids and bases cause chemical burns to skin and tissue, and blindness if they come in contact with
the eye.
Acids and bases will damage clothing.
NOTE!
- when working with acids always wear suitable safety goggles or face protection, protective
clothing and gloves.
Examples of chemical burns:

Corrosion from handling acidic chemicals.
Corrosion from leaking battery acid.
First aid
2. Emergency call
• Remove clothing from injured body parts.
• Rinse the injured areas with fresh drinking water.

• Cover the area with a sterile anti-bacterial bandage. Do not apply pressure.
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3.11.6 Fire and explosion
WARNING!
No fire, naked flames or electrostatic discharges!

Flammable materials or any gases arising from them can cause a fire and explosion hazard.
NOTE!
- do not transport any flammable fluids with the machine unless they are in fireproof containers.
- only store small amounts of fuel or highly combustible or self-igniting material.
- wipe any spilled diesel fuel off the machine and neutralise it on the ground with bonding agents.
- clean the machine with non-flammable fluids.
- do not store cleaning cloths in the machinery room and remove flammable residues such as
pools of oil, ash and waste paper.
- only refuel the machine in a well ventilated area or provide an adequate supply of fresh air.
- ensure there is good metallic contact between the pump nozzle and the filler neck during
refuelling. If possible, ground the machine at the fuelling station while it is being refuelled.
- do not smoke when handling flammable materials.
Examples of fire and explosion hazards:

Escaped fuel is a fire hazard.
- Detonating gas in combination with a spark when charging or discharging

batteries.
- Vapourised fuel in combination with an electrostatic discharge between the
machine and the fuel rig.
First aid
2. Emergency call
• (For further information see: Chapter 3, Firefighting)
• (For further information see: Chapter 3, Burns)
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3.11.7 Poisoning and suffocation
WARNING!
Inadequate ventilation or fresh air!

Poisonous vapours or other atmospheres hazardous to health can lead to poisoning or suffocation.
NOTE!
- ensure adequate ventilation in the cab.
- use breathing apparatus when working with hazardous materials.
Examples of poisoning and suffocation hazards:

- Engine exhaust fumes contain carbon monoxide and other hazardous gases.
- If the machine is used in areas where hazardous substances are present,
contact with hazardous gases is a possibility.
- The refrigerant from the air conditioning system circuit displaces the oxygen in
the air.
First aid
2. Emergency call
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3.11.8 Electromagnetic influence
WARNING!
Electromagnetic influence when the machine is deployed near transmitting stations, radar
stations or directional radio systems.
Electronic implants (pacemakers) may malfunction or stop working.
Malfunction or failure of the control system.
NOTE!
- the machine must be stopped if there is suspected electromagnetic interference to the controls.
Examples of electromagnetic influence:

- Malfunction or failure of the control system if operating the machine near
transmitters, directional radio systems or radar stations.
- Environmental influence through the use of electromagnetic rigging material or
integrated radio devices.
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3.11.9 Exposure to wind
DANGER!
The effect of the wind can endanger life!

Toppling over of the machine.
NOTE!
- Observe the permitted wind speeds in the foreword to the applicable load chart.
- Find out and take into consideration the wind conditions at the site and the weather forecasts for
the period of operation.
- Before starting work, the machine operator must know the weather report and the current wind
speed at the site where the machine is operating. If excessive wind speeds are expected within
the next few hours, work must not start and precautions must be taken to protect against storm
damage.
- Watch out for dangerous gusts of wind.
- Hoist the loads slowly and carefully and do not let them become unstable.
DANGER!
If maximum permissible wind speed is exceeded!

Toppling over of the machine.
- Set down and secure the load.
- Move machine to its "parked position" (for further information see: Chapter 5, Parked position).
Leader length in m [ft] maximum permitted wind speed

for operation and for assembly and dismantling in m/s
[mph]
LRB 125 12,8 - 15 [42'-49'] 20 [45mph]
LRB 125/18 16,6 [54'] 20 [45mph]
LRB 155 18 - 24 [60'-80'] 20 [45mph]
LRB 255 21 - 33 [70'-108'] 20 [45mph]
LB 16 18 [59'] 20 [45mph]
LB 20 21 [69'] 20 [45mph]
LB 24 23 [75'] 20 [45mph]
LB 28 26 [84'] 20 [45mph]
LB 36 26 [84'] 20 [45mph]
Effect of wind on the machine and the lifting capacity:

- acts like an additional load on the leader.
- increases the risk of the machine toppling over.
If you do not have an anemometer fitted to the gibbet, the table below will enable you to roughly
estimate the wind force. The wind speed at the leader may be greater than the wind speed at or
near ground level.
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Wind force Wind speed Effects of the wind

Inland
Beaufort Designation m/s km/h mph
0 Calm 0 - 0,2 1 less than Smoke rises vertically.
1
1 Gentle air 0,3 - 1,5 1-5 1-3 Wind direction shown by smoke drift
movement but not yet by wind vanes.
2 Light breeze 1,6 - 3,3 6 - 11 4-7 Wind felt on face; leaves rustle; vanes
moved by wind.
3 Gentle 3,4 - 5,4 12 - 19 8 - 12 Leaves and small twigs moving. Wind
breeze extends light flag.
4 Moderate 5,5 - 7,9 20 - 28 13 - 18 Raises dust and loose paper; moves
breeze twigs and small branches.
5 Fresh breeze 8 - 10,7 29 - 38 19 - 24 Small trees in leaf begin to sway.
White horses form on lakes.
6 Strong wind 10,8 - 13,8 39 - 49 25 -31 Large branches in motion; whistling
heard in telegraph wires, umbrellas
blown inside out.
7 Moderate gale 13,9 - 17,1 50 - 61 32 - 38 Whole trees in motion.
8 Fresh gale 17,2 - 20,7 62 - 74 39 - 46 Breaks twigs off trees.
Walking outdoors is considerably
more difficult than normal.
9 Strong gale 20,8 - 24,4 75 - 88 47 - 54 Slight structural damage (slate and
chimney
pots removed, etc.)
10 Severe gale 24,5 - 28,4 89 - 102 55 - 63 Trees uprooted.
Considerable structural damage oc-
curs.
11 Storm ap- 28,5 - 32,6 103 - 117 64 - 73 Widespread damage.
proaching
hurricane
force
12 Hurricane 32,7 - 36,9 118 - 133 74 and Total devastation.
above
Wind strengths according to the Beaufort scale
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3.11.10 Snow and ice loads
DANGER!
Snow and ice on the machine!

Structural breakdown.
WARNING!
Falling chunks of snow and ice!

Never work with a machine that is iced up or covered in snow.
NOTE!
- lay down the piling and drilling equipment and carefully remove any large accumulations of ice
and snow.
- remove snow and ice from all sensitive parts such as limit switches, guides, etc.
- snow and ice loads increase the boom weight and the area exposed to the wind.
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3.11.11 Lightning strikes
WARNING!
Electric shock from lightning!

Coming into contact with a direct or indirect current caused by a voltage flashover or step voltage
can be fatal.
Risk of falling when working at heights.
It can also cause a total loss of control, damage to the electronics or to local welding spots on
supports, especially on the swing ring.
NOTE!
- Lay down the leader before a storm breaks.
- During a storm, keep away from large, free-standing metal parts (e.g. the machine).
- Earth machines where the steel structure does not have a direct contact to earth.
- Only evacuate the cab in the event of fire.
The closed machine operator's cab acts as a Faraday cage. The charge is channeled through the
machine and into the ground.
These factors will lead to a premature shutdown of the LML - it will no longer be possible to work at
the maximum permitted lifting capacity.
Promptly lay down the boom if any of the following criteria apply:
- The site experiences frequent storms
- Long boom combinations are being used
- On exposed sites
Measures to take after a lightning strike on the machine has been observed or is suspected:
- Thoroughly inspect the machine, paying particular attention to any damaged cables, hoses and
ropes.
- Check that the control system is working correctly.
- Slowly move the swing and listen for any unusual noises.
- Inspect the boom for damage.
- Inform Liebherr after sales service.
- On exposed sites
First aid
2. Emergency call
• (For further information see: Chapter 3, How to respond in the event of a
current transfer)
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3.11.12 Overhead power lines
WARNING!
Live overhead power line!

Electric shock as a result of voltage flashover or step voltage.
NOTE!
- Before starting work inform the power supply company. The power supply company representa-
tive will issue written approval for the setting up and operation of the machine.
- Maintain a safe distance as specified in national guidelines or by a representative from the power
supply company.
- Inform all employees on the site where the machine is to be used about the dangers of electrical
voltage.
- When moving the machine, watch out for unevenness in the ground that could reduce the
distance to the power line.
- Assign a signalman to observe the machine and the line, to monitor the safe distance and to
maintain continuous contact with the machine operator.
Examples of current transfer from overhead power lines:

- Coming into direct contact with an overhead power line.
- If the safety distance is not maintained, an arc will form.
- An overhead power line comes down and a dangerous resistance area forms in
the ground around it.
The safety systems of the different national electricity grids react differently in the event of a fault.
One may not assume that the underground power line will be automatically and permanently shut
down after a short to earth. A resistance area develops around the machine and/or the damaged
underground cable (see Chapter 3, How to respond in the event of a current transfer).
First aid
2. Emergency call

current transfer)
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Guideline values for safe distances from overhead power lines
Overhead power line
The necessary safe distance depends on the rated mains voltage of the power line.
Safe distances and the operation of electrical installations are laid down in EN 50110-1:2004.
These values are guidelines only and may vary from country to country.
NOTE!
- The power supply company can provide exact information about the rated mains voltage.
NOTE!
- The stated safety distances apply if the leader is laid down or removed.
Nominal supply voltage (effective value) Safe distance X

up to 1 kV (1000 volts) 1m
from 1 kV to 110 kV 3m
from 110 kV to 220 kV 4m
from 220 kV to 380 kV, and if nominal voltage is unknown 5m
Safe distances from overhead power lines for operation of the machine in Germany
Nominal supply voltage (phase to phase) Safe distance X

ft m
up to 50 kV (50,000 volts) 10 3.1
from 50 kV to 200 kV 15 4.6
from 200 kV to 350 kV 20 6.1
from 350 kV to 500 kV 25 7.6
from 500 kV to 750 kV 35 10.7
from 750 kV to 1000 kV 45 13.7
Safe distances from overhead power lines for operation of the machine in the USA
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Nominal supply voltage (phase to phase) Safe distance X

ft m
up to 750 V 4 1.2
from 750 V to 50 kV 6 1.8
from 50 kV to 345 kV 10 3.1
from 345 kV to 750 kV 16 4.9
from 750 kV to 1000 kV 20 6.1
Safe distances from overhead power lines during transport of the machine in the USA
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3.11.13 Excavation work
DANGER!
Damaged, live underground power line!

Electric shock
DANGER!
Damaged gas pipe!

Explosion and fire!
NOTE!
- Before starting work inform the power supply company. The power supply company representa-
tive will issue written approval for the setting up and operation of the machine.
- Maintain a safe distance as specified in national guidelines or by a representative from the power
supply company.
- Inform all employees on the site where the machine is to be used about the dangers of electrical
voltage.
- Assign a signalman to observe the machine, monitor the safe distance and maintain continuous
contact with the machine operator.
Examples of current transfer from underground power lines:

- Penetration of the insulating sheath: Voltage transferred to the machine
- Damage to an underground power line: Creation of an arc, fire
- Damage to a high-voltage cable: Formation of a resistance area around the
fault location
The safety systems of the different national electricity grids react differently in the event of a fault.
One may not assume that the underground power line will be automatically and permanently shut
down after a short to earth. A resistance area develops around the machine and/or the damaged
underground cable (see Chapter 3, How to respond in the event of a current transfer).
Examples of explosion or fire in gas pipes:

- Displacement of or damage to the pipe casing: Formation of an explosive
gas/air mixture
- Damage to a gas supply pipe: Development of high pressure
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First aid
2. Emergency call
current transfer)
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3.11.14 Working in the dark
CAUTION!
Poor visibility in the dark!

Risk of injury.
Ensure adequate lighting is provided (at least 100 lx).
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3.11.15 Environment
NOTICE
Risk of damage to the environment caused by pollutants

If their release is not controlled, fuels, oils, cleaning agents, coolant, etc. can enter the ground or
rivers and cause environmental damage.
- Observe safety instructions and information.
Note
- If the machine leaks, immediately collect the escaping liquid and seal the leak.
- Bind any spilled liquid with binding agent or neutralise it with suitable agents.
- When draining or catching liquids use suitable containers (capacities and resistant to chemicals).
- Carry out cleaning work on firm and channelled ground.
- Observe the national and international environmental regulations for the disposal of chemicals or
waste.
- Notify the emergency services and authorities if large amounts of substances that are harmful to
the environment escape.
Examples of environmental hazards:

- Leakages
- Incorrect fluid refills
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3.12 What to do in dangerous situations

3.12.1 How to respond in the event of a current transfer
Resistance area, step voltage
12
Resistance area, step voltage
x extent
U voltage
Us step voltage
In the event that current is conducted to the machine from coming into contact with a power line, the
current is distributed from the point of entry in the earth. The voltage decreases according to a
funnel-shaped curve - a resistance area is formed.
The extent of the resistance area depends on:
- voltage
- current intensity
- ground resistance
If anyone moves within the resistance area, a potential difference, known as the step voltage Us,
forms between their feet.
The step voltage increases:
- the closer the person is to the current transfer location.
- current intensity
- the greater the step.
First response to a current transfer

- Remain calm.
- Alert the relevant power supply company.
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Do not leave the cab.

• It is relatively safe to remain in the closed operator's cab as it acts as a Faraday cage.
• Only evacuate the cab in the case of fire.
- If the Litronic control system is still functioning:
• Move the machine out of the danger area.
• Remain in the cab until the current is no longer being transferred through the machine.
Leaving the machine in cases of current transfer and fire

- Never touch live parts of the machine (hoist rope, load, crawler, etc) if you are in contact with the
ground.
- Jump in a direction that avoids any contact with live parts.
- Jump to a safe distance from the machine and land on both feet at the same time.
- Land on both feet at the same time with legs closed (do not straddle).
- Never hold on to the machine or any live parts.
- Hop away on both feet with both legs pressed together.
- While hopping away, keep well clear of any live parts.
First aid
- Alert the emergency services.

- Persons may only be rescued by trained personnel.
NOTE!
- Seek medical attention after electrical accidents. The person affected may experience symptoms
of an irregular heartbeat some time after the accident.
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3.12.2 Procedure in the event of fire
WARNING!
- Switch off the engine.

- Alert the emergency services.
- Move people out of the danger zone, administer first aid if required (for further information see:
Chapter 2, Burns).
- Only if there is no risk to your personal safety should you start to fight the fire (for further
information see: Chapter 2, Firefighting).
WARNING!
Even if the fire appears to be extinguished, escaping fuel or oil coming in contact with hot
components may reignite.
Once there is no longer any danger of the fire restarting:
- Start assessing the damage.
3.12.3 Firefighting
Fire classes
WARNING!
If unsuitable extinguishers are used, they may be ineffective or even introduce additional hazards.
- Use an extinguisher that is appropriate for the fire class.
Fires involving solid and chiefly organic materials that normally smoulder
Fires involving liquids or liquefying materials
Fires involving gases
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Fires involving metals
Use of the fire extinguisher
NOTE!
Fire extinguishers are subject to national regulations.
- The operator must therefore provide, replace and test the extinguishers as required.
- Remove the fire extinguisher from its mount on the machine and prepare it for use (for further
information see Chapter 2, Safety equipment).
- Locate the seat of the fire and fight it with short, well-aimed bursts.
- While fighting the fire, ask your colleagues to alert the fire brigade.
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Incorrect Correct
Fight the fire with the wind behind you
Extinguish the fire from the front to the back and

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

top to the bottom
Do not use extinguishers in succession but use

several extinguishers at the same time
Make sure that the fire does not reignite - always

extinguish glowing embers with water
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Incorrect Correct
Do not put the fire extinguishers back in place after

use - refill them
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3.13 Hand signals

The hand signals:
- are used for communication purposes when there is visual contact between machine operator and
signalman or other site personnel
- are clearly defined in national and international standards
Note
- All persons involved must decide among themselves which hand signals are to be used.
The following overview comprises:

- hand signals in accordance with BGV A8 (Germany)
- hand signals in accordance with ASME/ANSI B30.5 (United States of America)
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3.13.1 General hand signals in accordance with BGV A8
Caution, Start, Stop
- Hold the right arm stretched vertically upwards

- Palm facing forwards
Stop, Interruption
- Stretch out both arms to the side horizontally

- Palms facing forwards
Stop - Danger
- First stretch out both arms horizontally to the sides

- Palms facing forwards
- Now alternately bend in and stretch out the arms
Lift
- Bend the right arm and hold upwards

- The hand makes a small, circular movement
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Lower
- Stretch out the right arm downwards

- Palm facing inwards
Slowly
- Stretch out right arm horizontally

- Palm facing downwards
- Move hand slowly up and down
Depart

- Move the arm back and forth sideways
Approach
- Bend both arms

- Palms facing inwards
- Beckon with the forearms
Remove
- Bend both arms

- Palms facing outwards
- Wave away with the forearms
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Travel right (from the signalman's viewpoint)
- Bend right arm slightly while holding horizontal

Travel left (from the signalman's viewpoint)
- Bend left arm slightly while holding horizontal

Indicate reduction of distance
- Hold both palms parallel and move them toward each other to
indicate the distance
3.13.2 Special hand signals for attachment operations
Lift load slowly

- The outstretched finger points upwards
- The right hand makes small, circular movements
- Stretch out the left hand and hold it over the right hand
Lower load slowly
- Hold the right arm downwards

- The outstretched finger points downwards
- The right hand makes small, circular movements
- Hold the left hand under the right hand
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Raise the main boom

- The outstretched thumb points upwards
- Stretch out the left hand and hold it over the right hand
Lower the main boom
- Bend the right arm

- The outstretched thumb points downwards
- Stretch out the left hand and hold it under the right hand
Lift main boom and hold load

- Make a fist with the left hand and hold it under the right hand
Lower main boom and hold load

- Make a fist with the left hand and hold it under the right hand
Raise main boom and lower load

- Stretch out left arm and point index finger down
- Move the left hand in circles and hold it under the right hand
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Lower main boom and lift load

- Bend left arm and point index finger up
- Move the left hand in circles and hold it under the right hand
Swing uppercarriage to the right
- Bend the left arm and hold it up

- The thumb points outwards in the direction of rotation
- Point index finger down and make circles
Swing uppercarriage to the left
- Bend the right arm and hold it up

- The thumb points outwards in the direction of rotation
- Stretch out the left arm downwards
- Point index finger down and make circles
Open grab

- Open hand downwards
Close grab

- Close the hand into a fist
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3.13.3 Hand signals for lifting operations in accordance with ASME/ANSI B30.5
Lifting loads

- The outstretched index finger points upwards
Lowering loads

- The outstretched index finger points downwards
Use main winch
- Tap the safety helmet with the fist

- Then give further hand signals
Use auxiliary winch

- Tap the underside of the right elbow with the left hand
- Then give further hand signals
Raise the main boom

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Lower the main boom

Move slowly
- Give the required signal with one hand (e.g. lift load)
- Hold the other hand above or below the other hand
Raise main boom and lower load

- Stretch and bend the remaining fingers alternately for as long the
load has to be lowered
Lower main boom and lift load

- Stretch and bend the remaining fingers alternately for as long the
load has to be raised
Swinging

- The extended fingers point in the direction of rotation
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Stop
- Stretch out one arm horizontally

- Swing arm back and forth horizontally
Emergency stop
- Stretch out both arms horizontally

- Palms facing downwards
- Swing both arms back and forth horizontally
Travelling
- Bend one arm

- Make a movement in the travel direction with the open hand
Shut down and lock machine
- Hook your hands in front of your body
Travel with both crawler chains
- Hold both fists in front of the body

- Indicate travel direction with circular motions
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Travelling with one crawler track
- Bend the arm and hold up a fist on the same side as the stationary
crawler track
- Bend the other arm in front of the body on the side of the moving
track
- Indicate the travel direction by making circular movements with the
fist
Extend boom

- Thumbs facing outwards
Retract boom

- The thumbs point towards each other
Retract boom (one-handed signal)
- Hold one fist in front of your chest

- Your thumb points to your chest
Retract boom (one-handed signal)

- Hold one fist in front of your chest

- Your thumb points to your chest
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3.14 Steps
13
1 Steps, bogie 4 Leader line*

2 Circumferential platform* 5 Platform
3 Ladders
DANGER!
Risk of lethal injury by falling!

Use, platforms, steps and ladders when carrying out maintenance, repair or inspection work.
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14
3.15 Safety harness and fall protection
slide *
DANGER!
There is a risk of falling when doing maintenance or

inspection work on the erected lead.
Precautions:
• Only climb up the lead using the lead access ladder
and a correctly fastened safety harness with fall pro-
tection slide.
• If the lead is vertical,
• the lead access ladder must be folded into the working
position with the segments bolted.
• The lead is set down on the ground and the piling and
drilling unit moved down.
• The diesel engine of the machine is switched off.
15
3.15.1 Putting on the safety harness
The safety harness is stored behind the driver's seat in
the cab.
A detailed description is included in the storage bag.
Putting on the safety harness

1.) Pick the safety harness up by the loop at the back
(Figure 15, item 2) (straighten any tangled parts) and
place the (orange) shoulder straps (Figure 16, item 4)
over the shoulders as for a rucksack.
2.) Fasten the chest strap (Figure 16, item 6) with the
clip (Figure 16, item 5).
16
3.) Fasten the waist strap (Figure 16, item 8) with the
friction buckle (Figure 16, item 7).
4.) Fasten the leg strap (blue, Figure 16, item 11) by
bringing it forwards between the legs and closing it with
the friction buckle (Figure 16, item 7).
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Adjust the harness
• Check that the metal loop (Figure 16, item 9) on the waist strap (Figure 16, item 8) is centered; if
not, center it.
• Adjust the chest strap (Figure 16, item 6) to provide sufficient ease of movement. Using the friction
buckles (Figure 16, item 7), adjust the length of the shoulder straps to suit your body so that the
waist strap (Figure 16, item 8) rests near the hip bones.
• The back plate (Figure 15, item 1) should be at shoulder blade height, and the front (Figure 16,
item 9) in the center of the body.
• Pull the waist strap (Figure 16, item 8) tight so that the fall protection slide operates properly.
17
3.15.2 How the fall protection slide works
The fall protection slide (Figure 17, item 2) runs on the
safety rail (3) of the lead access ladder. The fall protec-
tion slide is connected to the correctly worn safety har-
ness by the karabiner (1) and is simply carried along
during ascent.
In the event of a fall the protection slide jams on the rail
within a few centimeters [inches].
Check the operation before use

Before using the safety harness for the first time, make
sure that you are familiar with it and its individual func-
tional parts. Hook up to the fall protection slide (Fig-
ure 17, item 1) near the ground and load the safety
harness to test it. If anything is not right, check the strap
settings and correct them.
CAUTION!
Have a specialist check the safety harness and fall

protection slide regularly (at least once a year).
Never use a safety harness that is faulty or incom-
plete! Danger of death!
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NOTES:
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4. CONTROLS
4. CONTROLS
4.1 General
This chapter describes the control and operating elements. Depending on their function they are
located on the superstructure, the undercarriage or in the cab.
All other devices important to safe operation are listed in section 3.5 "Safety and monitoring devices".
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4. CONTROLS
4.2 Operational controls on the undercarriage

1
Undercarriage viewed from rear
1 Track adjustment cylinder control lever
The control elements on the undercarriage are only used when assembling and dismantling the
machine. See Chapter 6 "Assembly and disassembly".
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4. CONTROLS
4.3 Operational controls on the superstructure

2
Superstructure, rear view
1 Refueling pump control desk See Chapter 9 "Refueling pump"

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4. CONTROLS
4.4 Cab
4.4.1 Cab overview
Overview of cab Figure 4-01
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4. CONTROLS
Names of the components in Figure 4-01:

1 Venetian blind for roof window 11 Door lock
2 Work floodlight, rear 12 Platform, front
3 Flashing light 13 Windshield wiper, front
4 GSM antenna 14 Window lock (both sides)
5 First-aid kit 15 Sun visor
6 Emergency hammer 16 Rear-view mirror, inside
7 Ventilation nozzle 17 Work floodlight, front
8 Switch cabinet X1 18 Windshield wiper, top
9 Side platform 19 Reading lamp
10 Rear-view mirror, outside 20 Radio antenna
not shown: Roof guard on the cab
Details:
Cab platform:
The front cab platform (Figure 4-01, item 12) is bolted on securely. The side cab platform must be
folded in during transport. The side platform is locked by means of bolts, cotter pins and retaining
springs.
Cab door:
The driver's door can be fixed in three positions
- completely closed
- half open
- completely open
Open the door fully to get into the cab.
Slowly pull the door shut. At a certain point you will feel a resistance (lock).
Exert a slight pressure to lock the door into position. It is now secure.
Continue pulling the door to close it completely.
NOTE!
Always make sure that the door is locked. Crushing hazard!
An optional Door catch is available. The door is secured in the fully open position. Pushing the lever
(top left, rear) forwards releases the locking device, allowing the door to be closed.
Cab window:
The front window in the cab can be slid open.
Push the two knobs on both sides (Figure 4-01, item 14) simultaneously. The window will open. Use
the anchoring rod to secure it in the desired position.
To close the window, pull the anchoring rod until the window is closed and the lock has engaged.
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4. CONTROLS
4.4.2 Control stand overview
Overview of control stand Figure 4-02
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4. CONTROLS
Names of the components in Figure 4-02:

1 Left-hand control panel (X12) 16 Hooter
2 - 17 Mounting position: handwheel for drilling
free-wheel
3 Left-hand control panel (X11) 18 LCD screen
4 Left joystick for slewing gear, Kelly winch 19 Right-hand control panel (X23)
and drilling drive 2 (FOW drilling)*
5 Safety lever for Litronic control system 20 Ignition starter switch
6 Service hour meter 21 Right joystick for drilling drive (Kelly and
CFA drilling)*,
Drilling drive 1 (FOW drilling)*
Feed winch and auxiliary winch*
7 Grip 22 -
8 Recirculated air/fresh air switch 23 Radio
9 Air vents 24 Additional control panel (X25)
10 Hand lever for left and 25 PDE control panel*
right travel gear
11 Pedal for Kelly winch free-wheel 26 EMERGENCY SHUT-DOWN button
12 Spirit level for inclinometer* 27 PDE external card reader with control
computer*
13 Pedal for left-hand travel gear 28 Printer*
14 Pedal for right-hand travel gear 29 Washer fluid container
15 Gas pedal*
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4. CONTROLS
4.4.3 Overhead view of control stand
Overhead view of control stand Figure 4-03
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4. CONTROLS
Names of the components (Figure 4-03)
1 Spirit level for inclinometer 14 Ashtray

2 Pedal for Kelly winch free-wheel 15 -
3 Pedal for left-hand travel gear 16 Radio
4 Air vent 17 Windshield wash container, front wind-
shield
5 Hand lever for left and right travel gear 18 PDE control computer*
6 Pedal for right-hand travel gear 19 Printer*
7 PDE control panel* 20 Drink holder
8 LCD screen 21 Windshield wash container, roof window
9 Right-hand control panel (X23) 22 Left-hand control panel (X12)
10 Right joystick 23 Left-hand control panel (X11)
11 Ignition starter switch 24 Safety lever for Litronic control system
12 Emergency shut-down switch 25 Left joystick
13 Cigarette lighter 26 Grip
not shown: Hooter

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4. CONTROLS
• All important operational controls are mounted in the control stand. Space is available for extra
equipment with additional operational controls or control panels.
• All the necessary settings on the LCD display (Figure 4-02, item 18) are made using the 8 function
key symbols.
The brightness of the LCD display can be adjusted separately from the Litronic service panel.
• The keys on the control panels (X11 and X23) and the additional control panel (X25) are in the
form of a foil keypad and equipped with LEDs. If the integrated LED stays on after an individual
button has been pressed, it is working as a switch. If the LED goes out when released, it is
working as a button.
The control panel lighting adapts automatically to the surrounding lighting level.
• General functions keys are on the left control panel (X11) (Figure 4-02, item 3) for e.g. the
headlights, wipers, heating, etc. The rest of the keys are reserved for optional and supplementary
functions such as air conditioning.
• Certain electrical functions of the left control panel (X11) can also be activated when the ignition
starter switch is in the park position (P) (e.g. reading lamp, car radio, etc.).
• All the device-specific functions are located on the right control panel (X23) (Figure 4-02, item 19)
and on the additional control panel (X25) (Figure 4-02, item. 24).
• The left control panel (X12) is used for selecting particular operating modes. Only assembly mode
is used on this machine.
• The EMERGENCY SHUT-DOWN button (Figure 4-02, item 26) stops the diesel engine and all
movements.
NOTE!
The EMERGENCY SHUT-DOWN button may only be used in an emergency!
• The Safety lever (Figure 4-02, item 5) on the left control stand
- in the raised position disables all the joysticks and foot pedals (slewing gear, travel gear etc.),
- thus preventing these controls from being used unintentionally.
The safety lever must
- be lowered for operation and raised during breaks,
- arranged so that it always has to be raised when leaving the cab.
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4. CONTROLS
CAUTION!
Raising the safety lever

- immediately stops the joysticks working,
- only stops the drives after the predefined integration time.
Until the slewing gear has braked, the superstructure can continue turning for a dangerously
long time!
• All hydraulic functions (such as hydraulic cylinder adjustments, track adjustment, etc.) are only ever
available when the diesel engine is running.
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4. CONTROLS
3
4.5 Joysticks, pedals
Left joystick (Figure 3)
The left-hand joystick is used to adjust:
- the slewing gear
- the Kelly winch and
- drilling drive 2 (FOW drilling) * / Kelly winch
The buttons on the left joystick have the following func-
tions:
1 -
2 Lead outreach (forwards/backwards)
3 Inclining the lead forward/back or left/right
4 Second tower system
5 Lead support *
6 Reset Kelly winch rope length */Auger cleaner*/
relative displacement cylinder *
7 Vibrator button
8 Kelly-winch free-wheel *
9 Automatic tower system
4
Right joystick (Figure 4)
The right-hand joystick is used to adjust:
- Drilling drive (Kelly drilling, CFA drilling) *,
- Drilling drive 1 (FOW drilling) *,
- Feed winch and auxiliary winch *
The buttons on the right joystick have the following
functions:
1 Rocker switch for diesel engine gas adjustment
2 Saving movements:
feed and drilling drive(s)
3 Torque change-over (drilling drive 1) *
4 Switching between drilling drive 1 - auxiliary winch * /
Drilling drive 2 Kelly winch/
Engine speed adjustment - eccentric adjustment
5 Rock gear (Kellydrilling) /
Torque change-over (drilling drive 2)
6 Fast feed speed/vibrating drilling drive *
7 Vibrator button
8 FOW drilling: drilling drive 2 (tube) opposed
when operating drilling drive 1 *
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4. CONTROLS
5
Pedal arrangement
The pedals in the cab have the following functions:
1 Pedal for Kelly winch free-wheel * / Brake pedal for
the Kelly winch free-fall brake *
2 Left travel gear
3 right travel gear
4 Hooter
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4. CONTROLS
4.6 Left control panel (X11)
Front windshield wiper
Upper windshield wiper
Control panel left Figure 4-04
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4. CONTROLS
Description of keys
Light Emitting Diode (LED)

All keys on the left control panel contain LEDs that visibly indicate which
functions or settings are currently active.
"Blower setting" preselect key

For adjusting the blower settings of the heating and the air conditioning* unit.
Three different fan speeds are available. The blower setting is indicated by a
corresponding number of LEDs.
Potentiometer "Temperature settings heating/air conditioning unit*" poten-

tiometer
To set the temperature for the heating and air-conditioning* systems. The tem-
perature is controlled electronically (see Chapter 5 under "Machine operation -
auxiliary functions").
"Intermittent wiper on/off" key

To switch to intermittent control of the relevant wiper (see Chapter 5 under
"Machine operation - auxiliary functions").
"Windshield wiper on/off" key

To switch the relevant windshield wiper on or off.
"Windshield washer on/off" key

The relevant windshield washer operates for as long as the key remains pressed.
"Interior lighting on/off" key

Switches interior lighting on or off in the superstructure.
"Work floodlights on/off" key

Switches the work floodlights on and off.
"Air conditioning on / off" key *

Switches the air conditioning unit* on and off.
"Fast travel on / off" key *

Switches the fast travel * on and off.
"Compressor on / off" key *

Switches the compressor * on and off.
"Slide greasing on / off" preselect key *

Preselects the slide greasing *.
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4. CONTROLS
4.7 Left control panel (X12)
Left control panel (X12) Figure 4-05
NOTE!
The keys on control panel (X12) remain active for as long as the control lamp under the key is
illuminated.
"Assembly mode" preselect key

Assembly mode is intended solely
- for assembly, conversion and dismantling of the machine,
- for settings (flow rate, working pressure etc.)
- for bypassing limit switches
(when the "Bypass limit switch" preselect key on the
right control panel (X23) is operated).
Assembly mode is activated by pressing this preselect key.
"Unsecure free-fall" preselect key *

Not used on this machine.
"Enable LML bypass" preselect key *

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4. CONTROLS
"Extend tilting-back support cylinders" key

"Retract tilting-back support cylinders" key

Key "Preselect operating mode"

Preselects the operating mode.
NOTE!
Further keys may optionally be added.
DANGER!
In all operating modes enabled by a preselect key,

- the safety functions are switched off or available only to a limited extent,
- fatally dangerous situations and severe damage to the machine are then possible.
The safety precautions appropriate to the operating mode apply!
Precautions:
The machine operator must know exactly when to use these operating modes and be aware of their
special characteristics and dangers.
The control panel cover can be locked to prevent improper use.
As soon as a special operating mode is no longer needed, the preselect key concerned must be
switched off immediately.
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4. CONTROLS
4.8 Right-hand control panel (X23)
Right-hand control panel (X23) Figure 4-06
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4. CONTROLS
Description of keys/buttons
LED for function display

All buttons and selection buttons on the right control panel contain LEDs that
visibly indicate which functions or settings are currently active.
"Self-locking free-wheel * on/off" selection button

For the maintenance of free-wheel mode* for the Kelly winch
(The Kelly winch must be designed for free-wheeling)
"Slewing gear speed setting" preset button
Select between three different speed settings for the slewing gear. The appro-
priate symbol appears on the LCD screen to show that it has been selected.
"Cylinder adjustment functions on/off" preset button

For approval of cylinder adjustment functions (track adjustment). The required
cylinder can then be controlled using the appropriate button or control lever.
"Bypass limit switches" preset button

Assembly mode:
all limit switches for assembly or dismantling of the machine are
permanently bypassed.
Working mode:
the limit switches are bypassed as long as the selection button is pressed.
"Casing oscillator on/off" key *

Switches the casing oscillator* on and off.
Key "Reinforcement vibrator on / off" *

For switching the reinforcement vibrator on and off.
"Close clamping tongs" key *

To close the clamping tongs or switch on the clamping tongs system.
"Open clamping tongs" key *

Opens the clamping tongs.
"Constant gas programming" key

This button is used to store or delete the current speed of the diesel engine.
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4. CONTROLS
Potentiometer
The two potentiometers on the right control panel can be used to make various settings, depending
on the options installed on the machine. Two separate functions can be assigned to each of the two
potentiometers. The function assignment is indicated by the corresponding LED on the selection
display.
The potentiometer is adjusted from minimum to maximum by turning it clockwise. It can be turned
through two revolutions. It can be fixed in the desired position with the small lever.
Potentiometer 1
Preset display "Additional hydraulics flow rate" *

For adjusting the flow rate to the casing oscillator. See "Casing oscillator" in
Chapter 5
Preset display "Function 2"

This function is not used at present.
Potentiometer 2
Preset display "Casing oscillator power regulation" *

For power regulation of the casing oscillator. * See "Casing oscillator" in Chapter
5

NOTE!
The potentiometer setting always applies to the active selection.
(LED in the preset display lights up.)
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4. CONTROLS
4.9 Additional control panel (X25)

6
Additional control panel (X25)
All buttons and preselect keys on the additional control panel (X25) are fitted with
an LED which
- lights up to indicate that the function has been selected or activated
- flashes in the case of direction keys if a cylinder is moved by means of
a joystick (direction indicator).
Potentiometer
The four potentiometers on the additional control panel (X25) can be used for various settings
according to the options built into the machine. Two separate functions can be assigned to each of
the four potentiometers. The current function assignment is indicated by the corresponding LED on
the preset display.
The potentiometer is adjusted from minimum to maximum by turning it clockwise.
Principle of cylinder adjustment

Cylinder adjustment functions are selected on the additional control panel (X25) and then actuated
by pressing the corresponding direction keys (T1, T9, T19 and T27).
The LEDs in the corresponding direction keys only light up when a cylinder adjustment function has
been selected and enabled.
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Potentiometer 1
Preset display "Feed pressure control"

For setting the pressure for the pressure control of the feed.
See Chapter 5 under "Feed operation".

Potentiometer 2
Preset display "Feed speed"

For setting the speed of the feed.
See Chapter 5 under "Feed operation".

Potentiometer 3
Preset display "Automatic control" *

Automatic control is available as an option and is customer-specific.

Potentiometer 4
Preset display "Drilling drive speed"

For setting the speed of the drilling drive.
See Chapter 5 "Drilling mode".

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4. CONTROLS
Description of keys/buttons
"Raise/Right" key
The preselected cylinder can be moved in the directions "Raise" or "Right" (when
the LED is illuminated).
"Lower/Left" key
The preselected cylinder can be moved in the directions "Lower" or "Left" (when
"Lift/Open" button
The preselected cylinder can be moved in the directions "Raise" or "Open" (when
"Lower/Close" button
The preselected cylinder can be moved in the directions "Lower" or "Close"
(when the LED is illuminated).
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"Lead support cylinder left" selection button

For selecting the left lead support cylinder (Z2L).
"Extend tensioning cylinder" pushbutton T5

The tensioning cylinder is extended. This function is only available in assembly
mode.
"Lead support" selection button *

For selecting the optional lead foot cylinder.
"Lead support cylinder right" selection button

For selecting the right lead support cylinder (Z2R).
"Relative movement"* selection button

For selecting the relative displacement cylinder (see "Double rotary drilling" in
Chapter 5).
"Retract tensioning cylinder" pushbutton T14

The tensioning cylinder is retracted.
"Base arm positioning" selection button

To select the base arm adjustment cylinder (Z4).
"Centering guide for pile driving" selection button*

Selects the pile centering guide (see Chapter 9 under "Pile centering guide").
"Superstructure support" selection button *

Selects the superstructure hydraulic jacks.
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4. CONTROLS
"Auxiliary winch" selection button

Selects the pile auxiliary winch (see Chapter 5 under "Operating the auxiliary
winch").
In double-rotary drilling mode, also used to select Kelly winch.
Pre-selection key "Parallel operation winch 2" *

For pre-selection of the parallel operation (see chapter 5 "Parallel operation").
"Automatic control" * selection button

Selects automatic control. Automatic control is customer-specific (e.g. automatic
hoisting).
"Drilling free-wheel on / off" * button

For switching the drilling free-wheel on and off.
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4.10 Emergency shut-down button

The emergency shut-down buttons
- form part of a safety circuit,
- allow the machine to be shut down quickly in a dangerous situation.
The mounting positions of the two standard emergency shut-down buttons are shown in Chapter 3
under "Safety devices".
As soon as an emergency shutdown key is pressed,

- the diesel engine shuts down,
- all movements stop immediately.
CAUTION!
An emergency shutdown key must only be used for emergency shutdown and not as a
normal procedure for shutting down the diesel engine!
An emergency shutdown may place the machine under extreme stress.
CAUTION!
If an emergency stop is triggered while a load is being lifted, the multi-disc stopping brakes
must afterwards be inspected by Liebherr service personnel to restore them to proper
working order.
Once an emergency shut-down switch has been pressed and after proper working order has been
restored, it must be turned to unlock it..
NOTE!
All emergency-off switches must be unlocked in order to restart the diesel engine.
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4.11 Overview of the LCD screen

NOTE!
The values on the following pages are not binding for this machine, and are shown purely for the
purpose of clarification!
4.11.1 Main areas of the screen

The LCD screen of the Litronic control system is divided into four main areas. These main areas
generally apply to all screens.
Overview of the LCD screen
1 Status displays 3 Function key symbols

2 Control displays / settings 4 Screen status LEDs
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4.11.2 Description of the main areas of the screen

Status displays (Figure 7, item 1)
The different status displays appear in the upper part of the LCD screen as symbols. Up to 8
symbols can be displayed simultaneously.
The status displays show
- current preselections,
- the operating mode,
- speed settings,
- tripped limit switches.
The status displays

- do not appear in the start-up screen and the "Fault monitor" page,
- are represented by the same symbols on all the other screens.
Example of a status display:
"Slewing gear speed" display

Displays preselected speed setting 3 for the slewing gear.
Control displays (Figure 7, item 2)
In the central area of the LCD screen all the currently required control displays are shown (e.g.
display fields, engine and filter monitoring, error texts etc.).
Example of a control display:
"Diesel engine speed" display

Indicates the current speed of the diesel engine in rpm. .
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Function key symbols (Figure 7, item 3)
The function key symbols are located in the lower area of the LCD display.
The function key symbols
- may change depending on the screen.
Example of a function key symbol:
"Power unit page" symbol

Pressing this function key takes you to the page for "Power unit monitoring".
Screen with integrated control area (no. 1)
The operator taps directly on the function symbols at the

bottom of the screen.
Changing the values on the LCD display

Do not use sharp objects such as ballpoint pens or pencils as
these will damage the surface of the screen. Tap the function
symbols with the index finger to change the values and to
move between screens.
Thetwo LEDs (Figure 7, item 4) indicate the status of the LCD screen:
The green LED lights up during normal operation.
The red LED lights up if an error occurs.
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4.11.3 Screen page sequence

The Litronic control unit provides the machine operator with various screen pages for operating the
machine:
Start-up screen
The start-up screen
- appears briefly on the LCD screen when the ignition is
turned on,
- disappears as soon as the Litronic control system is ready
for operation,
- is then replaced by the current mode screen.
"Mode screen" page

The mode screen
- is the default display during operation,
- provides the machine operator with all essential information.
The appropriate field appears on the mode screen depending
on the selected operating mode. The following fields are
possible:
- Kelly drilling field,
- CFA drilling field,
- FOW drilling field,
- Soil mixing display field
Other displays can be called from within the mode screen by

pressing the corresponding function key.
"Select operating mode" page

This page is used for selecting the operating mode.
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"Power unit monitoring" page

This page contains all the important data relating to the
central power unit.
"Fault monitor" page

This page
- shows error messages as plain text in the appropriate
language,
- can consist of several error pages.
"Settings" page
This page is used for entering the required values, depending
on the operating mode.
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4.12 "Mode screen" page

8
"Mode screen" page
The mode screen contains important displays and information for the selected operating mode.
Description of status displays
"Kelly winch free-wheel"* symbol

Indicates that the Kelly winch is in free-wheel (drilling free-wheel). See Chapter 5
"Kelly winch operation".
"Self-locking Kelly winch free-wheel"* symbol

Indicates that the Kelly winch free-wheel (drilling free-wheel) is currently locked
(see Chapter 5 "Kelly winch operation").
"Assembly mode" symbol

Indicates that assembly mode has been activated.
"Movement saved" symbol

The movement of the feed and/or the drilling drive(s) has been saved.
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"Fuel level" symbol

This symbol flashes when the fuel level falls below approximately 15% (reserve
indicator).
"Hydraulic oil temperature too low"* symbol

See "Cold weather kit" in Chapter 9.
"Slewing gear speed" display

Indicates the speed setting for the slewing gear (1, 2 or 3).
The desired speed setting for the slewing gear is set with a selection button on
the right-hand control panel.
"Drives are limited" symbol

This symbol flashes in the status display if several limit switches trip simulta-
neously and movement is being initiated at the same time in a direction that is
blocked by a tripped limit switch.
If only one limit switch has tripped and a movement is initiated in the direction it has blocked, then
the corresponding limit switch symbol starts flashing in the status display instead of the previous
"Drive is limited" symbol.
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The following limit switch symbols can be displayed:
"Upper limit switch, auxiliary winch" symbol

The hoisting limit switch for the auxiliary winch has been activated.
Hoisting of the auxiliary winch is blocked.
"Lower limit switch, auxiliary winch" symbol *

The 3-windings limit switch on the auxiliary winch has been activated.
The lowering direction of the auxiliary winch is blocked.
"Upper limit switch, Kelly winch" symbol

The hoisting limit switch for the Kelly winch has been activated.
The raising direction of the Kelly winch is blocked.
"Lower limit switch, Kelly winch" symbol *

The 3-windings limit switch on the Kelly winch has been activated.
The lowering direction of the Kelly winch is blocked.
"Upper limit switch, feed" symbol

The upper limit switch for the universal slide has been activated.
Feed is blocked in the lifting direction.
"Lower limit switch, feed" symbol

The lower limit switch for the universal slide has been activated.
Feed is blocked in the lowering direction.
"Limit switch, lead inclination right" symbol

The lead is inclined five degrees to the right.
Inclination of the lead to the right is blocked.
"Limit switch, lead inclination left" symbol

The lead is inclined five degrees to the left.
Inclination of the lead to the left is blocked.
"Front lead outreach limit switch" symbol

The limit switch for maximum outreach has been activated.
The forward inclination of the lead (extension of lead support cylinders) is
blocked.
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Kelly drilling display field
The Kelly drilling field appears on the LCD display if

- drilling mode and
- Kelly drilling
is selected using the "operating modes" function key symbol.
Elements of the Kelly drilling display field
Inclination display (looking down on to the lead)

-0.3° . . . . . . . . . . . . . . . . . . . . . Inclination in X-direction (to the left)
0.1° . . . . . . . . . . . . . . . . . . . . . Inclination in Y-direction (forwards)
+ . . . . . . . . . . . . . . . . . . . . . . Actual value, current position of lead
. . . . . . . . . . . . . . . . . . . . . . . Setpoint value, value set for the in-
clination of the lead
Lead pump working pressure

Analog display of the working pressure of the lead pump (cylinders
etc.)
11.5 m Kelly winch rope length metering

Rope length metering
- shows the position and movement direction (+/-) of the Kelly bar
(e.g.: 11.5 m),
- is used to determined height differences,
- displays depth with a "-" before the figure,
- can be reset to zero at any time with the appropriate
function key,
- should be set to zero immediately prior to activation

to enable an accurate measurement.
9.85 m/min Kelly winch rope speed

Displays the speed of the Kelly winch rope in m/min [ft/min].
3.50 PDE depth

The PDE depth is displayed if
- PDE recording was interrupted and
- the Kelly winch was being used.
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0 mm per rev. Drilling progress

Penetration of the drilling tool into the ground per revolution
Drilling drive working pressure

Shows the working pressure of the drilling drive in analog form.
Drilling drive speed*

Shows the torque of the drilling drive in analog form.
24.5 Drilling drive speed

Shows the speed of the drilling drive (e.g.: 24.5) in rpm.
Low torque
Low torque (high speed) of the drilling drive is selected with the
relevant button on the right joystick.
Maximum outreach
Shows when the maximum outreach of the lead has been reached.
The warning buzzer sounds. No functional shutdown takes place.
The "increase outreach" function is blocked.
Feed display
Shows the feed force in analog form.
- Pulling:
the bar "in the lead symbol" rises from bottom to top.
- Pressing:
the bar "in the lead symbol" goes from top to bottom.
- standstill
Display of the load on the slide.
Shows the feed force in digital form (e.g.: 127) in kN [lb].
Slow feed speed

Slow feed speed is selected.
Fast feed speed

Fast feed speed is selected via the relevant button on the right-
hand joystick.
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15.3 m Rope length metering feed

- shows the position and movement direction (+/-) of the slide
(e.g. 15.3 m),
- is used to determined height differences,
- can be reset to zero at any time with the appropriate
function key,
- should be set to zero immediately prior to activation
to enable an accurate measurement.
4.71 m/min Feed speed

The feed speed is displayed in m/min [ft/min].
Diesel engine speed

Indicates the current speed of the diesel engine in rpm .
If the speed is too high, the bar in the display flashes.
Auxiliary and Kelly winch load capacity display *

Shows the current load on the auxiliary winch in both analog and
digital form (e. g. 50) in kN [lbs] and on the the Kelly winch also in
analog and digital form (e. g. 300) in kN [lbs].
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Kelly drilling field with casing oscillator

- drilling mode and
- Kelly drilling
via the "Operating modes" function key symbol and
- the casing oscillator
is selected on the control panel right (X23).
Casing oscillator working pressure

Shows the working pressure of the casing oscillator in analog form.
Drilling free-wheel
Drilling free-wheel has been switched on.
IMPORTANT!
The other elements have already been described in the Kelly drilling field.
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CFA drilling display field
The CFA drilling field appears on the LCD screen if

- drilling mode and
- CFA drilling
Elements of the CFA drilling display field
Concrete pressure*
Shows the concrete pressure in analog form, if the optional
concrete pressure sensor is connected.
The display can be scaled if required (e.g.: 5-10 bar).
Concrete flow measurement*

Displays the concrete flow in m³ [yd³], provided that this option was
selected.
4.71 m/min Feed speed

The feed speed is displayed in m/min [ft/min].
-3.50 m PDE depth

The PDE depth is displayed if
- PDE recording was interrupted and
- the the crowd winch was moved
(e.g.: auger was extended).

IMPORTANT!
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FOW drilling display field,
The DOUBLE ROTARY drilling field appears on the LCD screen if

- drilling mode and
- DOUBLE ROTARY drilling
Elements of the FOW drilling display field
Drilling drive 1 working pressure

Shows the working pressure of drilling drive 1 in analog form.
24.5 Drilling drive 1 speed

Shows the speed of the drilling drive (e.g.: 24.5) in rpm, if the
optional tachometer is connected.
Drilling drive 2 working pressure

Shows the working pressure of drilling drive 2 in analog form.
17.3 Drilling drive 2 speed

Shows the speed of the drilling drive (e.g.: 17.3) in rpm, if the
optional tachometer is connected.

IMPORTANT!
The other elements are already described in the CFA drilling field.
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4. CONTROLS
Description of the function key symbols
Some function keys have several function key symbols assigned to them, which are displayed
according to which operation is currently being carried out. The following default function key
symbols are displayed when the mode screen is first opened.
"Select operating mode" symbol

This function key symbol is used to switch to the "Select operating mode" page.
"Power unit monitoring" symbol

This function key symbol is used to switch to the "Power unit monitoring" page 2.
This symbol flashes and the warning buzzer sounds if an error is reported on the
power unit page.
"Fault monitor" symbol

This function key symbol is used to switch to the "Fault monitor" page 4.
This symbol flashes and the warning buzzer sounds if an error is reported.
"Settings" symbol
This function key symbol is used to switch to the "Settings" page.
This symbol only appears when in assembly mode.
"Toggle function keys" symbol

By activating this function key symbol, other function key symbols appear accord-
ing to which operation is being carried out.
"Acknowledge warning buzzer" symbol

With this function key symbol the warning buzzer can be switched off.
The warning buzzer sounds whenever there is an error message.
NOTE!
Pressing this function key does not acknowledge or rectify the error.
"Reset feed" symbol

Pressing this function key symbol resets the "Rope length feed" display to "0".
"Reset Kelly winch" symbol

Pressing this function key symbol resets the "Kelly winch rope length" display to
"0".
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The following function key symbols only appear after pressing the "Switch function keys" function
key.
"Lead inclination setpoint" symbol

By pressing this function key symbol, the "Lead inclination setpoint" symbol starts
to flash, the actual inclination (digital and analog) is hidden and the current
setpoint value is shown instead. The new setpoint can be entered via the Litronic
service panel and confirmed by pressing "ENTER".
"Set inclinometer to zero" symbol

Pressing this function key causes the digital inclinometers in the display field to
start to flash. The inclinometer can now be set to zero by pressing "Confirm
input" function key.
"Confirm input" symbol.

By pressing this function key symbol, the digital and analog lead inclinometer
display is reset to zero.
The following function key symbols only appear after pressing the "Switch function keys" function key
twice.
"Kelly winch rope layer switch" symbol

This function key symbol selects the Kelly winch for programming of the rope
layer switch. The display (e.g. 11.5) starts to flash for 3 seconds.
"Set rope layer switch 1- 2" symbol

This function key symbol programs the rope layer switch for the selected winch
from the 1st to the 2nd rope layer (while the rope length display flashes).
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4.13 "Select operating mode" page

9
"Select operating mode" page
This screen page is used for selecting the operating mode.
The status displays are described in Chapter 4 under "Mode screen".

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Description of the control displays
"Working mode" display

Indicates that "Working mode" is selected. The additional control panel (X25) is
connected.
"CFA drilling" display

If you tap on the display shown, "CFA drilling" operating mode is selected on the
screen.
"FOW drilling" display

If you tap on the display shown, "Double-rotary drilling" operating mode is
selected on the screen.
"Soil mixing mode" display

If you tap on the display shown, "Soil mixing" operating mode is selected on the
screen.
"Kelly drilling" display

If you tap on the display shown, "Kelly drilling" operating mode is selected on the
screen.
NOTE!
When an item on the screen is selected, this can be seen by the way the border around the item
stands out.
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"Mode screen" symbol

This function key symbol is used to switch to the "Mode screen" page.
"Confirm input" symbol

Press the "Confirm input" function key symbol to accept the input.
"Switch off ignition" symbol

After this function key symbol has been activated, the illustrated symbol appears
on the screen.
See the description of how to select an operating mode in Chapter 5.
NOTE!
All the other function key symbols are described in Chapter 4 under "Mode screen".
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4.14 "Power unit monitoring" page

10
"Power unit monitoring" page
This screen page provides information on the operating status of the central power unit.
Description of the control displays
WARNING!
Ignoring a fault indication can seriously damage the machine. If a fault indication appears, the
diesel engine will not be stopped automatically.
Immediately a fault indication appears, safely shut down the machine so that the fault can be
rectified.
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"Power divider temperature too high" symbol

This symbol flashes if the gear oil temperature in the power divider reaches 105
°C .
"Coolant level too low" symbol

This symbol flashes if the coolant level in the cooling system's equalizing reser-
voir has fallen below the minimum. No precautionary shutdown occurs - the
machine operator is responsible for topping up the coolant.
CAUTION!
Risk of burns!
Let the engine cool down before refilling the coolant as explained in section 7
"Hydraulic oil level too low" symbol This symbol flashes when the hydraulic oil
level in the hydraulic level has fallen below the minimum. All machine move-
ments are stopped - the machine operator is responsible for topping up the
hydraulic oil immediately.
CAUTION!
Risk of burns!
Top up the hydraulic oil as explained in section 7.
Charge check display

Displays the current charge of the batteries.
"charging OFF" means that the batteries are not being charged; "charging ON"
means that the batteries are being charged by the alternator.
The current battery voltage is displayed below the battery symbol in V .
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Power unit display field
This field shows all the important data of the central

power unit in symbols and bars.
Symbols of the power unit display field
"Charge air pressure" symbol

Shows the current charge air pressure of the diesel engine in bar.
"Lubricating oil pressure" symbol

Shows the current lubricating oil pressure of the diesel engine in
bar.
"Diesel engine speed" display

Indicates the current speed of the diesel engine in rpm .
"Cooling water temperature" symbol

Indicates the current coolant temperature in the cooling system in
°C .
"Fuel level" symbol

Displays the current level of fuel in the fuel tank expressed as a %
of the maximum tank volume.
"Hydraulic oil temperature" symbol

Indicates the current hydraulic oil temperature in the hydraulic tank
in °C .
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NOTE!
All the other monitoring indicators are described in Chapter 4 under "Mode screen".

NOTE!
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4.15 Motor error message
4.15.1 Serious motor error message
WARNING!
Severe damage to the machine results when a serious motor error message is ignored. The
diesel motor is not automatically stopped when a motor error message appears.
Safely switch off the machine with the appearance of a serious motor error message.
With the appearance of a serious motor error message, the motor display flashes “Switch off
immediately” on the operating screen.
Motor display - Switch off immediately
As a result of the fault message, the speeds of these functions and movements are reduced to 50%:
- Lift lifting winches 1 + 2

- Lift feed
- Drilling drive
- Running gear
- Hammer
- Grabber
- Milling head
Course of action with the appearance of a serious motor error message:
• Discontinue dangerous movement.
• Place load on the ground.
• Switch off diesel motor.
• Determine cause of error and take corrective measures.
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Potential causes of error include:
- Coolant temperature > 104 °C

- Charge air temperature > 80 °C
- Fuel temperature > 90 °C
- Oil pressure safety curve fallen short of
- Coolant level too low
- Hydraulic oil level too low
- Water in the fuel
- Problem with the high pressure regulation
- Fuel pressure too low
- Fuel rail pressure too high
The cause of error appears either on the unit monitoring page or on the error display page.
NOTE!
If the cause of error cannot be determined and remedied, contact Liebherr customer service.
4.15.2 General motor error message
NOTE!
With the appearance of a general motor error message, carry out an error diagnosis and error
correction as soon as possible.
With the appearance of a general motor error message, the motor display flashes “General motor
error” on the operating screen.
Display - General motor error
The following measures should be taken immediately with the appearance of an error mes-
sage:
• Determine cause of error and take corrective measures.
Conduct an error diagnosis in the test system (see chapter: Litronic test sytem).
NOTE!
If the cause of error cannot be determined and remedied, contact Liebherr customer service.
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4.16 "Fault monitor" page

11
"Fault monitor" page
This page displays error messages in plain text in the appropriate language.
Example of an error message
"1/1 M0033: Force measuring axle 1 boom signal too low or absent"
A warning buzzer sounds if an error occurs.
The first number before the error message (1/1 M0033) is a consecutive number.
The second number (1/1 M0033) indicates how many errors are currently present.
The error number (1/1 M0033) defines the error and makes it easier to find.
Description of the symbols in the display area
"Error message acknowledged" symbol

This symbol appears beside the error text after the error message has been
acknowledged.
NOTE!
Before carrying out any further operation with the machine the cause(s) of the errors should be
remedied and the error messages acknowledged.
Acknowledging the error messages alone will not remedy the causes of the errors.
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"Up arrow" symbol

This symbol appears in the top right corner of the LCD display if there are
previous error messages or error pages.
"Down arrow" symbol

This symbol appears in the bottom right corner of the LCD display if there are
more error messages or error pages to follow.

"Power unit monitoring" symbol

This function key symbol is used to switch to the "Power unit monitoring" page.
This symbol starts flashing if an error is reported on the power unit page.
"One error message up" symbol

This function key symbol is used to move upwards to the next error report.
Symbol "One error message down"

This function key symbol is used to move downwards to the next error report.
"One page up" symbol

This function key symbol is used to move up one page.
This symbol only appears when there are at least two error pages. The Litronic
control system creates a new error page as soon as there are more than 5 error
messages.
"One page down" symbol

This function key symbol is used to move down one page.
This symbol only appears when there are at least two error pages.
"Acknowledge error message" symbol

This function key symbol acknowledges all error reports on the error page
displayed.
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NOTE!

NOTE!
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4.17 "Settings" page

12
"Settings" page
This screen page

- is used for entering the required values, depending on the operating mode,
- only appears when in assembly mode.
Description of the setting range

The values listed in this range

- can be adjusted by the driver,
- depending on the operating mode selected,
- have an accompanying comment in the relevant language*,
- should be entered in the selected units (SI or US).
NOTE!
The permissible limit values must not be exceeded. In the case of accessory units, specifications
from their manufacturers apply.
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NOTE!
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13
4.18 Litronic service panel on the LCD

screen
4.18.1 Menu bar
The menu bar (Figure 13, item 1) for the Litronic® ser-
vice panel is displayed following the start up screen on
the right hand side of the LCD screen.
The menu bar function symbols use Touch Screen func-

tionality to:
- switch to the Litronic® test system,
14
- switch to the keyboard menu (Figure 14, item 2),
- adjust the volume of the warning buzzer,
- adjust the brightness of the LCD screen.
Test system
Switch over to Litronic® test system.
Keyboard
Switches from the menu bar to the keyboard menu (Figure 14, item 2).
Increase volume
Adjusts the volume of the warning buzzer.
Decrease volume
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Increase brightness
With this button the LCD screen can be
- set to three different levels of brightness,
- switched to inverse display mode (for use at night).
Decrease brightness
15
4.18.2 Keyboard menu
The menu bar function symbols use Touch Screen func-

tionality to:
- adjust the volume of the warning buzzer,
- adjust the brightness of the LCD screen,
- switch to the Litronic® test system,
- switch to the menu bar,
- Enter setting and correction values for the

Litronic® control system.
CAUTION
Setting and correction values for the Litronic ®

control system should only be entered or adjusted
by authorized qualified personnel.
Minimise
Switches from keyboard menu to menu bar.
Numerical values
Enter numerical values.
Decimal point
Enter a decimal point.
P
This key is not used with this range of machines.
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Inverse
To change values from positive to negative and vice versa.
E
Enter exponents.
Example: To quickly enter the value "1000", the following key sequence can be
used: "1", "E", "3".
Increase brightness
Decrease brightness
Increase volume
Decrease volume
Correction values
Switches to the CORRECTION screen of the Litronic® test system.
Mode screen
Switches from the Litronic® test system to the most recent mode screen.
Test system
Switch over to Litronic® test system and also to the most recent mode screen.
Enter
Entered values are accepted by the Litronic® control system.
Cursor back
To correct an entered value in the selected (inverse) numeric field on the LCD
screen.
Cursor advance
The cursor on the LCD screen moves to the next numeric field.
Full Stop
Enters a full stop in the setting and correction values or switches to the LCD
screen test system.
NOTE
Entering an incorrect value can cause the LCD screen to fail.
Touch the "Exit" field in the menu bar to quit the test system.
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NOTES:
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5. OPERATION
5. OPERATION
5.1 General
This chapter explains how to operate the machine.
It guides you through the working procedures and describes the operational steps
- for daily use,
- for operating the main components such as the slewing gear, travel gear or lead,
- for drilling, vibrator and hammer mode with detailed information,
- for safely shutting down the machine.
5.1.1 Safe working with the machine

As the machine operator you are responsible for the safe operation of the machine.
Pay special attention to the following:
- The safety precautions in Chapter 3.
- Familiarize yourself with the layout of the controls before starting up the machine
(see Chapter 4).
- Take note of the information in this chapter and remember what you learnt on the
manufacturer's training course.
DANGER!
Operating errors can endanger human lives and severely damage or wreck the machine!
The machine is equipped with various safety devices to prevent dangerous operational conditions.
These safety devices cannot however prevent damage due to operating errors or negligent working
methods.
Precautions:
• Simultaneous lifting and slewing of the load at maximum speed is prohibited!
• Do not make any compromises regarding the stability of the machine. Never exceed the permitted
load. The ground must be able to withstand sufficient loads!
• Do not carry out any jerky movements with the machine; avoid any sudden acceleration or
braking.
• Start every movement from a rest position slowly and sensitively.
• Do not allow any dynamic effects, such as oscillation or jerky lifting and lowering of load.
• Always work with foresight and with a good overview: Allow plenty of time and space for braking a
movement.
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5.2 Checks before daily operation
CAUTION!
Never use a damaged machine!

All defects and errors found are to be reported at once to the appropriate superiors and rectified
promptly by a qualified engineer.
When there is a change in machine operator, the next operator should also be informed of any
defects or faults that do not directly jeopardize safe operation.
5.2.1 Tour of inspection

Before each daily start-up, a visual inspection of the machine must be carried out as follows:
• Check the basic machine and equipment to see whether
- there are any leaks (hydraulic, engine and transmission oil, coolant, diesel oil),
- there is any (deliberate) damage,
- all safety devices are in place,
- all bolts and screw fastenings are securely tightened,
- ropes do not show any sign of wear.
• Are there obstacles in the work area?
- Can the superstructure turn without being impeded?
- Are any overhead power lines within range of the lead?
• Are the safety signs complete and legible?
(See section 3.6 "Safety labels on the machine".)
5.2.2 Checks
IMPORTANT!
Pay attention to the following during the checks:
Level checking and refilling of fuels and lubricants are described in Chapter 7 "Maintenance"; the
required safety precautions are described in section 3.7.5 "Danger of fire and explosion".
• Open the cab door and the maintenance doors on the superstructure.
• Make sure there is a clear view from the cab:

- Clean the windshield and side windows.
- Clean the outside mirror and adjust it if necessary.
- If necessary, remove ice and snow from the cab and superstructure.
- Fill up the screen wash container; use a screen wash fluid containing anti-freeze in the winter
The anti-freeze must not be flammable
• Check that the load capacity charts needed for the current operation are kept in the cab.
• Check that both fire extinguishers
- are in position and ready for use,
- have undamaged seals,
- have not passed their inspection date.
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5. OPERATION
• Check engine oil level.

• Check gearbox oil level
• Check coolant level.
• Empty the water separator of the fuel system.
• Perform daily lubrication according to maintenance plan (see Chapter 7).
• Check hydraulic oil levels.
1
• The shut-off valve must be open (Figure 1, position 1;
parallel to the suction pipe).
CAUTION!
The hydraulic system will be destroyed if the diesel

engine is started with the shut-off valve closed (Fig-
ure 1, position 2, at right angles to the suction pipe).
• Check the battery main switch.

The main switch must be on; for an explanation see
Chapter 7.
• Unlock all emergency shut-down buttons by turning
them.
For layout and explanations see Chapter 4.
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5.3 Daily start up
DANGER!
Only use the machine if you are authorized to do so and have read and understood this
operating manual!
Prerequisites:
- Sufficient battery capacity to start the rope excavator.
- The "Checks before daily operation" described in section 5.2 must have been carried out.
- All emergency shutdown keys must be unlocked.
5.3.1 Switch on ignition

The ignition is switched on using the ignition switch
(Figure 2) on the right-hand control panel.
Possible switch positions:

P Parked position
0 Ignition Off
1 Ignition On
2 Start Position
• Turn the ignition switch to position 1 "Ignition on".
• First the start-up screen appears on the LCD screen.

The Litronic control system then performs an automatic self-test. This takes about 15 - 30
seconds.
• The start-up screen is then replaced by the mode screen (with the selected operating mode).
NOTE!
In the event of a fault
- the mode screen is not displayed
- instead, an error message from the Litronic test system appears on the LCD screen.
NOTE!
After switching the ignition off wait for at least 5 seconds before switching it back on. Otherwise error
messages may occur.
If the mode screen does not appear after several attempts to switch the ignition on, notify the
appropriate LIEBHERR customer service and provide details of the error message displayed.
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3
5.3.2 Checking the fuel level
The fuel level is displayed on the "Power unit monitor-
ing" screen.
As soon as the bar in the tank level indicator (Figure 3,
item 2) or the "Fuel level" (1) indicator on the mode
screen starts to flash, the tank is only approximately
15 % full of diesel (reserve indicator).
In this case, the machine must be refueled at the next
opportunity.
4
5.3.3 Refueling the machine
IMPORTANT!
Pay special attention to the safety notices in
- section 3.7.5 "Fire and explosion hazards",
- "Diesel fuels", Chapter 7.
Procedure for refueling with the refueling pump
The handling of the electric refueling pump* is described

in section 9.
Procedure for refueling from a tanker lorry
• Switch off the engine.

• Switch off cab heater.
• Switch off auxiliary heating*.
• Direct the tanker.
• Unscrew and remove the filler cap (Figure 4, item 1).
• Check that the filler sieve (2) under the cap cover is free of dirt, clean if required and replace.
NOTE!
The filler sieve must be in place while refueling!
• Fill tank with the appropriate diesel oil according to the season (summer or winter diesel);
see section 7.
• Close and lock filler cap after refueling.
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5.3.4 Selecting the operating mode
DANGER!
Fatally dangerous situations and severe damage to the machine can occur when operating
the machine, depending on the operating mode.
Precaution:
The machine operator must know exactly when to use these operating modes and be aware of their
special characteristics and dangers.
5
Operating note
• Activate the "Select operating mode" function key sym-
bol (Figure 5, item 1).
The "Select operating mode" page (Figure 6) is dis-
played.
6
• Tap on the required display, e.g.: "FOW drilling"
(Figure 6, item 1).
The border of the selected display appears bold.
The symbols are listed in Chapter 4 under "Selecting
operating mode".
7
• Press the "Select operating mode" button (Figure 7,
item 1) on the left-hand control panel (X12) and tap
simultaneously on the "Confirm input" symbol (Figure
6, item 2) on the screen.
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5. OPERATION
8
The "Switch off ignition" symbol (Figure 8, item 1)
flashes on the screen. All the machine's functions are
blocked.
9
• Turn ignition off, wait briefly, then turn ignition back on
again.
The required operating mode is selected.
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5. OPERATION
5.3.5 Starting the diesel engine
DANGER!
Do not use any starting aids containing ether when outdoor temperatures are low, in view of
the explosion hazard!
Prerequisites for starting the diesel engine
• All start up checks have been carried out.

• The ignition must be turned on. All emergency shutdown buttons are unlocked.
• The Litronic control system must be ready for operation. There must be no error messages.
• The mode screen must appear on the LCD screen.
• The "Fuel level indicator" must not be flashing; there must be sufficient fuel.
After switching on the ignition in cold temperatures, the diesel engine is automatically preheated by
the flame starting system and made ready to start.
The "Flame start cycle activated" symbol appears during the preheat period in the
status display of the mode screen.
The preheat period
- lasts longer when outside temperatures are low,
- is not required if the diesel engine is still warm enough following an interruption.
As soon as the diesel engine is ready to start, the "Ready to start" symbol
replaces the previous symbol.
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5. OPERATION
10
The diesel engine can now be started (Figure 10):
• Turn ignition key briefly to position 2 and release as
soon as the diesel engine is running.
• The ignition starter switch returns to position 1 (Igni-
tion on) of its own accord.
The "Ready to start" symbol disappears as soon as
the diesel engine is running.
IMPORTANT!
Do not keep the ignition starter switch in position 2 for
more than 10 seconds. Stop trying to start the engine
and wait for at least 20 seconds before making another
attempt.
The engine should be allowed a short warm-up period
before being subjected to full load!
IMPORTANT!
The voltage dip during the start procedure can cause
error messages. In this case, proceed as set out below:
Acknowledge any error messages that are shown by
pressing F8 on the screen.
11
5.3.6 Adjusting the engine speed
The speed of the diesel engine is adjusted using the
rocker switch (Figure 11, item 1) on the right-hand
joystick; this is a continuous adjustment from idle to
maximum rpm:
• Press rocker switch to the left = increase speed

• Press rocker switch to the right = decrease speed
Automatic idle
Without moving a joystick, the rpm set with the rocker
switch of the diesel engine only remains set for approx.

7 seconds . The speed is then reduced to idling. Mov-
ing a joystick causes the diesel engine to accelerate
back up to the previously set speed.
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5. OPERATION
Electronic load limit regulation

The electronic load limit regulator protects the diesel engine from possible overload and a sudden
standstill.
If, due to overload, the speed of the diesel engine falls below the defined current nominal speed, the
hydraulic flow rate of the pumps is reduced until the diesel engine reverts to the set speed.
Constant speed
A specific speed value can be selected from across the entire speed range and set permanently.
Procedure:
• Set the required speed with the rocker switch.
Use the "Constant gas programming" button on the right-hand control panel (X23)
to store the current speed of the diesel engine.
The LED in the button lights up.
Press the button again to delete the constant speed; the diesel engine then runs at idling speed.
NOTE!
The constant speed entered has to be at least 1400 rpm so that the diesel engine works effectively
and supports loads.
NOTE!
The Safety lever is to be lowered for operation and raised during breaks.
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5. OPERATION
5.3.7 Lower safety lever (access lever) 12
WARNING!
Personal injury and damages to the machine with

improper actuation of the operating elements!
Only actuate operating elements from the driver's seat.
Position seat in the operator’s cabin.

Lower safety lever (1).
After lowering the safety lever the operating elements in

the cabin are enabled.
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5. OPERATION
5.4 Machine operation - main functions

13
Control functions
The adhesive film shown above

- is affixed to the lower edge of the front windshield,
- contains information about joystick operation and the functions of the pedals.
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5. OPERATION
5.4.1 Checks/activities before starting work
CAUTION
Do not use the machine if errors and malfunctions occur that may impair work safety.
All defects and errors are to be reported to the relevant supervisor and rectified by a qualified
engineer.
The following checks/activities have to be performed before starting to use the machine:
• Check the displays for anything unusual.
• Check all controls and displays to ensure that the main functions of the machine are working
properly.
• Test all controls for the main functions of the machine (see Chapter 5):
- Adjusting the lead,
- Check the inclinometer,
- Operate the slewing gear and travel gear,
- Operate the winches and move towards the hoisting limit switches.
WARNING!
Danger of accidents and possible damage to the machine!

If there is no load on the hoisting rope, the winches must not be activated to unreel the rope!
Otherwise, the rope will be lifted off the winch, causing the 3-windings limit switch * and the
rope length metering * to malfunction!
Do not operate any unroped winches. The 3-windings limit switch will otherwise malfunction!
• Test all lighting and all signaling devices (see Chapter 5).
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5. OPERATION
5.4.2 Operating the travel gear
WARNING!
In travel mode the machine may topple over

- as a result of operating errors,
- if the permitted operating limits are exceeded.
The following points must therefore be observed:

• Travel is only permitted where the ground is firm and stable (see Chapter 3 under "Ground
conditions on the site").
• The ground conditions must be checked over the whole route.
• Pay attention to wind speeds. Do not travel ifs the wind speed exceeds 20 m/s [45 mph].
• Before traveling, lower the drilling unit as far as possible.
• Do not start moving in a jerky fashion.
• Do not travel with a swaying load.
• Adapt the speed of travel to the situation. Reduce the speed when negotiating slopes and humps
and when traveling with loads.
• Always drive with foresight!
• Always place the travel drives of the crawler carriers on the counterweight side in order to avoid
operator error in travel gear operation. The superstructure must be parallel to the undercarriage.
IMPORTANT!
With every travel movement the warning light on the cab roof flashes, optionally accompanied by a
warning sound.
Traveling with lowered lead

When traveling with the lead lowered, it is particularly important
- to check stability constantly,
- to pay attention to the slewing radius of the lead when turning with the travel gear.
Do not rotate the superstructure when the lead is lowered!
Traveling with raised lead (on even ground)

The lead
- must always be kept vertical (manually or using the automatic tower system),
- should be lowered to just above the ground.
Traveling with a load

The load
- must be lowered as far as possible.
Traveling with a load is only permitted
- on level, firm ground
- provided that the permitted values shown in the load capacity charts are not
exceeded (see Chapter 2 "Load capacity charts"),
- if the outreach is reduced accordingly.
Maximum traveling speed with load: 0.5 km/h
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5. OPERATION
14
Traveling on a slope with raised lead (Fig-
ure 14)
When traveling on a slope (across the incline)
- extend the track adjustment to the working track
(wide track),
- do not turn the machine with the travel gear,
- do not rotate the superstructure,
- do not negotiate inclines steeper than 5° across the
slope,
- always keep the lead vertical.
Traveling on inclines with raised lead (Fig-

ure 15)
When driving up or down inclines
- always position the lead so that it is facing up the hill,
- do not rotate the superstructure,
- check that the slewing gear brake is closed,
- do not negotiate inclines steeper than 10°,
- keep resetting the lead to the vertical position.
15
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5. OPERATION
16
Pedal control
The travel gear is proportionally controlled with the two
pedals in the cab:
• Push left pedal (Figure 16, item 1) forwards

= the left crawler carrier moves forwards.
• Push left pedal downwards (front of pedal swings up)
= the left crawler carrier moves backwards.
• Press right pedal (Figure 16, item 2) forwards = the
right crawler carrier moves forwards
• Push right pedal downwards = the right crawler carrier
moves backwards.
IMPORTANT!
The stated movement directions only apply if the travel
drives of the crawler carriers are on the counterweight
side.
17
Hand lever control
Special hand levers (Figure 17) can be screwed to the
foot pedals.
These hand levers allow travel movements to be con-
trolled extremely sensitively.
Operation is the same for pedals as for hand levers.
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5. OPERATION
Traveling straight ahead
CAUTION!
Before reversing, check the route for possible hazards.

Only reverse with the help of a signalman!
The signalman
- monitors areas that the crane operator cannot see,
- directs the machine operator over radio or with hand signals.
Traveling forwards
• Push both pedals forwards at the same time.
Traveling backwards
• Push both pedals downwards at the same time.
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5. OPERATION
18
Turning with travel gear
Moving left (Figure 18, Position A)

• Press the right pedal forwards.
Moving right (Figure 18, Position B)

• Press the left pedal forwards.
IMPORTANT!
Always turn with the largest possible radius.
Be kind to the travel gear: avoid small-radius turns or
reversing turns as far as possible.
19
Turning on the spot
Turning to the right (Figure 19, Position A)

• Press the left pedal forwards.
• At the same time press the right pedal downwards.
Turning to the left (Figure 19, Position B)

• Press the right pedal forwards.
• At the same time press the left pedal downwards.
IMPORTANT!
Be kind to the travel gear: Avoid turning on the spot
whenever possible.
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5. OPERATION
5.4.3 Activating the slewing gear
CAUTION!
Danger of toppling over!

Do not rotate the superstructure when the lead is lowered.
The slewing gear turns the superstructure of the machine from 0 - 360°.
An unlimited number of revolutions can be performed.
The speed setting must be adjusted and checked before the start of every slewing movement.
Setting the speed
WARNING!
There are three levels of slewing speed for the machine. If too high a slewing speed is
chosen, the machine may be damaged or topple over.
Precaution:
Before starting any slewing movement, the machine operator must check that the slewing speed
setting is appropriate.
Select one of the three following speeds for the slewing speed of the superstructure:
• Level 1 = 0 - 1 rpm
• Level 2 = 0 - 1.5 rpm
• Level 3 = 0 - 2 rpm
Speeds can be set using the "Slewing gear speed setting" selection button on the
right-hand control panel.
The "slewing gear speed" display shows the set slewing speed on the LCD
screen in the status display of the mode screen.
NOTE!
The slewing gear speed must be reduced in the case of

- gusting wind,
- loads close to the maximum permitted load.
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5. OPERATION
Checking the slewing range
WARNING!
Collision hazard! Rotating the superstructure can cause damage to the machine.
Position the erected lead so that the hydraulic jack cannot collide with the crawler carriers
when the superstructure is turned.
Pay attention to the auxiliary rope, the hose kit and any additional equipment.
Open/close slewing gear brake

The slewing gear brake
- fixes the position of the superstructure,
- is always closed when the machine is started up,
The slewing brake is opened or closed automatically.
IMPORTANT!
Operation of the slewing gear is blocked while
- the lead is being positioned with the joystick
(lead inclination, lead outreach, lead height adjustment, lead rotation)
- the lead support* is extended.
CAUTION!
When turning the superstructure on a slope, always keep the lead vertical (manually or using
the automatic tower system).
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5. OPERATION
Slewing the superstructure
WARNING!
Before making any rotary movements of the superstructure, the machine operator must
personally satisfy himself that no people or obstacles are situated in the danger zone!
The machine may be damaged by abrupt acceleration and braking of superstructure turning
movements. Therefore every slewing movement must be started and braked in a sensitive
fashion.
Maximum slewing speed with load: 1 rpm.
20
The superstructure is rotated progressively to left or right
with the left joystick (Figure 20, item 1):
• Move the joystick to the left = superstructure rotates to
the left (counter- clockwise)
• Joystick in neutral = superstructure remains in posi-
tion, slewing gear brake is closed/closing
• Move the joystick to the right = superstructure rotates
to the right (clockwise)
IMPORTANT!
With every rotary movement of the superstructure, the warning light on the cab roof flashes,
optionally accompanied by a warning sound.
The slewing speed of the superstructure

- depends on the selected speed level,
- is proportional to the joystick position:
• Move the joystick further in the direction of rotation = superstructure rotates more quickly (slewing
gear accelerates)
• Joystick in the neutral position = superstructure is braked and the slewing brake closes
• Move joystick beyond the neutral position opposite to the direction of rotation = superstructure is
braked and accelerated in the opposite direction
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5. OPERATION
21
5.4.4 Positioning the lead with the additional con-
trol panel (X25)
General
Basically, the lead can be positioned using
- the additional control panel (X25) or
- the left and right joysticks.
The cylinder adjustment functions are selected with
preselect keys on the additional control panel (X25), and
then actuated using the corresponding direction keys.
The LEDs in the corresponding direction keys only light
up when a cylinder adjustment function has been se-
lected and the direction has been enabled.
When adjusting using direction keys, as opposed to
adjusting by joystick, the speed is automatically reduced
by up to 50%.
The arrangement is as follows: Allocation of direction keys:

The additional control panel (X25) is notionally divided into two halves. The cylinders whose selection
buttons are arranged on the left side are adjusted using the left direction keys (key T1 and key T17).
The cylinders whose selection buttons are arranged on the right side are adjusted using the right
direction keys (key T8 and key T24).
Operating cylinder adjustment functions simultaneously:

Thanks to the notional division of the additional control panel into two halves, a function of the left
half can always be actuated with a function of the right half. Keys T5 and T14 are assigned to the
right half.
It is always possible to preselect the cylinder functions for positioning the lead, provided that the
automatic tower system has not been preselected.
Lead positioning (apart from lead height adjustment) is blocked if the optional lead foot cylinder is
extended.
WARNING!
• Pay attention to movement restrictions!

These depend on
- the outreach of the lead,
- the attached working unit.
• Do not fasten a rope winch to the basic machine!
Serious accidents may otherwise occur when positioning the lead.
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5. OPERATION
22
Inclining the lead
The lead is inclined by operating the holding arm support
cylinder to left and right (Z2L and Z2R) in the Y direction
(forwards/backwards) and the X direction (across).
Prerequisite: The limit switches for left or right lead
inclination must not have tripped.
• Lead support cylinder, left (Z2L)
"Lead support cylinder left" selection button

For selecting the lead support cylinder (Z2L).
"Raise/Right" key
Extend lead support cylinder left The lead is inclined forwards to the right.
"Lower/Left" key
Retract lead support cylinder left. The lead is inclined backwards to the left.
• Lead support cylinder, right (Z2R)
"Lead support cylinder right" selection button

For selecting the lead support cylinder (Z2R).
"Lift/Open" button
Extend lead support cylinder right. The lead is inclined forwards to the left.
Retract lead support cylinder right. The lead is inclined backwards to the right.
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5. OPERATION
23
Adjusting the lead outreach
With the lead in a vertical position, it is possible to work
with different lead extensions. The extension of the lead
is adjusted by operating the base arm positioning cyl-
inder (Z4).
• Base arm adjustment cylinder (Z4)
"Base arm positioning" selection button

To select the base arm adjustment cylinder (Z4).
"Lift/Open" button
To retract the base arm adjustment cylinder. The outreach is increased.
Prerequisite: The limit switch for maximum outreach must not have tripped.
To extend the base arm positioning cylinder. The outreach is reduced.
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5. OPERATION
24
Positioning the lead foot*
The lead foot plate can be adjusted by operating the
lead foot cylinder (Z8).
"Lead support" selection button

For selecting the lead foot cylinder.
"Lift/Open" button
Retract the lead foot cylinder.
Extend the lead foot cylinder.
NOTE!
When the lead foot cylinder is extended, the following functions are blocked:
- the slewing gear,
- the travel gear,
- Positioning the lead
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5. OPERATION
5.4.5 Adjusting the lead with the joystick

General
Basically, the lead can be adjusted using the additional control panel (X25) or using the left and right
joysticks.
The cylinder adjustment functions are selected by operating the corresponding key (on the joystick)
and moving the joystick.
The selection of a cylinder is automatically indicated on the additional control panel (X25) (LED lights
up). Operation of the cylinder (moving of the joystick) is signaled by flashing of the LED of the
corresponding direction key.
When the key is released or the joystick returned to its neutral position, the cylinder is no longer
selected.
NOTE!
The same safety instructions apply as for adjustment using the additional control panel (X25).
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5. OPERATION
25
Inclining the lead (forwards/backwards and
across)
Pressing the button (Figure 25, item 1) on the left
joystick and moving the left joystick forwards/backwards
and left/right causes the lead to lean in the correspond-
ing direction.
Procedure:
Press the button (Figure 25item 1) on the left joystick and:
• Joystick in neutral = lead remains in position
• Move joystick to the left = lead leans to the left
• Move joystick to the right = lead leans to the right
• Move joystick forwards = lead leans forwards
• Move joystick backwards = lead leans backwards
IMPORTANT!
When the lead is adjusted with the joystick along the Y axis (forwards/backwards) only, the X
inclination remains constant.
Prerequisites:
- no other cylinder adjustment via the joystick must be active.
- the lead support cylinders (Z2L, Z2R) must not be shut down.
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5. OPERATION
26
Lead outreach
joystick and moving the left joystick forwards/backwards
adjusts the outreach of the lead. The current inclination
of the lead is maintained.
Procedure:
• Joystick in neutral = lead remains in position
• Move joystick forwards = increase lead outreach
• Move joystick backwards = reduce lead outreach
Prerequisites:
- no other cylinder adjustment via the joystick must be active.
- the base arm positioning cylinder (Z4) must not be shut down
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5. OPERATION
27
Positioning the lead foot (lead support) *
joystick and moving the left joystick left/right extends or
retracts the lead foot cylinder.
Procedure:
• Joystick in neutral = lead foot cylinder remains in position
• Move joystick to the left = retract lead foot cylinder
• Move joystick to the right = extend lead foot cylinder
Prerequisites:
- no other cylinder adjustment via the joystick must be active,
- the lead foot cylinder must not be shut down.
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5. OPERATION
28
5.4.6 Lead inclinometer
An inclination sensor is fitted to the lead to measure
longitudinal and transverse inclination.
The display field on the LCD screen shows
longitudinally (Y direction): a range of +10/-20° in analog
form and a range of +/- 45° in digital form
and
transversely (X direction): a range of +/-10° in analog
form and a range of +/-9.9° in digital form
If a value is above or below the range, "?.?" appears in
the corresponding numeric field.
• Setting the lead inclinometer to 0°

The inclinometer can be set to "ZERO" via the controller. The lead must be as vertical as possible
(X and Y direction) when this is done.

Press the "Switch function keys" function key symbol.
"Set inclinometer to zero" symbol

Pressing the "Set inclinometer to zero" function key symbol causes the digital
inclinometers in the display field to start to flash.
"Confirm input" symbol

Pressing the "Confirm input" function key symbol resets the inclinometers to zero.
The function key symbol must be pressed within 5 seconds.
The digital and analog inclinometer should read zero if this has been successful.
IMPORTANT!
If data are entered incorrectly or too late, then the old value will be retained.
The settings mode can be quit by pressing the "Switch function keys" function key symbol.
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5. OPERATION
29
5.4.7 Automatic tower system
The automatic tower system sets the lead to the preset
inclination (a programmed setpoint value).
• Entering the lead inclination setpoint

The setpoint is shown in the display field of the screen by the Symbol " " (Figure 29, item 1) and
+
the actual value by the " " symbol ( 2).
The actual value appears in digital form in the numeric fields to the right of and below the display
field (3)
Procedure:

Activate the "Switch function keys" function key symbol.
"Lead inclination setpoint" symbol

When this function key symbol is pressed, the "Lead inclination setpoint" symbol
starts to flash, the actual inclination (digital and analog) is hidden and the current
setpoint value is shown instead.
"Cursor advance" button

Select the setpoint value to be changed by pressing the "Cursor advance" button
on the Litronic service panel (the numeric field selected is displayed inverted).
"Cursor back" button

A value that has been entered can be corrected by pressing the "Cursor back"
button on the Litronic service panel.
Enter the setpoint value using the keypad on the Litronic service panel.
Limit values
left/right: maximum 5°/5°
forwards/backwards: maximum 10°/20°
"Enter" key
The values are not accepted by the control system until you press "Enter".
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5. OPERATION
IMPORTANT!
If incorrect data are entered, then the old value will be retained.
The settings mode can be quit by pressing the "Switch function keys" function key symbol. and
re-displaying the actual lead inclination values.
30
• Actuate automatic tower system
When you press the button (Figure 30, item 1), the lead
support cylinders automatically move the lead to the
preset inclination.
It is adjusted in the X and Y directions simultaneously.
IMPORTANT!
The automatic tower system can also be operated during
traveling and slewing operations. It works provided the
lead inclination is less than -30°.
Prerequisites:
- Assembly mode must not be activated,
- no other cylinder adjustment via the joystick must be active,
- the lead support cylinders must not be shut off and
- the inclination sensor must not exhibit any sensor error.
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5. OPERATION
31
5.4.8 Second tower system
The second tower system adjusts the leader to a preset
angle (a second programmable target value).
Input the target value of the second leader angle

The target value is shown in analogue in the display field on the screen by the Symbol " " (Fig. 31,
+
No. 1) and the actual value is shown with the symbol " " ( 2).
The target value is digitally displayed in the numeral fields on the right and below the display field
(3).
Procedure:
Activate the function key symbol switch function key.
Activate the function key symbol second target value leader angle.
Adjust the leader angle to the second target value using the joystick in accor-
dance with the "Adjusting the lead with the joystick" chapter.
Actuate the function key symbol to confirm the input. This confirms the second
target value setting.
32
• Drive to the second target value

In order to drive to the second target value, actuate the
buttons (Fig. 32, No. 1) until the actual value is identical
to the second target value.
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5. OPERATION
33
5.4.9 Operating the auxiliary winch*
Selecting the auxiliary winch
Selection of the auxiliary winch is only necessary in
drilling mode, as the same joystick is used for the drilling
drive.
It can be selected by pressing
• the selection button (Figure 33, item 2) on the addi-
tional control panel (X25),
• the button (Figure 33, item 1) on the right joystick.
It can only be selected with the drilling gear at a stand-
still.
Display: The LED in the selection button lights up.
WARNING!
The auxiliary hoist rope is pulled up independently with no load (or a load less than 50kg) if
the auxiliary hook has been moved to above the level of the hook fixing point. Lifting without
loads (or with loads smaller than 50kg) is not permitted!
When not using the auxiliary winch, the auxiliary hook is always to be hung at the hook fixing
point.
In double-rotary drilling mode the selection button (Figure 33, item 2) can also be used to switch to
the Kelly winch.
Selection button (Figure 33, item 2) activated (LED illuminated): Kelly winch active
Selection button (Figure 33, item 2) not activated (LED illuminated): Pipe active
DANGER!
As the load is being lowered, the rope can be pulled out of the rope fixation on the winch!
It is a mandatory requirement that at least three so-called safety windings remain on the winch.
The length of rope needed for this purpose depends on the lead configuration and type of use.
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5. OPERATION
34
WARNING!
Danger of accidents and possible damage to the

machine!
The 3-windings limit switch* will behave unexpect-
edly in the event that
- the auxiliary winch is turned with no rope on it.
- the hoisting rope continues to unwind, even
though the load hook is already lying on the ground
(loose, irregular rope winding on the winch).
Operating the auxiliary winch

The auxiliary winch is adjusted in direct proportion to movement of the right- hand joystick (Figure 34,
item 1) from the rest position up to maximum speed.
• Move the joystick to the left = raise auxiliary winch
• Joystick in neutral = auxiliary winch remains in position
• Move joystick to the right = lower auxiliary winch
The adjustment range of the auxiliary winch is limited by the hoisting limit switch and the 3-windings
limit switch*.
Movement limits of the auxiliary winch
As soon as the load hook triggers the hoisting limit switch when being lifted by
the auxiliary winch, the "Upper limit switch auxiliary winch" symbol in the status
display of the mode screen starts to flash.
The lifting direction of the load hook is blocked.
On lowering the load hook, as soon as the end of the hoisting rope is reached on
the auxiliary winch (3 safety windings), the "Lower limit switch auxiliary winch"
symbol in the status display of the mode screen starts to flash.
The lowering direction of the load hook is blocked.
NOTE!
No diagonal pull is allowed with the auxiliary winch (via the auxiliary jib)!
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35
5.4.10 Actuating the Kelly winch*
DANGER!
As the load is being lowered, the rope can be pulled

out of the rope fixation on the winch!
It is a mandatory requirement that at least three so-
called safety windings remain on the winch.
The length of rope needed for this purpose depends on
the lead configuration and type of use.
WARNING!
Danger of accidents and possible damage to the machine!

The 3-windings limit switch* and the optional rope length metering will behave unexpectedly if
- the Kelly winch is turned with no rope on it.
- the hoisting rope continues to unwind, even though the load hook is already lying on the
ground (loose, irregular rope winding on the winch).
Actuating the Kelly winch

The Kelly winch is adjusted in direct proportion to the movement of the left joystick (Figure 35, item
1) from the rest position up to maximum speed.
• Move the joystick back = raise Kelly winch
• Joystick in neutral = Kelly winch remains in position
• Move joystick forwards = lower Kelly winch
The adjustment range of the Kelly winch is limited by the hoisting limit switch and the 3-windings limit
switch*.
Movement limits of the Kelly winch
As soon as the load hook triggers the hoisting limit switch when being lifted by
the Kelly winch, the "Upper limit switch, Kelly winch" symbol in the status display
of the mode screen starts to flash.
The lifting direction of the load hook (of the Kelly bar) is blocked.
On lowering the load hook (Kelly bar) on the Kelly winch, the "Lower limit switch,
Kelly winch" symbol in the status display of the mode screen starts to flash as
soon as the end of the hoisting rope is reached (3 safety windings).
The lowering direction of the load hook is blocked.
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5. OPERATION
5.4.11 Kelly winch rope length metering*

11.5 m "Kelly winch rope length metering" display (in the Kelly drilling display field)
• Zeroing display
After pressing the "Switch function keys" function key symbol, special function key symbols for
resetting the displayed rope lengths are shown.
Resetting to the indicated value "0"
- can be done at any time,
- is used to determine differences in height (depths), which can be done in two different ways:
Symbol "Reset Kellywinde"

By activating F4 the "rope length metering" display is resetted.
By activating this symbol on the monitor PDE, the display "kelly winch cable
length" is reset to "0".
36
• By pressing the click button (figure 36, no. 1) on the
left control lever, the display "kelly winch cable length"
is reset to "0".
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5. OPERATION
NOTE!
To display the rope length exactly, a rope layer switch and the reeving must be programmed for the
Kelly winch.
Programming rope length metering
• Programming the reeving

As the Kelly rope can be reeved, the reeving must be defined so that the rope length can be
calculated.
Procedure:
"Assembly mode" selection button

To select assembly mode.
"Settings" symbol
The "Settings" function key symbol is used to switch to the "Settings" page.
999 Flow rate [in l/min]

999 Pile diameter [cm]
999 Max. pressure [bar]

9 Main winch reeving
9 Number of pumps
99 Concrete pressure sensor measuring range [bar]

99 Concrete pressure display scaling [bar]
99 Quantity of concrete/pulse [l/pulse]
"Settings" page
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5. OPERATION

Select the flow rate by pressing the "Cursor advance" button on the Litronic
service panel (the numeric field selected is displayed inverted).

"Enter" key
NOTE!
Switch off assembly mode. You exit setting mode.

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5. OPERATION
• Programming rope layer

As the Kelly rope can also be operated on a multi-layered basis, the rope layer switch must be
defined so that the rope length can be calculated.
The rope layer switch
- is already programmed upon delivery of the machine,
- normally only has to be reprogrammed after a rope change or winch repair.
After twice pressing the "Switch function keys" function key symbol, special function key symbols for
programming the rope layer switch are shown.
Description of the function key symbols for programming the rope layer switch
"Set rope layer switch 1-2" symbol

Use the "Set rope layer switch 1-2" function key symbol to program the rope
layer switch for the selected winch from the 1st to the 2nd rope layer.
"Kelly winch rope layer switch" symbol

The "Kelly winch rope level switch" function key symbol selects the Kelly winch
for programming of the rope layer switch.
Procedure
• Press "Switch function keys" function key symbol twice.
• Actuate the Kelly winch.
An assistant watches the Kelly winch and tells the machine operator as soon as a rope layer switch
from the first to the second layer occurs.
• Stop the Kelly winch at the precise moment that the rope switches from the first to the second
layer. If a rope layer switch is not reached because of the rope length, raise the load hook to the
highest point.
• Press the "Kelly winch rope layer switch" function key symbol.
The corresponding rope length display in the mode screen starts to flash.
NOTE!
The preselection only remains active for 3 seconds 5 seconds after pressing the appropriate
function key. The rope layer switch must be programmed during this time.
• Press the "Set rope layer switch 1-2" function key symbol for the current rope layer switch.
The Litronic control system
- then determines the point of transition to the next rope layer,
- calculates all further rope layer switches,
- shows the rope length for the first layer, minus three safety windings, on the LCD screen,
- can now display the current rope length exactly.
NOTE!
Only one rope layer switch has to be programmed for each winch.
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5.4.12 Kelly-winch free-wheel*

General
The optional Kelly winch free-wheel retracts the Kelly rope automatically without allowing slack to
form.
The electrical pedal in the cab is used to brake the load (Kelly bar or auger) in a controlled manner.
The Kelly bar can also be lowered into the bore hole during free-wheel.
WARNING!
Operating errors can damage the machine and the drilling tool.
The pedal can be used to control free-wheel between minimum and maximum speed. In
addition, the load cannot be brought to a complete standstill when the pedal is fully
depressed.
Kelly winch free-wheel
- may only be enabled if a sufficient load (Kelly bar) is fastened to the rope.
- may only be enabled if the load is below ground.
- may be operated before the drilling drive is switched on
Free-wheel operation must therefore only be used by experienced and specially- trained operators.
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37
Switching on free-wheel
• Press the button on the left-hand joystick (Figure 37,
item 1) and keep it pressed.
• Push the brake pedal of the Kelly winch free-wheel
(Figure 38, item 1) down completely.
IMPORTANT!
Before operating the brake pedal, press the button to
prevent accidental enabling of free-wheel.
38
After pressing the pedal the following symbol appears on the LCD screen:
"Winch 2 free-wheel" symbol
• Lower load in free-wheel: Release pedal in a controlled manner

• Braking the load free-wheel: Press down the pedal carefully and sensitively.
• Lift the load again: Activate appropriate joystick. The pedal can be released. The pedal can remain
pressed while the load is being raised.
Free-wheel is turned off by activating the joystick (lifting direction).
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39
If the free-wheel is frequently used, it can also be used
in a self-locking capacity, i.e. the key (Figure 37, item 1)
does not have to be activated each time.
Switching on self-locking free-wheel*

• Switch on free wheel, as described above, and press
the "Self-locking free-wheel" key (Figure 39, item 1) on
the right-hand joystick (X23) so that the LED illumi-
nates.
After pressing the "Self-locking free-wheel" key, the fol-

lowing symbol appears on the LCD screen:
"Self-locking free-wheel" symbol
Switching off free-wheel / self-locking free-wheel
Before leaving the cab, the machine operator must check that the free-wheel function has been
switched off correctly.
Free-wheel is canceled automatically when
• the left-hand joystick (Figure 39) is moved (only backwards) or
• when the button on the left-hand joystick is pressed (Figure 39, no. 1).
Self-locking is not canceled.
The symbol in the status display on the LCD monitor goes out when the control
system has deactivated the free-wheel.
In self-locking free-wheel, this symbol goes out in the status display of the LCD
screen.
• Raise the safety lever
After cancellation, the free-wheel can be reactivated if self-locking is activated by fully pressing the
pedal.
Self- locking free-wheel is canceled by pressing

• the "Self-locking free-wheel key" (Figure 38). The LED goes out
WARNING!
Raising the safety lever is not the correct way to switch off free-fall; it is simply a safety
precaution.
NOTE!
The free-wheel is switched off automatically once the diesel engine is switched off.
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40
5.4.13 Feed operation
Feed operation (slow speed)
The feed cylinder is adjusted in direct proportion to
movement of the right-hand joystick (Figure 40, item 1)
from the rest position up to maximum speed.
• Move joystick forwards = lower universal slide
• Joystick in neutral = slide remains in position
• Move the joystick back = raise universal slide
41
Activating feed (fast speed)
To switch the feed speed from slow to fast
• press the latch button (Figure 41, item 1) on the right
joystick.
IMPORTANT!
If a selected switching threshold is exceeded the feed
automatically switches to slow.
This symbol appears in the display field on the LCD screen as soon as slow
speed is selected for the feed.
This symbol appears in the display field on the LCD screen as soon as high
speed is selected for the feed.
NOTE!
It is always possible to switch the feed speed from fast to slow.
If the control switches back to slow speed, fast speed is blocked until free running is selected again.
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42
Limiting the maximum feed speed
The maximum feed speed can be limited by the poten-
tiometer (Figure 42) on the additional control panel
(X25).
Movement limits of the universal slide
As soon as the universal slide trips the upper limit switch on being raised, the
universal slide is blocked in the lifting direction.
As soon as the universal slide trips the lower limit switch on being lowered, the
universal slide is blocked in the lowering direction.
43
Storing the feed movement
The feed movement can be stored.
Procedure:
- Move the joystick
- Press button (Figure 43, item 1) on the right-hand
joystick.
- put the joystick back to the neutral position
The universal slide rises or falls by itself.
The stored feed speed can be limited by the potentiom-
eter (Figure 42) on the additional control panel (X25).
The "movement stored" symbol appears on the LCD screen.
Deleting stored value:

move the right joystick
If several movements are stored, all the others will be deleted as well.
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44
Feed display
The feed force is shown in the display field on the LCD
screen in both analog (Figure 44, item 1) and digital (2)
form.
45
Contact pressure control
The potentiometer (Figure 45, item 1) on the additional
control panel (X25) can be used to regulate the contact
pressure during feed lowering.
• Turn the potentiometer clockwise = increase the con-
tact pressure
• Turn the potentiometer counter-clockwise = reduce the
contact pressure
If the potentiometer is engaged, the LED in the preset
display lights up.
IMPORTANT!
The "drilling ABS" is described in Chapter 5 under "Drill-
ing mode".
"Reset feed" symbol

Pressing the "Reset feed" function key symbol resets the "Feed rope length"
display to "0".
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46
5.4.14 Parallel operation *
General
In parallel operation the rope of winch 2 (Figure 46, item
1) is secured to the front of the drilling drive (3) via the
pulling device (2). Winch 2 runs in parallel with the feed
system.
The pulling device is described in chapter 9 "Options".
Parallel operation is used to

- increase the tensile force in the feed system during hoisting,
- achieve a uniform distribution of the weight of the drilling drive, relieving the load
on the guides.
Reeving the rope

Reeve the rope of winch 2 around the kelly jib correctly as described in Chapter 8 "Changing kelly
ropes" and secure it to the drilling drive.
WARNING!
The machine can be severely damaged!

When the rope is secured to the drilling drive
- winch 2 must not be actuated again,
- parallel operation must be switched on.
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Switching on parallel operation

• Select parallel operation on the auxiliary panel (X25).
"Parallel operation winch 2" pre-selection key

Press this key to select parallel operation. The LED in the pre-selection key
flashes when the following conditions are met:
- mounting mode is not selected
- no mooring is selected
- all joysticks are in the neutral position
NOTE!
The pre-selection "Parallel operation winch 2" remains also after shutting down the machine and
starting it up again.
47
• Switch on free-wheel
For safety reasons free-wheel must now be switched
on.
Procedure:
Press and hold down the button on the left-hand joystick
(Figure 47, item 1) and fully depress the pedal for the
free-wheel on winch 2 (Figure 48, item 1).
See "Kelly-winch free-wheel" in Chapter 5
IMPORTANT!
Parallel operation is only selected when the LED in the
"Parallel operation winch 2" pre-selection key lights up.
48
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Functions in parallel operation

Raising the feed
If the feed winch is being raised, winch 2 turns at the preset pressure in the lifting direction.
The pressure of winch 2 is controlled according to the feed winch (or the load on the feed winch).
To prevent the feed winch from being loaded, the moment on winch 2 must not exceed that on the
feed winch.
Service personnel can set a particular basic tension and the maximum tension. If both are set to
the same value, winch 2 always pulls with the same preset force, regardless of the load on the
feed winch.
Lowering the feed
If the joystick is in neutral or the feed winch is lowering, the clutch on winch 2 is opened.
Constant tension can be adjusted with the handwheel in the cab (Figure 48, item 2).
Adjusting the lead
When the lead is being adjusted winch 2 is steered with the preset basic tension in the lifting
direction. This prevents the rope from slackening at winch 2.
Switching off parallel operation
"Parallel operation winch 2" pre-selection key

Parallel operation can be switched off by pressing the pre-selection key on the
auxiliary panel (X25) again. The LED in the pre-selection key goes out.
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5.5 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
interfaces (Litronic® monitor, Service Notebook, Modem* etc.).
5.5.1 Properties
The Litronic® test system provides the following functions:
• It displays the identification number and version of the installed software
• It displays all in/outputs of the modules with comments
• It displays the internal memory variables with comments
• It displays a selection list
• It displays the correction values (machine setting values)
• It displays messages (message stack)
• It displays special functions:
- Modem configuration*
- Memory card control (CF)
- CAN configuration/status
5.5.2 General
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
program 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.
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5.5.3 Starting the Litronic® test system

The Litronic® test system is started by pressing this key on the Litronic® service
panel. It can be started at any time while the ignition is switched on and also
during operation.
• The Litronic® test system main menu (figure 49) appears on the LCD screen.
49
1 Header line: Description of the page cur- 3 Input line: Displays the values entered,
rently showing with the option of making corrections, dis-
plays status messages and prompts to
enter data
2 Main section: Contains the actual data 4 Menu bar: Changing configuration of the
eight function symbols
DANGER !
While the Litronic® test system is in operation, fault messages from the Litronic® control do
not display!
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5.5.4 The menus

The description of the menu bars below always covers all the function symbols concerned.
5.5.5 Main menu

From this menu it is possible to go to the various other menus, or end the Litronic® test system and
go back to the operating screen by pressing the BACK function symbol.
The following menus are subsidiary to the main menu:
• INPUT/OUTPUT
• MEMORY
• SELECT
• MESSAGES
• CORRECTION
• SPECIAL
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5.5.6 INPUT/OUTPUT menu

This menu is used to view all the in/outputs of the modules.
Description of the function symbols

• NEXT CAN LINE switches to the next CAN line.
• PREVIOUS MODULE and NEXT MODULE switch between the modules on the selected CAN line.
• PREVIOUS and NEXT move the cursor up and down in order to mark a channel in the selected
module. The marked channel is displayed by an I or O shown in inverted display.
• You can accept the channel you have marked into the select list by pressing SELECT. If it has
already been selected, it is deleted from the list. You can see whether a channel is selected by the
inverse display format of its designation.
• MENU 1/2 switches between the two menu bars.
• DOCUMENT displays 16 channels (in/outputs), with comments, on one page. On digital modules
(32 channels) you can switch to the second page by pressing PREVIOUS and NEXT.
• UNDOCUM displays all in/outputs on one page.
• IDENTIFY displays 16 in/outputs on one page with the identifier on one page. On digital modules
(32 channels) you can switch to the second page by pressing PREVIOUS and NEXT.
• BACK goes back to the main menu.
5.5.7 MEMORY menu

This menu displays the reference memory (flag) used internally.

• NEXT SECTION switches between the 16 flag sections: X-B-W-D, 1-2-3-4.
• PREVIOUS PAGE and NEXT PAGE switch between the pages. Each page contains 16 flags from
the selected section.
• PREVIOUS and NEXT switch between the flags. The marked flags are displayed by an M in
inverse display format.
• You can accept the flag you have marked into the select list by pressing SELECT. If it has already
been selected, it is deleted from the list. You can see whether a flag is selected by the inverse
display format of its designation.
• DOCUMENT displays the flags with comments.
• IDENTIFY displays the flags with the identifier.
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5.5.8 SELECT menu

You can enter values into the select list so that you do not need to be constantly switching between
the pages of the in/output and flag menus. You can then view and work on these entries together on
the SELECT menu. The select list can consist of several pages.
Should you add a new value to a full select list, the oldest value is dropped from the list.
These select lists can also be saved to the memory card, and reloaded from it.
Options for making entries in the select list

• using the SELECT function symbol directly on the INPUT/OUTPUT, MEMORY or CORRECTION
menu (gathering the entries)
• using the ADD function symbol on the SELECT menu by entering the IEC address
• load from a file using the LOAD FROM CARD function symbol on the SELECT menu
Options for deleting entries on the select list

• using the SELECT function symbol directly on the INPUT/OUTPUT, MEMORY or CORRECTION
menu to reselect a selected value
• using the DELETE function symbol on the SELECT menu to delete the marked entry

• ADD inserts a new entry onto the select list. A menu bar appears for you to enter the IEC address
(see "Add Selection menu").
• DELETE to delete the marked entry from the list.
• PREVIOUS and NEXT switch between the various entries on the select menu. The marked entry
is displayed by an I, O or M shown in inverted display format.
• NEXT PAGE switches to the next page of the select list, in order to examine more values.
• IDENTIFY displays the in/outputs or flags with the identifier.
• DOCUMENT displays the in/outputs or flags with comments.
• LOAD FROM CARD loads a new select list from a file. A menu appears for you to select from a
list of files, or to enter the name of a file (see "Select File Load menu").
• SAVE TO CARD saves the current select list in a file. As you do so a menu appears for you to
select the name of a file (see "Select File Save menu").
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Add Selection menu
This menu is called by pressing the ADD function symbol from the SELECT menu. You can use it to
enter the IEC address of a new select entry. The IEC address is entered into the input line by means
of the corresponding function symbols and the number keys on the Litronic® service panel.
Example:
• Required IEC address: %QW1.17.1.
• Enter %, Q and W using the corresponding function symbols.
• 1.17.1 is entered as normal numbers, and can be corrected accordingly, accept the address using
the TAKE & BACK function symbol.

• You can select the IEC type flag, input or output using M, I or Q. This is changed each time it is
activated and appears in the input line. It is corrected by pressing again a different type.
• You can select the size of the IEC entry using X, B, W and D. This is changed each time it is
activated and appears in the input line. It is corrected by pressing again a different size.
• TAKE & BACK switches back to the SELECT menu and as it does so the IEC address is
accepted from the input line.
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5. OPERATION
Select File Load menu
This enables you to load a saved select list from the memory card.

• CHARACTER NEXT inserts a new character at the end of the input line. You can also create new
characters by entering numbers and letters.
• CHARACTER DOWN and CHARACTER UP change the last character in the input line.
• PREVIOUS and NEXT move the cursor up and down in the list. Once a file is selected its name is
transferred into the input line. This is the more straightforward way of selecting the file you want.
• LOAD loads the selected file that is displayed in the input line, and switches back to the SELECT
menu.
• BACK aborts the procedure and switches back to the SELECT menu.
Select File Save menu
This enables you to save a select list on the memory card.

• CHARACTER NEXT inserts a new character at the end of the input line. You can also create new
characters by entering numbers and letters.
• CHARACTER DOWN and CHARACTER UP change the last character in the input line.
• PREVIOUS and NEXT move the cursor up and down in the list. When a file is selected its name is
transferred into the input line.
• SAVE saves the select list in a file (enter the file name in the input line) and switches back to the
SELECT menu.
• BACK aborts the procedure and switches back to the SELECT menu.
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5.5.9 CORRECTION menu

This menu is used to display correction values. It is very similar to the MEMORY menu, but only
displays correction values.

• NEXT SECTION switches between the 4 correction value sections: X-B-W-D.
• PREVIOUS PAGE and NEXT PAGE switch between the pages. Each page contains 16 correction
values from the selected section.
• PREVIOUS and NEXT switch between the correction values. The marked correction values are
displayed by an M in inverse display format.
• DOCUMENT displays the correction values with comments.
• IDENTIFY displays the correction values with the identifier.
• BASE MIN & MAX displays the correction values with the base value, the upper and lower limits.
• SAVE TO CARD saves the current correction values in a file. As you do so a menu appears for
you to select a file name, a standard file name (made up from today's date) is suggested. Of
course you can change this name if you want (see "Select File Save menu").
• You can accept the entry you have marked into the select list by pressing SELECT. If it has
already been selected, it is deleted from the list. You can see whether a correction flag is selected
by the inverse display format of its designation.
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5.5.10 MESSAGES menu

This menu shows the saved application messages (signal generator error) and all system errors
(CAN bus, modules, CPU etc.). These are stored in a buffer memory.

• ALL lists all stored messages (max. 15000).
• PREVIOUS START and NEXT START switch between all messages that were stored at every
separate start.
• PRIORITY MAXFILTER and PRIORITY MINFILTER list the stored messages filtered by their
priority rating.
• GROUP FILTER lists the stored messages filtered by certain groups.
• SINCE START lists only those messages that have occurred since the most recent machine start.
• LANGUAGE enables you to load another language for the messages. Messages that are not
found in the language you have selected will be displayed in english. This switch function works
only on the MESSAGES menu and not on the Litronic® test system (see "Language Selection
menu").
• PREVIOUS and NEXT switch between the messages.
• SAVE TO CARD saves all messages (ALL or SINCE START) in a file. As you do so a menu
appears for you to select a file name, a standard file name (made up from today's date) is
suggested. Of course you can change this name if you want (see "Select File Save menu").
Language Selection menu
You can select the language for messages on this menu.

• PREVIOUS and NEXT switch between the various languages.
• Use SELECT to select and load the marked language.
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5. OPERATION
5.5.11 SPECIAL FUNCTIONS menu

From this menu it is possible to go to the various other menus, or go back to the operating screen
by pressing the BACK function symbol.
The following menus are subordinate to the SPECIAL FUNCTIONS menu:
• MODEM
• DISPLAY INFO
• DRIVE
• SYSTEM LANGUAGE
• TIME
• SAMPLE
• LEVEL
• SYSTEM STATUS
• CAN CONFIG
• MDE/PDE
• CAN LINE INFO
• CLIENTS
Modem Function menu*
This menu can be used to configure and operate the modem*.

You can view the current status of the modem* (Online, Offline, False PIN etc.) in the input line.

• DIAL dials a previously entered telephone number.
• HANGUP terminates an active modem connection.
• RLP ON/OFF switches the radio-link protocol for GSM modem connections on or off. This setting
takes effect only after the next time the system is switched on.
• V32/V110 switches the V32 or V110 protocol for GSM modem connections on or off. This setting
takes effect only after the next time the system is switched on.
• PREVIOUS and NEXT switch between the ports, the standard modem client is COM2.
• PIN INPUT allows you to enter the PIN code manually for the GSM modem.
• MODEM CONNECT allows you to start the modem server program on an unused port.
• BACK goes back to the SPECIAL FUNCTIONS menu.
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5. OPERATION
Drive Function menu
This menu displays information about the current disk drive.

• REMOVE CARD has to be activated before you can remove a memory card from the drive.
Another option is to switch off the Litronic® control system. If you insert a new card it is detected
automatically.
• DIR LIST shows the files and the directories (no sub-directories) on the current drive.
• PREVIOUS DRIVE and NEXT DRIVE switch between the various drives available on the Litronic®
control.
• CHECK CARD checks the current drive for errors.
Time Function menu
This menu displays the date and time.

• DAYLIGHT SAVING changes the time setting to summer time.
• TIMEZONE MOVE WEST moves the time zone setting one hour to the west.
Priority Level menu (only for LIEBHERR service staff)
This menu can be used to enter the Litronic® code to reach Supervisor level. Supervisor level is
required to set the time, for example.

• LEVEL CHANGE accepts the value in the input line, and checks whether it is in fact a valid
Litronic® code.
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CAN Configuration menu
This menu displays all the CAN modules installed, together with their application status.

• NEXT PAGE moves to the next page.
CAN Line Information menu
This menu displays all the CAN lines installed, together with their settings.

• MODULE INFO switches to the CAN Configuration menu.
Display Configuration menu
This menu can be used to set the options for how the INPUT/OUTPUT menu displays.

• ALL MODULES displays all the CAN modules ("used" and "not used") on the INPUT/OUTPUT
menu.
• ONLY USED MODULES displays only the CAN modules that are currently set to "used" on the
INPUT/OUTPUT menu.
• NUMBER STYLE switches the in/outputs or flags between standard and hexadecimal display.
• UPDATE INTERVAL changes the speed at which the display of in/outputs or flags updates.
System Language Selection menu
This can be used to change the system language. You can select a language or load the internal
standard language. The system language selected will activate only when the Litronic® control is
switched on again and restarted.

• PREVIOUS and NEXT switch between the various languages.
• SELECT loads the marked language as the new system language, and goes back to the SPECIAL
FUNCTIONS menu.
• USE DEFAULT loads english as the new system language, and goes back to the SPECIAL
FUNCTIONS menu.
• BACK aborts the procedure and switches back to the SPECIAL FUNCTIONS menu.
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Sampling Trace menu
"Sampling Trace" is used to for online data charting of previously ascertained in/outputs.
This menu shows information about the "Sampling Trace" and enables you to alter its status, and to
save the charted data.

• SAMPLE ACTIVE activates the Sampling Trace function once the options have been defined. This
begins the charting operation and checks the trigger conditions.
• TRIGGER MANUALsimulates the trigger conditions. This function symbol is available only when
the "Sampling Trace" is in active status and the trigger conditions have not yet been met.
• END MANUAL ends "Sampling Trace" charting and automatically goes back to Ready status. This
function symbol is available only when "Sampling Trace" is active.
• LOAD FROM CARD loads a configuration from a saved Ssampling Trace file. As you do so a
menu appears for you to select the name of a file (see "Select File Load menu").
• SAVE TO CARD saves the charted data and the Sampling Trace configuration in a file. As you do
so a menu appears for you to select the name of a file (see "Select File Save menu").
• SAVE TO SELECT saves the variables used in the "Sampling Trace" in the select list. This
deletes any existing inputs in the select list.
• LOAD FROM SELECT loads the currently selected variables into the Sampling Trace list.
• PREVIOUS and NEXT switch between the configuration data. The marked (active) input is
displayed in inverse format.
• CHANGE changes the marked entry to the value in the input line. However this only happens if
this value is within the valid limits.
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System Status menu
This menu displays the current system status (running, stopped etc.) and the timing for the PLC
tasks (programmable logic controller).

• SYSTEM TASKS displays information about the system tasks.
• BOARD INFO displays information about the board (voltage, temperature etc.).
MDE/PDE menu
This menu displays the status of the MDE (machine data entry), the PDE (process data entry) and of
the data logger.

• MDE displays the MDE data.
• PDE displays the PDE data.
• SELECT GRAPHIC lists saved graphics (such as the company logo) in order to print out the PDE
data. The required graphic can be selected.
• LOGGER displays the data logger data.
• SAVE TO CARD saves the MDE, PDE or data logger data in a file. As you do so a menu appears
for you to select a file name, a standard file name (made up from today's date) is suggested. Of
course you can change this name if you want (see "Select File Save menu").
Clients menu
This menu displays the status of the individual communications interfaces (clients).

• PREVIOUS and NEXT switch between the interfaces.
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50
5.6 Operating the machine - auxiliary func-
tions
5.6.1 Driver's seat
IMPORTANT!
The driver's seat must be adjusted to the best possible
position for the physique of the operator in order to
prevent premature tiredness.
• By pulling up the lever (Figure 50, item 4) on the front

side of the driver's seat, the angle of the backrest can
be adjusted.
Height and inclination adjustment
• The height and inclination of the front edge of the seat

can be changed using the levers (2 +3).
• The inclination of the two armrests can be adjusted
with the knob (1).
Weight adjustment
• The springs in the driver's seat can be adjusted to suit

the driver's weight using the adjustment wheel (5). The
weight settings are marked on the adjustment wheel.
51
Complete seat horizontal setting
• In order to find the correct distance from the pedals,

the driver's seat including the left-hand and right-hand
control stand can be moved backwards and forwards
with the help of the lever (Figure 51, item 2).
• To find the correct distance from the joysticks, the
driver's seat can be moved with the lever (1).
• The driver's seat must always be set up so that the

operator can reach all the operational controls easily
and without getting tired.
IMPORTANT!
Correct use of this driver's seat ensures that the effec-
tive vibration accelerations measured in accordance with
ISO 2631 Part 1 conform to the requirements for protec-
tion against full body vibration.
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52
5.6.2 Additional control panel (X25)
The bracket holding the additional control panel (X25) *
can be adjusted with the three clamping levers and the
adjusting knob underneath.
5.6.3 LCD screen adjustments

The screen display can be individually adjusted to the current lighting conditions on the site using the
brightness control and inverse display.
"Brightness adjustment" button

By pressing this button in the Litronic service panel the following adjustments can
be accessed, one after the other:
- normal display - subdued

- normal display - medium-bright
- normal display - bright
- inverse display - subdued
- inverse display - medium-bright
- inverse display - bright
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5.6.4 Windshield wiper
53
"Windshield wipers on/off" key (Figure 53)

The wipers for the front and roof glass of the cab are switched on and off with
these keys in the left control panel (X11). This function is also active with the
ignition in the "Park" position.
Intermittent wiper
"Intermittent wiper on/off" key (Figure 53)
By pressing this button in the left control panel (X11), an intermittent period of
between 4 and 16 seconds can be set.
Setting:
Press key, wiper makes one sweep. Keep the key pressed until the next sweep
is to be made. The length of time for which the key remained pressed is now
saved as the intermittent wiper period.
IMPORTANT!
The set intermittent wiper interval is cleared and reset to 8 seconds when the diesel engine is shut
down. You will need to reset it when the diesel engine is next started.
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Windshield wash system

Key " Windshield wash system on/off" button (Figure 52)
The windshield wash system is active for as long as the respective button
remains pressed.
IMPORTANT!
The windshield wash system also works when the ignition switch is in the "Park" position.
54
Windshield cleaning liquid
The containers for the windshield cleaning liquid (Fig-
ure 54) are located behind the driver's seat.
1 Windshield wash container, roof

2 Windshield wash container, front
3 Sealing cap
IMPORTANT!
When the machine is supplied, the tank is filled with
windshield cleaning liquid of type "Special glass cleaner
F1".
The screw cap must be removed (Figure 54, item 1)

before the windshield cleaning liquid can be topped up.
IMPORTANT!
Commercially available windshield cleaning fluid can also
be used.
For safety reasons, however, it must not be flammable!
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5.6.5 Lighting
55
Interior lighting in the superstructure
"Interior lighting on/off" key (Figure 55, item 1) in the left control panel (X11).
To switch on, the ignition switch must be in the "P""Park" or "1""Ignition on"
position.
Work floodlights
(Figure 55, item 3)
"Work floodlights on/off" key (Figure 55, item 2) in the left control panel (X11).
To switch on, the ignition switch must be in the "1""Ignition on" position.
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56
Cab lighting
The switch for the cabin lighting (Figure 56, item 2) is

located on the lamp itself.
To switch on the cab lighting, the ignition switch must be
in the "P""Park" or "1""Ignition on" position.
The cab light has three switch positions:
• on/off via door contact switch
• generally off
• generally on
Reading lamp
Behind and above the driver's seat on the right is the
Reading lamp .
It can be switched on and off with the ignition in the
"Park" or "Ignition on" positions.
The switch is located on the reading lamp itself (Fig-
ure 56, item 1).
57
5.6.6 Radio
The radio
- is fitted at the rear of the right-hand control stand
(Figure 57, item 1),
- also works in "Park" position of the ignition
switch,
- has its own operating manual.
58
5.6.7 Hooter
The hooter
- is operated with a footswitch,
- also works in "Park" position of the ignition
switch.
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5.6.8 Ashtray
A removable ashtray is built into the right control stand behind the emergency shut-down switch in
the base.
CAUTION!
Danger of fire!
Only use ashtray while smoking to collect ash and cigarette ends.
The ashtray has a limited capacity, and should therefore be emptied regularly.
Do not put combustible waste in it!
Empty ashtray:
• Pull out the ashtray and use your thumbs to press gently downwards on both sides.
• Now pull out the ashtray a little further until it has cleared the locking device.
• Remove the ashtray from the mounting.
5.6.9 Cigarette lighter and socket in the cab
• The cigarette lighter is located on the right-hand control stand beside the ash tray.
• The socket is located near the radio on the right-hand control stand.
CAUTION!
The socket carries 24 volts of direct current!

Before connecting a device, check that it can operate with 24 V!
The cigarette lighter and the socket also work with the ignition in the "Park" position.
Using the cigarette lighter:

• Press the button on the cigarette lighter in until it clicks into position.
As soon as the lighter's coil glows, it springs back to its initial position and can
be pulled out.
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5.7 Operating instructions

5.7.1 General
DANGER!
Overloading will cause the lead to fail!

Buckling is a sudden failure, which occurs without warning.
Prerequisites
• Only perform operations that are in line with the intended purpose (see Chapter 3).
• Assembly must have been completed according to Chapter 6 (lead in the working position,
counterweight mounted).
• Check the ground conditions on the site.
• Place the lead on the ground when raising the auger.
• The ground pressure under the lead outrigger plate can be very high during the raising process.
Pay attention to the ground.
• Follow the load capacity charts (see Chapter 2).
CAUTION!
Exceeding the permitted limits (maximum capacity, working pressure, etc.) will result in
damage to the accessory unit!
Take note of the information provided by the manufacturer and adjust the values accordingly on the
Litronic control system.
Technical data, special safety precautions, operating and maintenance instructions for the accessory
units can be found in the manufacturers operating manuals.
WARNING!
Danger of accidents and possible damage by ropes!

Do not fasten ropes to the basic machine or to the lead. Otherwise damage will occur on adjusting
the lead or turning the superstructure.
A rope may be fastened to the hook fixing point only if the appropriate winch is fitted directly to the
lead (not to the base arm or in the superstructure). Otherwise damage may occur on adjustment of
the lead.
Drilling operation
• Drill only with the lead standing vertical.
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5.8 Drilling operation

5.8.1 General
The functions described below apply to all drilling modes.
59
"Drilling ABS"
The "drilling ABS" (Anti-lock Braking System) limits the
contact pressure of the feed above a certain drilling
pressure.
The contact pressure set with the potentiometer on the
additional control panel (X25) (Figure 59) is automatically
reduced.
If the potentiometer is engaged, the LED in the preset
display lights up.
60
Changing the drilling drive torque
The drilling drive can be operated with high or low
torque.
• Press the button on the right-hand joystick (Figure 60,

item 1) on the right joystick.
IMPORTANT!
The drilling drive must always be at rest when switching
between high and low torque.
This symbol appears in the display field on the LCD screen as soon as low
torque (high speed) is selected for the drilling drive.
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61
Storing drilling movement
The drilling movement can be stored.
Procedure:
- Move the joystick
- Press button (Figure 61, item 1) on the right-hand
joystick.
- put the joystick back to the neutral position
The drilling drive automatically moves right or left.
The "movement stored" symbol appears on the LCD screen.
Deleting stored value:

move the right joystick
If several movements are stored, all the others will be deleted as well.
62
Limiting the drilling speed
The speed of the drilling drive can be limited by the
potentiometer (Figure 62, item 1) on the additional con-
trol panel (X25).
IMPORTANT!
In the case of FOW drilling, the speed of drilling drive 1
(auger) is limited with the potentiometer on the additional
control panel.
63
Vibrating the drilling drive
The drilling drive is vibrated by pressing the latch button
(Figure 63, item 1).
This action attempts to empty the auger by quickly re-
versing it.
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64
Auger cleaner *
Cuttings can be removed from the auger either by vibra-
tion or by using the auger cleaner.
The auger cleaner works by guiding a scraper to the
auger so that the cuttings are scraped off when the
auger is rotated.
• When the latch button (Figure 64, item 1) on the left
joystick is pressed, one direction is activated and re-
mains active while the button is being pressed. If the
button is pressed again, the direction of movement
changes.
IMPORTANT!
When the auger cleaner is not in use, it free-wheels.
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5.8.2 CFA drilling *

General
CFA or continuous flight auger drilling is a process in which an uncased pile is produced on the site
without a liner tube.
This is done as follows:
- The auger is inserted to the final depth. The ground will be partially displaced in the process.
- As it is withdrawn, concrete is injected through the hollow auger. It is important
not to withdraw too quickly to prevent the hole from collapsing and the pile
being interrupted (the optional concrete pressure display should prevent this).
- After the auger is removed, the reinforcement (reinforcing cage)
is pressed in and vibrated.
For CFA drilling the following are required:
- an auxiliary winch
- a feed system.
Select CFA drilling

"CFA drilling" display
See Chapter 5 "Daily start-up".
The CFA drilling display field appears on the LCD screen.
CFA drilling display field

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Setting the drilling drive

Procedure:

"Settings" symbol
Press function key F6 to switch to the "Settings" page.
999 Flow rate [in l/min]

999 Pile diameter [cm]

9 Number of pumps

"Settings" page
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NOTE!
If a flow rate of 350 l/min [92.5 gal/min] is set, the number of pumps must be set to two.
"Enter" key
NOTE!

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65
Operating the drilling drive
The drilling drive is activated in proportion to the move-
ment of the right-hand joystick (Figure 65, item 1).
• Move joystick to the left = drilling drive rotates to the
right
• Joystick in neutral = drilling drive remains in position
• Move joystick to the right = drilling drive rotates to the
left
66
Double-rotary drilling drive for SOB application *
In double-rotary drilling the drives (auger and pipe) can
be bolted together. The drive torques of both auger and
pipe are thus combined.
However, two ball valves must be used to equalize the
hydraulic pressure in both drives.
67
Procedure:
• Activate double-rotary drilling
• Move the relative displacement cylinder downwards
• Connect adapter to the auger drive (Figure 66, item 1)
• Turn the auger until it is in the correct position for
bolting
• Raise the relative displacement cylinder
• Bolt the auger and pipe together (Figure 66)
• Move both ball valves to position 1 (Figure 67)
• Activate SOB operation
Operation is as described above.
For double-rotary operation, move the ball valves to

position 2 (Figure 67)
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5.8.3 Double rotary drilling *

Double-rotary (front of wall) drilling is a process similar to CFA drilling in which two drilling drives are
linked via a relative displacement cylinder. The first drilling drive drives the auger and the second
drilling drive drives the external casing. The drilling drives can be moved relative to one another
(auger or tube leading) with the displacement cylinder.
- The auger is inserted to the final depth.
The soil is removed via an ejector.
- As it is withdrawn, concrete is injected through the hollow auger. It is important
not to withdraw the auger too quickly to prevent the hole from collapsing and the pile being
interrupted (the optional concrete pressure display should prevent this).
- After the auger is removed, the reinforcement (reinforcing cage) is pressed in and
vibrated.
NOTE!
Changing the torque
The torque can be changed for the two drilling drives separately.
The drilling pressure and speed are displayed for each drilling drive separately.
Selecting FOW drilling

"FOW drilling" display
The FOW drilling display field appears on the LCD screen.
FOW drilling display field,

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Setting the drilling drives

Procedure:

"Settings" symbol
999 Auger flow rate [in l/min]

999 Pipe flow rate [in l/min] 999 Pile diameter [cm]
999 Max. auger pressure [bar]

999 Max. pipe pressure [bar] 9 Main winch reeving

"Settings" page
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NOTE!
If a flow rate of 350 l/min [158 gal/min] is set, the number of pumps must be set to two.
"Enter" key
NOTE!

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68
Operating drilling drive 1 (auger)
Drilling drive 1 is controlled in direction proportion to the
movement of the right- hand joystick (Figure 68, item 1).
right
left
Turn down the potentiometer on the joystick fully, to
ensure that drilling drive 2 is not operated.
69
Changing the torque on drilling drive 1
Press the button (Figure 69, item 1).
When working at low torque (high speed), the "hare"
icon appears on the LCD screen.
70
Operating drilling drive 2
Drilling drive 1 is controlled in direct proportion to the
movement of the right-hand joystick (Figure 70, item 1).
• Move joystick backwards = drilling drive rotates to the
right
• Move joystick forwards = drilling drive rotates to the
left
71
Changing the torque on drilling drive 2
Press the button (Figure 71, item 1).
When working at low torque (high speed), the "hare"
icon appears on the LCD screen.
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72
Controlling both drilling drives with one
joystick
It is also possible to control both drilling drives with one
joystick.
• Drilling drive 1 is controlled with the right joystick
(left/right as described above).
• Drilling drive 2 is controlled by moving the potentiom-
eter (turning it upwards) on the right joystick, in op-
posed and proportional fashion.
IMPORTANT!
Drilling drive 2 can be controlled at any time with the left
joystick.
If the left-hand joystick is activated in the opposite direction to the potentiometer, drilling drive 2 is
stopped. The higher of the two values (of the potentiometer or joystick) is then adopted for drilling
drive 2.
The control system does not allow you to operate both drilling drives in the same direction with high
torque.
Relative displacement cylinder

With the relative displacement cylinder, the drilling drives can be moved relative to one another. You
can work with the auger leading the tube or vice versa.
Selecting the relative displacement cylinder

"Relative movement/sheet pile feeder" selection button
Press this button on the additional control panel to select the relative displace-
ment cylinder.
It can be controlled either via the additional control panel or by operating the
latch button (Figure 73, item 1) on the left-hand joystick.
Controlling the relative displacement cylinder from the additional control panel (X25)
"Lift/Open" button
Extend the relative displacement cylinder.
Retract the relative displacement cylinder.
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73
Controlling the relative displacement cylinder with
the left joystick
When the latch button (Figure 73, item 1) on the left

joystick is pressed, the relative displacement cylinder is
activated in one direction and remains active while the
button is being pressed.
If the button is pressed again, the direction of movement
changes.
The direction is displayed on the additional control panel
(X25) by the LEDs of keys T9 and T27.
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5.8.4 Soil mixing mode *

With soil mixing, a mixture of binding agents and soil is made on-site. In this process, any pore voids
present in the soil are filled with binding agent suspension. The result is a compacted soil defined on
the basis of the auger geometry.
One, two or three drilling drives or augers may be used.
Procedure:
Insert the auger(s) to the final depth. Whilst the auger is being drilled and withdrawn, the available
soil is mixed and the binding agent suspension is added through the hollow core pipe.
The drilling pressure and speed are displayed for each drilling drive separately.
Select soil mixing
"Soil mixing" display

The soil-mixing mode display field appears on the LCD screen.
Soil mixing display field

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Procedure:

"Settings" symbol
999 Auger 1 flow rate [in l/min] 99 Auger length [cm]

999 Auger 2 flow rate [in l/min] 999 Pile diameter [cm]

9 Number of augers
9 Number of pumps

"Settings" page
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NOTE!
"Enter" key
NOTE!

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74
Operating the drilling drives
The opposing drilling drives are controlled proportionally
with the right joystick (Figure 74, item 1).
• Move joystick to the left = main turning direction
• Joystick in neutral = drilling drives remain in position
• Move joystick to the right = main turning direction is
reversed
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5.8.5 Kelly drilling *

General
Kelly drilling is a process in which the drilling tool is connected to the drive via a telescopic bar (the
Kelly bar). This enables depths greater than the lead height to be reached.
- The drill (Kelly bar plus auger) is used to bring the pile step by step out of the
hole. The auger must be cleared each time.
An external casing usually needs to be introduced (depending on the soil)
to prevent the hole from collapsing.
- When the depth is reached the reinforcement (reinforcing cage) is inserted.
- After this the hole is concreted using a feed pipe.
The following are required for Kelly drilling:
- a Kelly winch
- an auxiliary winch
- a feed system.
Kelly drilling is often done together with the optional casing oscillator.The casing oscillator is an
additional device for inserting the external casing.
Selecting Kelly drilling
"Kelly drilling" display

The Kelly drilling display field appears on the LCD screen.

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Procedure:

"Settings" symbol
999 Flow rate [in l/min] 999 Auger length [cm]

9 Number of pumps
999 Casing oscillator flow rate [in l/min]
"Settings" page
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NOTE!
"Enter" key
NOTE!

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75
Operating the drilling drive
The drilling drive is activated in proportion to the move-
ment of the right-hand joystick (Figure 75, item 1).
right
left
76
Switching on rock gear
Switch on rock gear if you want to drill with high torque.
• Press the button (Figure 76, item 1) on the right-hand
joystick.
Rock gear is activated as long as the button is
pressed.
The "rock gear" symbol appears on the LCD screen.
Switching on drilling free-wheel

Switch on drilling free-wheel if you want to press the drilling drive onto the pipe while the casing
oscillator is in operation. Drilling free-wheel is only intended to be used when Kelly drilling.
"Drilling free-wheel on / off" * button

For switching the drilling free-wheel on and off (kelly drilling).
The "Drilling free-wheel" symbol appears on the LCD screen.
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5.9 Casing oscillator*

5.9.1 General
The casing oscillator is an accessory needed mainly during Kelly drilling to introduce the external
casing. Therefore it can only be selected in Kelly drilling mode.
5.9.2 Connecting the casing oscillator

The casing oscillator is attached to the undercarriage using the optional VRM adapter. Quick-fitting
unions are provided on the undercarriage for connection of the hydraulic pipes. Power is supplied to
the casing oscillator via an electric socket.
See (Figure). 77).
77
Connecting the casing oscillator

1 Leak oil 4 High pressure P1
2 Control pressure P3 5 Guiding rails
3 Return
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5.9.3 Adjusting casing oscillator

Procedure:

"Settings" symbol
The "Settings" function key symbol is used to switch to the "Settings" page.
999 Flow rate [in l/min] 999 Auger length [cm]

9 Number of pumps
999 Casing oscillator flow rate [in l/min]
"Settings" page
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"Enter" key
NOTE!

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5.9.4 Switch on the casing oscillator
"Casing oscillator on/off" button

Press this button to switch on the casing oscillator. The appropriate field appears
on the LCD display.
Kelly drilling field with casing oscillator

- Kelly drilling is selected on the screen and
- the casing oscillator is selected
on the right-hand control panel (X23).
The working pressure of the casing oscillator appears in the Kelly drilling field.
NOTE!
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5.9.5 Operating the casing oscillator

Adjusting the oil quantity
Potentiometer 1
The oil supply to the casing oscillator can be regulated with this potentiometer
from 0 - to maximum capacity.
Preset display "Additional hydraulics flow rate"*

The functional assignment of potentiometer 1 is displayed by the LED.
Power regulation
Potentiometer 2
The available power can be divided between the casing oscillator and the other
functions (winches or drilling drive).
The potentiometer relates to the power of the casing oscillator, i.e. the further it is
turned clockwise, the more power is made available to the casing oscillator.
Power regulation with potentiometer 2 is only active if
- the drilling drive,
- Kelly winch hoisting or
- the universal slide (feed) is being raised.
Otherwise, maximum power is available to the casing oscillator.
Preset display "Casing oscillator power regulation"*

The functional assignment of potentiometer 2 is displayed by the LED.
NOTE!
The casing oscillator is controlled externally.
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5.9.6 Saver circuit

A saver circuit has been installed to avoid heating with unnecessary power when the casing
oscillator is externally switched off.
Saver circuit:
The system pressure is measured by a pressure sensor in the hydraulic circuit. If the pressure in the
hydraulic circuit of the casing oscillator falls below a certain level, the pump is limited.
Then, if a load (cylinder) is operated, the pressure in the hydraulic circuit rises and the control
system turns the pumps back to the preset capacity.
5.9.7 Switching off the casing oscillator
"Casing oscillator on/off" button

Press this button (again) to turn the casing oscillator off.
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5.10 Reinforcement vibrator *

5.10.1 General
NOTE!
Technical data, special safety precautions, operating and maintenance instructions for the accessory
units can be found in the manufacturer's operating manual.
5.10.2 Pre-selecting vibrator operation

Display "Vibrator operation"
See chapter 5 "Start-up".
The display field vibrator operation is overlayed on the LCD-display screen.
Display field vibrator

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5. OPERATION
5.10.3 Operating the vibrator

General
The vibrator can only be switched on if the clamping tongs are closed. This is monitored by the
Litronic control with the aid of a pressure switch.
When the clamping tongs are closed for the first time, the clamping tongs system is also activated.
Clamping tongs system:
The clamping tongs are closed automatically the moment the clamping tongs pressure drops below a
certain value. This prevents the clamping tongs from becoming depressurized and opening acciden-
tally.
78
Starting the clamping tongs system
Closing the clamping tongs
The clamping tongs can be closed in two ways:
Right joystick:
• Press button (Figure 78, item 1)
Right control panel (X23)

• Press key (2)
Display on the LCD screen
"Clamping tongs" symbol

This symbol starts to flash on the LCD screen when the clamping tongs pressure
drops below a specified value or the clamping tongs are closed (manually or
using the clamping tongs system).
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5. OPERATION
Switching on the vibrator 79
The vibrator can be switched on in two ways:
Right joystick:
• Press button (Figure 79, item 1):

• Press key (2)
Switching off the vibrator

"Vibrator on/off" key
Switches the vibrator on and off.
Open clamping tongs (X23)
"Open clamping tongs" key

The clamping tongs are opened. Hold down the key until the clamping tongs are
open.
Prerequisite: the vibrator is switched off and has shut down.
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5. OPERATION
5.11 Shutting down the machine

5.11.1 Parked position
The parked position
- protects the machine from storm damage,
- is used in the range above the maximum permitted wind speed in operation up to a wind speed
of 20 m/s [45 mph]; this corresponds to gale force 8 (see section 3.8.1).
- is used in the range above the maximum permitted wind speed when not in operation up to a
wind speed of 36 m/s [80.5 mph]. If wind speed is above 36 m/s [80.5mph], the lead must be
lowered.
Placing the machine in the parked position:

• Only park the machine on level ground
• The superstructure must be parallel to the undercarriage.
• set down and secure all loads
• Make the lead vertical
• Set minimal lead outreach
• Lower the drilling rig on to the ground
DANGER!
At wind speeds above 20 m/s [45 mph], remaining near the machine poses a risk of fatal
accidents!
The wind stresses occurring may partially or totally wreck the machine and cause it to topple
over.
Precautions:
Operation must be halted when wind speeds of over 20 m/s [45mph] or gale force 8 are expected.
Place the machine in the parked position described above or lay down the drilling rig.
Observe the following safety rules and instructions when laying down the drilling rig:
• As machine operator, be aware of the current weather situation on site at all times in order to be
able to lay the drilling rig down safely and in good time.
• Always lay down the drilling rig completely.
If the drilling rig unit is not laid down completely, this may cause the machine to topple over and
wreck the slewing gear brake.
• In bad weather or if a storm is forecast and work is likely to be interrupted for more than a day, or
if the machine operator and assistants will be absent, the drilling rig must be laid on the ground.
• If during planning it is noticed that the drilling rig cannot be set down completely at the site due to
a lack of space and there is danger of a storm:
Special precautions against storm damage should be discussed and agreed with the manufac-
turer in good time.
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5. OPERATION
Work interruptions
DANGER!
When leaving the machine, it must generally be protected against unauthorized use, damage
by vandalism and possible environmental harm!
The following points must be observed:

• The machine must not impede traffic.
• Lower all loads fully to the ground and secure them.
• Make the lead vertical
• The diesel engine must be shut down before leaving the cab and the cab must be locked.
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5. OPERATION
80
5.11.2 Shutting down the diesel engine
CAUTION!
If the diesel engine is shut down suddenly while

running at high speed, the turbo fan of the tur-
bocharger can no longer be lubricated sufficiently.
To protect the turbocharger, let the diesel engine
idle for a short time before shutting it down.
Shut down procedure:
• Place all joysticks in the neutral position. Pull up the

safety lever.
• With the rocker switch (Figure 80, item 1), reduce the
engine speed to idle and let it idle for a short time. If
necessary, first press the button (Figure 80, item 2) to
delete the stored constant rpm.
• Turn the ignition starter switch to the "0" position
(Figure 81) to shut down the diesel engine.
81
IMPORTANT!
After shutting down the Litronic control system, wait at
least 5 seconds before re-starting it. Otherwise error
messages may occur.
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5. OPERATION
82
5.11.3 Park position of the ignition starter switch
The ignition switch has a park position (Figure 82, Posi-
tion "P"), that switches off the Litronic controls. This
reduces the load on the battery.
The park position is intended for longer work interrup-
tions where the machine operator remains in the cab.
Electricity is supplied to the following equipment:
- Interior lighting in the superstructure

- Cab lighting
- Windshield wipers
- Hooter
- Radio
- Heater fan
- Socket in the cab
- Cigarette lighter
See section 5 "Machine operation - auxiliary functions".
5.11.4 Checks before leaving the machine

The following points have to be observed when leaving the machine:
• The load must be set down on the ground and properly secured.
• The machine must be in the parked position as described above, on firm, level ground (see
Chapter 2 under "Ground conditions").
• No public safety feature or equipment may be impeded (emergency exits, access routes for rescue
vehicles, heliports, fire hydrants etc.).
• The shut down machine must not impede traffic.
• Ensure that a power supply is provided for the additional safety equipment (e.g. helicopter warning
lights).
• The ignition key must be pulled out and kept safely. The cab must be locked.
• The optional auxiliary heating must be switched off or correctly programmed for the next time work
begins.
• The machine must be fully locked.
• The site must be adequately secured.
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5. OPERATION
NOTES:
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5. OPERATION
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6. ASSEMBLY AND DISMANTLING

6.1 General
This chapter describes
- the operational planning,
- loading and unloading the machine onto and from the low-loader,
- assembly and dismantling of the machine,
- conversion operations for the different operating modes,
- transportation between sites.
Some of the illustrations in this section are simplified to make them easier to understand, and do not
fully correspond to the relevant assembly or dismantling steps. For example, the undercarriage of the
basic machine is shown without the superstructure.
The directional indications "right/left", "forward/back" are always from the point of view of the driver
sitting in the cab.
The precise measurements follow the ISO system of units. The measurements shown in square
brackets have in some cases been rounded during conversion.
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6.2 Operational planning
WARNING!
Faulty or incomplete operational planning can lead to dangerous situations and accidents!
Operational planning is vital for safe and problem-free operation of the machine. The operations
planner and the machine operator must obtain and analyze all necessary information about the
operation in good time before work begins. This mainly concerns the following information:
- The type of use and the required operating mode,
- The weight and dimensions of the loads to be lifted (drill pipe etc.)
- Required working area
- Heights and widths of thoroughfares leading to the site
- Position of overhead power lines with the stipulated safety distances
- Locations of underground cables, water and gas pipes on the site
- Spatial conditions on the site (e.g. movement restrictions caused by construction works)
- Load-bearing capacity of the ground on the site
- Other factors affecting the site (weather, air traffic, antennae, radar installations etc.)
Using this information, the operations planner or machine operator can assemble the equipment
needed for the operation in question, such as:
- inspecting the load capacity charts
- working equipment
- optional accessories
- tools and implements (torque wrenches, impact wrenches etc.)
- slinging equipment
- additional safety devices etc.
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6.3 Safety regulations for assembly and dismantling
WARNING!
Assembling and dismantling the machine involve numerous hazards and dangerous activities,
which may cause life-threatening injuries and serious damage to property.
The main causes of accidents are:
• Inadequate knowledge of the equipment of the machine and insufficient training.
• Insufficient attention paid to safety precautions and protective measures for reasons of time.
• Assembling or dismantling under unsuitable conditions (wrong location, unsatisfactory ground
composition, bad weather, failing light etc.)
6.3.1 Requirements for the erecting team

At least three people are needed for safe assembly and dismantling, that is, the machine operator
and two assistants.
The machine operator
- must be familiar with the national and local safety regulations applicable to the assembly,
dismantling and reconfiguring of the machine,
- briefs his helpers during a discussion of the operation,
- leads and supervises the erecting team.
The assistants must be
- experienced in the erecting of piling and drilling rigs and especially trained to erect, dismantle or
reconfigure this machine correctly and safely,
- aware of possible injuries resulting from operating machinery as described in section 3.7.1.
The erecting team must be equipped with
- the personal safety equipment described in section 3.3,
- walkie-talkies, if communication may be disrupted by noise.
6.3.2 Requirements for the site
WARNING!
Uneven ground, as well as slippery or soft ground on the site where the machine is
assembled or dismantled, can lead to serious accidents with life-threatening injuries and
serious damage to property. Incalculable dangers result from instability and sudden weight
transfers of the basic machine or attachments.
The essential requirements for the site

- are described in section 3.8.2 "Ground conditions at the site",
- apply to the assembly, dismantling and reconfiguring of the machine.
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NOTE!
If the load-bearing ability of the ground is inadequate, the standing area of the basic machine should
be enlarged. Consult a state-approved geologist or surveyor and place excavator mattresses or steel
plates of suitable size under the support plates.
The site must be large enough for
- delivery of the basic machine and the attachments with a low-loader and lorry,
- use of an auxiliary crane,
- carrying out all assembly operations free of obstructions.
On busy construction sites, secure the location to prevent access by unauthorized persons, prefer-
ably by means of barriers and warning signs.
Sufficient lighting should be provided on the building site if the assembly work is being carried out at
dawn or dusk or if visibility is poor due to bad weather.
6.3.3 Rules for executing the work
WARNING!
Mistakes during the assembly or dismantling operations can lead to serious accidents with
life-threatening injuries and damage to property!
Precautions:
• All activities and assembly procedures described in this chapter must therefore be carried out in
the described sequence.
• Any questions or uncertainties must be resolved at once by the erecting team.
• Auxiliary cranes that are used must have adequate load capacity.
• Slinging equipment (belts, chains etc.) must be checked and have the requisite load capacity.
• Use only the supplied tools to assemble and dismantle the machine.
• Working on the superstructure and on the lowered lead is permitted only with adequate safety
precautions.
• LRB 155, LRB 255: When working on the standing lead, the supplied safety equipment (lead
access ladder with safety rail, fall protection slide and safety harness) must be used.
• All required winches and cylinders should be operated slowly and carefully in order to
- be able to stop any movement immediately in case of danger,
- avoid high dynamic forces.
• Do not fasten the rope winch to the basic machine or to the lead.
• Always depressurize the whole system when working on the hydraulic plant.
Do not assume that all hoses are depressurized just because the machine is switched off. This
applies, for example, to the clamping tongs system during vibrator operation or to accumulators on
emergency lowering mechanisms.
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6.4 Unloading and preparing the machine

6.4.1 Prerequisites
• The erecting site must be selected and prepared in accordance with section 6.3.2.
• The machine must be on a low-loader, ready for unloading.
• The machine must have been inspected in accordance with section 5.2 "Checks before daily
operation" and be ready for operation.
• All window glass in the cab and the exterior mirrors must have been cleaned.
• The erecting team must have been instructed according to section 6.3.1 and be ready to go into
action.
6.4.2 Overview of assembly stages

• Putting the machine into operation
• Drive the machine off the low-loader.
• removing the superstructure locking
• Operate the track adjustment
• Assembly steps with lowered lead
- Bring the gibbet into the working position
- Reeve the ropes*
- Check and assemble the hoisting limit switches (if not mounted)*
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6.4.3 Bringing the rotating beacons* into operation position
Rotating beacons on the rear of the superstructure
For each rotating beacon, loosen the four screws (Figure 1, item 3) and bring both the beacons into
position as shown (1 and 2). Then tighten all screws.
When dismantling, reverse this procedure.
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6.4.4 Bringing the floodlights* into operation position
Floodlights on the front right of the superstructure
For each floodlight, loosen both the screws (Figure 2, item 1) and turn the floodlights into position as
shown (2). Then tighten all screws.
When dismantling, reverse this procedure.

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3
6.4.5 Putting the machine into operation
Folding down steps on the undercarriage
Lift and fold down the steps on the undercarriage
(Figure 3)
4
Place the side platforms on the cab (Figure 4) in the
working position.
Pull up the side platform (Figure 4, item 1) and fold
down.
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Fitting the ladder
WARNING!
If the ladder is not fitted correctly:

Risk of falling.
Secure the ladder on both sides with linch pins at the fixing pins.
The ladder must be checked for damage and cracks before it is fitted and before it is used.
Securing the ladder
Attach ladder (Figure 5, item 2) to fixing pins on the uppercarriage.

Secure the ladder on both sides with linch pins (1).
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Attach peripheral platform

Slide box-section profile (Fig. 2, no. 2) through the aperture (Fig. 2, no. 3), until the profile latches
on to the rear bracket (Fig. 2, no. 1).
Secure the platform using spring cotters (Fig. 9, no. 6) at points 4, 5 and 7.
Adjusting the driver's seat

Open the cab doors, check the seat position and adjust if necessary (see Chapter 5 under
"Machine operation - auxiliary functions").
Start diesel engine (Figure 7)

Make sure that the following requirements are met:
Exhaust end pipe is in working position.
"Ready to start" symbol appears on the LCD screen.
Turn ignition button to position 2.

Release as soon as the diesel engine is running.
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6.4.6 Drive the machine off the low-loader.
NOTE!
Travel gear not activating but the machine needs to be unpacked urgently?
Turn the ignition off briefly, disconnect additional control panel (X25) from the cab, start the machine
and drive carefully off the low-loader. Inform LIEBHERR Customer Service.
WARNING!
Driving the machine off or onto the low-loader is hazardous and serious accidents can occur!
Precautions:
- secure the transport vehicle to prevent it from rolling away, tilting or toppling over,
- detach all lashings, remove chains and wedges,
- before driving onto the loading ramp, clear away any dirt, snow or ice from the machine's chains
and track pads,
- do not operate anything apart from the travel gear during the loading/unloading operation,
- control the travel gear using the hand levers,
- drive slowly and smoothly,
- do not turn the superstructure with the chain,
- observe the operating manual for the low-loader,
- the loading ramp must have a non-slip (wooden) covering,
- with the drilling unit mounted, the slope must not exceed 10°
- a signalman must monitor the loading or unloading process and give appropriate instructions.
8
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9
6.4.7 Removing the superstructure locking
The superstructure locking mechanism prevents the su-
perstructure from slewing unintentionally.
It must be in place
- during transport,
- on decommissioning and
- during maintenance and repair work on the
rotary connection.
CAUTION!
Crushing hazard and risk of damage!

The slewing gear must not be operated when the
superstructure is locked.
Exception: to remove butt strap of the superstructure
locking if the bolt is stuck.
Be careful if the slewing gear must be operated to
remove the bolt and when laying down the butt strap on
the undercarriage. Crushing hazard!
Procedure:
• Pull out the retaining spring (Figure 0) and remove the
bolts (4) from the butt strap on the superstructure (2).
• Lay down the butt strap on the undercarriage.
• Put the bolts back into the butt strap and secure with
retaining springs and washers
CAUTION!

Do not rotate the superstructure when the lead is
lowered.
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6.4.8 Adjusting crawler carriers on work track

The crawler carriers can be adjusted between the transport and work tracks using the track
adjustment cylinders integrated into the undercarriage.
CAUTION!
Risk of damage!
Safety and operating information:
• The transport track (narrow track) is reserved exclusively for transportation operations.
When working, both crawler carriers should be extended to the working track (wide track).
Slewing the superstructure when on the transport track and with a rear counterweight fitted is
prohibited as the machine could tip over!
• Track adjustment may only be carried out on a firm, flat surface. The crawler carriers must not sink
into the ground or, during track adjustment, get caught on obstacles such as the edges of rocks.
• The crawler carriers should be adjusted in succession.
NOTE!
The width of the undercarriage depends on the width of the track pad. The track pad widths are
listed in Chapter 2 "Technical data".
DANGER!
Crushing hazard!
Keep unauthorized persons away from the machine during this process.
During the adjustment, be especially aware of possible crushing and trapping hazards.
Safety instructions for operation:
When adjusting the track width, safety issues demand that that three people be involved (the
machine operator and two assistants).
• The machine operator

sits in the cab,
operates the machine only on the instructions of the assistant in front.
• The assistant in front of the undercarriage
is responsible for bolting the crossbeams at the front,
provides instructions to the machine operator and the assistant at the rear,
monitors the procedure and warns the machine operator of any dangerous situations that may
arise.
• The assistant behind the undercarriage
is responsible for activating the track adjustment levers and for bolting the crossbeams at the back,
stays in contact with the assistant in front and receives instructions from the assistant in front.
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10
CAUTION!
It is vital to adhere to this procedure when adjusting

the crawler carriers:
Always extend the left crawler carrier first!
Extending the left crawler carrier
• Loosen all four crossbeam mountings on the central

undercarriage section (Figure 10).
For each crossbeam mounting:
• first undo the nut (1)
• then turn screw (2) in a clockwise direction until the
wedge is sufficiently loose
11
• Check (or press) the "Cylinder adjustment function
on/off" selection button in the cab on the right-hand
control panel: The LED in the keypad must light up
(Figure 11).
12
• Remove bolts from the front and rear of the central
section of the undercarriage (Figure 12).
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13
• Using the control levers, extend the track adjustment
cylinders by an equal amount. Push crawler track to
the outer bolting points of the crossbeams and align
them (Figure 13).
14
• Bolt the left crawler carrier to both brossbeams (Fig-
ure 14).
Extending the right crawler carrier

The assembly steps are exactly the same as those of the first crawler carrier and are therefore not
described or illustrated in detail.
NOTE!
Do not telescope the right-hand crawler carrier beyond the specified degree (wide track) as there is
no mechanical stop. There is a danger of damaging the hydraulic hoses.
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15
• Wedge the right and left crawler carriers to the two
crossbeams (Figure 15).
For each crossbeam mounting:
• first screw out screw (2) (anti-clockwise) to wedge
crossbeams,
maximum tightening torque: 120 Nm
• then tighten the nut (1).
16
• Attach covers to the four crossbeams (Figure 16, item
2).
For transport, the covers are inserted on the left-hand
side at the bolts (Figure 16, item 1).
IMPORTANT!
After extending, lightly grease the exposed sliding sur-
faces of the crossbeams.
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17
Folding down steps on the undercarriage
• Lift and fold down the steps on the undercarriage
(Figure 17)
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18
6.4.9 Bringing the jib into the working position
CAUTION!
Danger of accident!
Use suitable climbing gear.
• Remove spring plugs, washers and bolts (Figure 18,

item 1)
19
• Press the "Cylinder adjustment function on/off" (Fig-
ure 19) selection button on the right-hand control panel
(X23).
CAUTION!
Crushing hazard!
Do not stand between the lead upper and the jib!
• Fold jib into working position by moving the control

20 lever (Figure 20).
• Put both bolts back in and secure with washers and
spring plugs.
6.4.10 Reeve the ropes

• Reeving the Kelly and auxiliary ropes
Reeve the ropes before erecting the lead (see Chapter
8 "Repair").
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21
6.4.11 Fit the hoisting limit switch
Depending on the type of use and the installed options,
a hoisting limit switch must be mounted on each gibbet
(Figure 21, item 3 and 4) for the Kelly rope (Figure 21,
item 2) and auxiliary rope (1).
Mechanical bypass of limit switches

The limit switch rope (Figure 22, item 1) is hung from the
pin (2) and secured with a cotter pin. The limit switch is
bypassed in this way. No functional shutdown takes
place.
22
DANGER!
Bypassing of safety devices can lead to serious ac-

cidents.
Limit switches may only be bypassed briefly during as-
sembly and dismantling operations.
The limit switch chain must not be shortened!
The length of the limit switch chain is matched to the
speed of the winch and the shut-down period.
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23
Attaching the limit switch weight
• Detach the limit switch rope (Figure 22, item 1) from
the pin (2)
• Assemble limit switch weight (Figure 23) around the
hoisting rope.
• Fix the limit switch chain to the limit switch rope and
weight
• Firmly tighten snap hooks and chain locks.
Check their installation position!
• Check or simulate the operation of the limit switch
IMPORTANT!
The hoisting limit switch should be regarded as an emer-
gency limit switch and should not be actuated during
normal operation.
24
A length of shrunk-on tubing (Figure 24, item 1) has

been fitted to ensure fault-free operation.
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6.5 Load the counterweight

25
NOTE!
If the machine has been transported with the counterweight loaded you can ignore this section.
DANGER!

Without counterweights – i.e. additional counterweight(s)* (Figure 25, 1 and 2) and coun-
terweight (3) - there is a danger of toppling over.
Precaution:
- Do not tilt lead in assembled condition and set the minimal outreach.
Mount the counterweights – i.e. additional counterweight(s)* (Figure 25, 1 and 2) and counterweight
(3) – with an auxiliary crane or with the counterweight loader* (see Chapter 9 "Options").
NOTE!
If the piling and drilling unit is fitted, the counterweight can also be loaded after erection using an
auxiliary crane. When doing this make sure that the lead
- is not tilted forwards,
- is kept as close as possible to the ground in front.
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DANGER!
Risk of injury when loading the counterweight.

Precautions:
- Move the auxiliary crane slowly.
- Standing between the counterweight, additional counterweights and base machine or underneath
the counterweight is forbidden.
Preparations
- Check counterweights for damage,
- If necessary clean the bottom mounting surface and threaded holes,
- Lightly grease the bolts.
Mounting additional counterweight(s)*

• Sling the additional counterweight (Figure 25, item 1)
• Lift the additional counterweight, position at the rear of the superstructure and lower the coun-
terweight.
• Remove the bottom cover plate and screw the additional counterweight firmly to the superstructure
with four bolts (5) and washers from below.
• Repeat this process for any further additional counterweight (2).
see Chapter 7 "Maintenance" for the tightening torque.
Loading the counterweight

• Sling the counterweight (Figure 25, item 3)
• Lift the counterweight, position at the rear of the superstructure, attach the bolts above and lower
counterweight.
• Remove the bottom cover plate and screw the counterweight firmly to the superstructure with four
bolts (4) and washers from below.
see Chapter 7 "Maintenance" for the tightening torque.
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6.6 Erecting the leader
DANGER!
If the drilling rig is assembled incorrectly:

Risk of structural collapse. Falling parts.
Check the assembly of the drilling rig before it is erected.
Remove any loose parts, tools and implements.
At least one signalman should monitor the erecting process.
6.6.1 Prerequisites
Make sure that the following requirements are met:
Checking and maintenance operations have been completed.
Leader top is in the working position.
Kelly and auxiliary ropes are reeved.
Hoist limit switch * is fitted (and its operation checked).
Crawler side frames are extended to working width.
IMPORTANT!
Can be operated with the additional panel (X25) or with the control lever.
6.6.2 Overview of assembly steps

• Fully extend the support arm adjusting cylinder.
The leader is lifted from the uppercarriage.
• Extend the leader support arm cylinder
The leader is erected.
• Laying out the hose kit.
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26
6.6.3 Procedure
CAUTION!
If the leader claws are fitted incorrectly:

Drilling rig may be damaged.
Ensure that the claws on the left and right of the
uppercarriage are fitted facing outwards (see Fig. 26).
Fully extend the support arm adjusting cylinder

Press and hold down button 1 (Figure 27) on the left-hand control lever.
Move the left-hand control lever forwards.
The leader is lifted parallel to the uppercarriage.
27
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28
Extending the leader support arm cylinder

Make sure that the support arm adjusting cylinder is fully extended.
Extend the leader support arm cylinder until the leader is vertical.
or:
Use the automatic leader adjustment system to move the leader to a vertical position once the
inclination is less than approximately -30°.
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29
6.7 Assembly steps with erected lead
6.7.1 Fitting/removing the foot plate
Remove the spring plugs (Figure 29, item 3) and pull
out the bolt (2).
Position the foot plate (1) under the lead.
Lower the lead (or extend the lead foot cylinder *) until
the ball lies in the foot plate.
Fit the bolts (2) and secure them with the spring plugs
(3).
Dismantling is carried out in the reverse sequence.
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30
6.7.2 Fitting/removing the drilling drive
Attaching the drilling drive on the universal slide
Fasten drilling drive on four point with the provided
tackle (Figure 30, item 1).
Remove the spring plugs (Figure 30, item 6) and lower
bolts (7) on both sides.
Position the lead and accessory unit.
Insert the universal slide in the drilling gear slide from
below, so that the two upper bolts (4) can be inserted
in the guides provided (3).
Attach upper bolts of drilling gear slide in the lead
guides (3).
Insert the lower bolts (7) and spring plugs (6) and on
both sides.
Remove the tackle after attaching the drive.
Dismantling is carried out in the reverse sequence.

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Hose guide, multi-couplings
31
The hose guide (Figure 31, item 4)

- is mounted on the universal slide,
- provides the connection between the basic machine and the accessory unit (electrical and
hydraulic)
The multi-couplings (Figure 31, item 1).

- are mounted in the hose guide,
- make it easier to connect and detach the hydraulic connections
WARNING !
Hydraulic hoses under pressure when connecting/detaching multi-couplings!

Risk of injury. Damage to multi-couplings.
Only connect/detach multi-couplings when diesel engine is turned off (ignition key in position 0).
Make sure that the hydraulic system is depressurised.
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32
Connecting multi-couplings
Removing protective cover (Figure 31, item 7) from
the mating piece (8)
Remove the spring plug (Figure 31, item 6).
Remove protective cover and keep safe.
Remove the protective cover from the multi-coupling
(Figure 31, item 2)
Attach the lever and spring plug (Figure 32, item 1).
Move the lever downwards (3).
Take off the protective cover (Figure 31, item 2) and
keep safe.
Connect the mating piece to the multi-coupling
Note color codes of the hoses.
Remove any dirt on the two coupling halves.
Place the mating piece on the multi-coupling. Provided
that the couplings are precisely aligned.
Do not force them. It is better to reposition them.
Pull lever upwards (4) until the lock engages.
33
The lever visibly and audibly pulls the couplings
together.
Indicator pins (Figure 33, item 1) of the multi-cou-
pling protrude.
Remove lever and spring plug and keep safe.

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Disconnecting multi-couplings
To disconnect multi-couplings, go through the same procedure in reverse.
The following points must be observed:
- Turn off the diesel engine.
- Detach multi-couplings.
- Fit all protective covers.
Connect/disconnect electrical equipment
CAUTION !
Live connecting cable!

Electric shock. Damage to electrical equipment.
Before connecting/disconnecting the connecting cable (figure 31, no. 9), ensure that the diesel
engine is stopped (ignition key in position 0).
CAUTION !
Connecting cable not fixed!

Damage to connecting cable.
Insert connecting cable into the equipment’s dummy receptacle before transporting. Close cover
and lock locking lever.
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6.7.3 Fitting the Kelly bar

Installing the swivel
Position the swivel between the Kelly bar and the Kelly rope.
34
Swivel, variant 1
DANGER!
If pins are not completely secure:

Risk of load breaking away.
Ensure that the screws are secured with nitrowire (diameter: 3.2 mm) (Figure 34, item 1).
Insert pin (Figure 34).

Secure screws with nitrowire (diameter: 3.2 mm) (Figure 34, item 1).
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35
Swivel, variant 2
DANGER!
If pins are not completely secure:

Risk of load breaking away.
Ensure that the screws are secured with a cotter pin (Figure 35).
Insert pin (Figure 35, item 1).

Secure the pin with a nut (2) and cotter pin (1).
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36
CAUTION!
Kelly bar swings.

Damage to machine.
Raise Kelly bar with care and caution.
Fitting the Kelly bar

Ensure that the Kelly bar is attached to the Kelly rope by means of the swivel.
Tilt the leader forwards (Figure 36, item 2.).
Carefully raise the Kelly bar (Figure 36, item 2.).
Raise the Kelly bar until it hangs freely.
Raise the Kelly bar above the drilling drive.
Place the leader in a vertical position (Figure 36, item 3).

Retract the Kelly bar in the drilling drive.
Attach the drilling tool.
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6.8 Lay down the leader

6.8.1 Prerequisites
Ensure that the following conditions are satisfied:
The machine has been inspected in accordance with section 5.2 "Checks before daily operation"
and is ready for operation.
All window glass in the operator's cab and the exterior mirrors have been cleaned.
The assembly team has been instructed according to section 6.3.1 and is ready to go into action.
IMPORTANT!
Can be operated with the additional panel (X25) or with the control lever.
6.8.2 Overview of assembly steps
• Disassemble the drilling tool

• Lower the drilling drive all the way down
• Detach the Kelly bar
• Disassemble the drilling drive
• Put the leader in a vertical position
• Set the leader to minimum radius
• Fasten the hose kit
• Place the leader in a horizontal position
• Lay the leader down on the uppercarriage
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37
6.8.3 Procedure
Disassemble the drilling tool (Figure 38, items 1 - 3)
Move the drilling drive all the way down (Figure 37

and Figure 38, item 4.)
Detach the Kelly bar (Figure 39, items 5 and 6)
Disassemble the drilling drive (Figure 39, items 6 and

7)
Fix the rotary drive carriage with the rigging provided
(see Chapter 6 "Fitting/removing the drilling equip-
ment").
38
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39
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Place the leader in a vertical position (Figure 40, items 1 and 2).
Actuate the automatic leader adjustment system.
Set the leader to minimum radius (Figure 40, item 3.)

Fully extend the support arm adjusting cylinders.
Fasten the hose kit
Place the leader in a horizontal position (Figure 41, items 4 - 6).

Retract the support cylinders.
40
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41
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42
Lay the leader down on the uppercarriage
CAUTION!
The leader must be laid down correctly!

Ensure that the claws on the left and right of the
uppercarriage are fitted facing outwards as shown in
Figure 42.
Ensure that the ropes do not become trapped when
laying down the leader.
Fully retract the support cylinders.
Retract the support arm adjusting cylinder (see Figure 43, item 7)
43
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44
6.9 Dismantling and loading the machine
6.9.1 Place the gibbet in the transport position
CAUTION!
Danger of accident!
• Remove spring plugs, washers and bolts (Figure 44,

item 1)
45
• Press the "Cylinder adjustment function on/off" (Fig-
ure 45) selection button on the right-hand control panel
(X23)
• Remove the strain on the Kelly and auxiliary

ropes.
Lower the Kelly and auxiliary ropes a little.
The ropes must not be tensioned.
46
• Fold gibbet into transport position by moving the con-
trol lever (Figure 46).
• Put both bolts back in and secure with washers and
retaining springs.
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6.9.2 Transport lashings
CAUTION!
Danger of accident!
The equipment can slide.
Equipment must be correctly lashed.
• Attach hose kit to the lead.

The machine should be able to move with no prob-
lems.
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47
6.9.3 Track adjustment convergence
The crawler carriers are brought together on the trans-
port track in the reverse sequence to that in which they
were separated
(see "Adjust crawler carrier on working track" in
Chapter 6).
IMPORTANT!
Before moving the crawler carriers together, remove dirt
and dust from the sliding surfaces of the telescopic
outriggers and apply some grease.
• Check (or press) the "Cylinder adjustment function

on/off" selection button on the control panel in the cab:
The LED in the keypad must light up (Figure 47).
• The crawler carriers are retracted by pressing the

control levers on the undercarriage (Figure).
Sequence:
right crawler carrier retracted
left crawler carrier retracted
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48
6.9.4 Fit superstructure locking
DANGER!
Danger of accidents due to accidental turning of the

superstructure!
The superstructure locking must be fitted
- during transport,
- on decommissioning and
- during maintenance and repair work on the rotary
connection.
CAUTION!
Crushing hazard and risk of damage!

The slewing gear must not be operated when the
superstructure is locked.
Exception: to remove butt strap of the superstructure
locking if the bolt is stuck.
Take care when fitting the bolt. Crushing hazard!
Procedure:
• Pull out the retaining spring (Figure 48, item 3) and
remove the bolts (4).
• Turn the superstructure so it is exactly parallel to the
undercarriage (rear travel drives).
• Bolt the butt strap (1) to the superstructure (2) and
secure with retaining spring and washer.
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6.9.5 Driving the machine onto the low loader

See "Driving the machine off the low-loader" in Chapter
6.
49
6.9.6 Taking the machine out of operation
• Turn off the machine as described in Chapter 5
• Lock the cab
Move the platform on the cab (Figure 49) into the

transport position
• Fold up the side platform and lower it straight down.
• Lock the doors on the superstructure.

• Fold up the ladders near the crawler carriers.
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6.10 Transport
6.10.1 Safety precautions for loading and unloading
• The machine must be prepared for transport (placed in the transport position) according to the
instructions in this chapter.
• The low-loader and transport vehicles must be equipped with suitable fixtures and lashings for
securing the load.
• The transport vehicle must maintain a safe distance from crevices, ditches, humps, slopes and
ramps, to avoid any risk of accidents.
• The driver must leave the cab of the transport vehicle during the whole of the loading and
unloading activities and must not remain within the danger area.
Exceptions:
The cab has a protective roof to guard against falling heavy pieces of equipment.
If no loads are swung over the cab and the cab is protected from the loading floor by a front wall
reinforcement or impact wall.
• When loading and unloading, above all ensure that
- a signalman is available,
- persons are not endangered by falling, tilting or rolling items of equipment,
- an adequate safe distance is maintained from overhead power lines or contact lines (see Chapter
3 "Safety instructions"),
- the transport vehicle cannot roll away, topple or fall over,
- adequate lighting is available for working in poor light.
• When loading and unloading with an auxiliary crane
- only use cranes with adequate load capacity,
- use only tested slinging equipment,
- use the specified attachment points,
- keep all parts as close as possible to the ground.
• Lash or stow the machine and the equipment in accordance with the requirements so that no one
is endangered under normal traffic conditions.
• Specially mark all parts protruding beyond the loading floor so that they are noticeable to other
traffic at all times.
• When loading the transport vehicle, do not exceed the permitted values for total weight, axle loads,
static supporting load and trailer load.
• Unload the equipment with the same care as when loading. Clear away all loose chains and
wedges before unloading.
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Safety regulations for transport on public roads

• Observe national traffic regulations and local bylaws (relating to transport weight, width, markings,
escort vehicle, driving times and rest periods etc.)
- This also applies to transit countries.
• All necessary transport authorizations must be available before beginning transport.
• Check the transport route beforehand and in particular familiarize yourself with
- road widths,
- entrances to tunnels and underpasses,
- load capacity of bridges, roads and road fortifications,
- safe distances from overhead power lines.
• The driver must
- have the requisite physical and mental aptitude,
- have adequate training, knowledge and professional experience,
- exhibit appropriate personal attributes (such as age, reliability, etc.).
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6.10.2 Transporting the machine with a low-loader

When requesting a low-loader from a haulage firm, the following details of the basic machine must
be quoted (see Chapter 2 "Technical data"):
• Transport weight
• Transport height
• Transport width
The exact transport weight further depends on the fuel level and built-in options.
The machine is carried on a transport vehicle (low-loader) in the position illustrated below (Fig-
ure 50). Concerning the transport position of the machine, the following conditions must be observed:
• The hose kit must be fixed to the lead. The hose kit must be secured for transport with lashing
belts.
• The drilling drive and drilling tool must be removed for transport.
- Gibbet in the transport position
- Lead lower part is in the transport position and the drilling gear slide is dismantled.
• Ropes must be withdrawn or fixed for transport.
• The cab must be locked and the platforms must be in the transport position.
• The superstructure locking must be in place.
• The ladders on the undercarriage are folded up.
• In general, all parts which exceed the legal transport height or width are to be folded down,
removed or dismantled.
50
Machine in transport position (example)

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WARNING!
The basic machine can slide on the low-loader!

Precautions:
Deck out loading floor with non-slip underlay.
Check and retighten the lashing of the basic machine at latest after a day's traveling.
51
Lashing and securing the basic machine on the low-
loader (example)
• Attach four steel chains as shown in Figure 51

- to shackles on both sides of the crawler carriers
- anchor them crosswise on the low-loader (pay
attention to guying angle),
- tension them with ratchet type tensioners.
CAUTION!
With different lashing: On no account lay steel

chains over hydraulic pipes and do not damage
painted surfaces.
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6.10.3 Transporting overseas

If delivered by the manufacturer
the cab must be protected against transport damage by sturdy wooden shuttering,
attachments and accessories must be packed in wooden crates which are lined with plastic sheets
and waterproofed,
desiccants must be included in the packaging to protect electronic components.
CAUTION!
The basic machine and sensitive attachments may be exposed to salt water or a saline
atmosphere due to:
inappropriate transport,
damage to transport containers,
unsuitable or incorrect packaging.
Possible outcomes are:
partial or total ruin of the electronic control system,
corrosion damage, having an adverse impact on safety and operational reliability.
Precautions:
The basic machine may only be shipped below deck .
Packaging should only be entrusted to professional shipping companies.
Prior to assembly or placing in temporary storage, thoroughly rinse all parts of the machine that have
been exposed to salt water during the voyage with fresh water.
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6.11 Lifting the machine

6.11.1 Prerequisites
- Leader and gibbet in the transport position.
- Use slinging equipment that is sufficiently strong and in perfect condition.
- Only use cranes with adequate load capacity.
- Only lift the machine if wind speed is low (0-2 Beaufort).
6.11.2 Procedure
DANGER!
Risk of falling!
- Use suitable climbing gear.
- Ensure adequate safety.
52
Fit the claws on the uppercarriage facing inwards
(Figure 52).
Check that the claws grip the leader guide on both
sides.
• Tighten the screws. Observe correct tightening torque.
53
Attach transport shackles (Figure 53, item 1).
• Check machine counterweight.
• Position the transport shackles according to tables
6-01 - 6-04 and Figure 54.
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Centre of gravity of the machine

LB 20 Standard model with no options
Counter- Total weight in t, tank empty X in Z in X1 in X2 in
weight in t mm mm mm mm
None 51 454 1690 5340 6950
8 59 -55 1727 5852 6440
10 61 -176 1736 5970 6320
Table 6-01

None 53.5 434 1639 5360 6930
8 61.5 -51 1681 5850 6450
10 63.7 -167 1691 5960 6330
Table 6-02

None 69 311 1814 5660 9500
5 74 39 1835 5930 9240
5+5 79 -209 1853 6180 8990
5 + 10 84 -441 1867 6410 8750
5 + 5 + 10 89 -653 1881 6620 8540
Table 6-03

None 76.6 437 1757 5530 9630

5 81.5 183 1787 5790 9380
5+5 86.5 -52 1814 6020 9140
5 + 10 91.5 -273 1834 6240 8920
5 + 5 + 10 97 -478 1856 6450 8720
Table 6-04
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54
Position of the transport shackles
55
• Adjust the claws of the transport shackles (Figure 55, item 1) on the leader width.
Check that the claws grip the leader guide on both sides.
• Fit the pins (Figure 55, item 2).
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56
Fit the edge protection on each side (Figure 56, item
1).
Attach and secure the round slings (Figure 57, item 1) and tie-down straps (Figure 57, item 2).
57
Attach the machine as shown in Figure 54

- The slinging equipment is at least 10 m long.
- Longitudinal slinging angle: 0-20°.
- Latitudinal slinging angle: 85°-90°.
DANGER!
Risk of falling!
- Carry out movements slowly and with great care.

- Ensure that the machine is hanging level.
Lifting the machine

• Level out the machine and adjust the hoisting crossbars if required.
• Check that the machine is rising horizontally.
• Check that the centre of gravity is correct: to do this lift the machine a maximum of 100 mm.
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NOTES:
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7. MAINTENANCE
7. MAINTENANCE
• This chapter contains tables listing all the maintenance work that has to be carried out on the
machine.
• However, only the work that the machine operator (maintenance personnel) is allowed to perform
(after 8 and after 40 operating hours) is explained.
• Maintenance work after 500 (and more) operating hours may only be carried out by authorized
qualified personnel.
Maintenance personnel:
Trained personnel with the appropriate qualifications, specialist knowledge and experience, who are
needed to carry out maintenance tasks.
Symbols for the tasks carried out by maintenance personnel
x One-off task
o At regular intervals
+ As and when necessary
Every year at the start of the cold season
*
Authorized qualified personnel:
Specially trained personnel with comprehensive and in-depth knowledge about components and
systems and who have been authorized by LIEBHERR WERK NENZING to carry out this work.
These are primarily LIEBHERR service engineers who have been trained by the manufacturer itself
or one of its service agents.
Symbols for the tasks carried out by authorized qualified personnel
x One-off task
o At regular intervals
+ As and when necessary
Every year at the start of the cold season
*
7.1 General
NOTE !
In addition to the safety instructions set out in chapter 3, take particular care to ensure that persons
working on the superstructure are secured to prevent them from falling.
The maintenance and inspection intervals are specified as operating hours and calendar period;
whichever comes first is applicable. Whenever a maintenance interval with a higher hour/calendar
day count falls due, any work scheduled for the lower hour/calendar day counts should be carried
out as well.
The maintenance tasks must be carried out conscientiously. The intervals must not be exceeded but
may be shortened if necessary. Shortening of intervals largely depends on the operating conditions.
Whenever the machine will not be in use for at least 3 months, all exposed parts must be covered
and protected against the environment.
This protection must be removed before re-commissioning the machine.
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7. MAINTENANCE
7.1.1 Lubricants
Lubricants have 3 essential functions:

1.) Reducing friction
2.) Preventing corrosion
3.) Removing dirt or abrasion particles
Furthermore, note that the higher the quality of the lubricant, the longer the service life of the
components and the lower the amount of wear. High-quality lubricants also have a lower moisture
content, which means they last longer.
The specified lubrication intervals must not be exceeded, but can be shortened if necessary.
Shortening of intervals largely depends on the operating conditions.
The maintenance intervals should be shortened if:
- There are considerable temperature differences on the site
- Work is normally carried out at high temperatures
- Work is carried out in a corrosive environment (e.g. chemical plant)
- Work is carried out where the air is polluted and dusty
- Heavy loads are often lifted
IMPORTANT!
All lubricating tasks with specified intervals as listed in chapter 7, "Lubrication Chart", must be
strictly adhered to and are no longer included in the following maintenance table.
7.1.2 Welding work
DANGER!
The machine is constructed from high-strength fine-grained structural steel.

• Welding work may only be carried out by authorized qualified personnel following very precise
guidelines. The welding of ancillary profiles, plates, tubes, etc., must also be carried out by
authorized qualified personnel!
Welding work carried out by customers, or by individuals who have not been authorized by
LIEBHERR WERK NENZING, can result in considerable damage to the machine!
The results could be fatal!
IMPORTANT!
More information can be found in Chapter 7 "Welding repairs".
7.1.3 Cylinder
Grease the piston rods for the freely accessible cylinders:

The piston rods for all cylinders are chromed. Nonetheless, dirty and aggressive materials can
damage the chrome coating. The chrome coating is therefore only a provisory protection.
In order to prevent damage, ensure that the piston rods:

- are retracted and again extended at least once per week.
- inspected and kept clean.
- conserve weekly with the protective agent CORTEC VCI 369 (ID no. 861008614).
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7. MAINTENANCE
7.2 Maintenance chart

7.2.1 Work to be carried out
Maintenance/inspection
according to WORK TO BE CARRIED OUT
Operating hours
4000 hrs/every 2 years by maintenance personnel by authorised qualified personnel
6000 hrs/every 3 years
x One-off task x One-off task
1000 hrs/half-yearly
o At regular intervals o At regular intervals

500 hrs/3-monthly
2000 hrs/annually
special intervals
+ As and when necessary + As and when necessary
40 hrs/weekly
Every year at the start of the cold season Every year at the start of the cold sea-
* *
8 hrs/daily
son
HYDRAULIC SYSTEM
o Check oil level in the hydraulic tank through the top sight glass and top
up if necessary. See chapter 7 for the oil type and filling capacity.
All cylinders must be retracted.
Exception: Tilting-back support cylinders on LR/HS
o Carry out a hydraulic oil analysis ten hours after every oil change
(reference measurement)
x Carry out a hydraulic oil analysis after 500 h
o Carry out a hydraulic oil analysis after 1000 h / 1 year
o Change NON-LIEBHERR hydraulic oil after 2000 h / 2 years
o Change Liebherr "Hydraulik 37" hydraulic oil after 4000 h / 4 years
o Change Liebherr "Hydraulik Plus" and "Hydraulik Plus Arctic" oil after
6000 hrs / 6 years
o Check the hydraulic system for leaks
o Check all hydraulic hoses
o Recommendation: Change all the hydraulic hoses every 12000 hrs; time
interval depends on embossed date
o Check and if necessary adjust the working pressures of the hydraulic
system
o Check that the rotary connection is firmly attached and does not leak
o Change the ventilation filter on the hydraulic tank
o Change the hydraulic filter elements
o o Clean the magnetic rod in the return filter (weekly for the first 250
operating hours)
o Check and clean oil cooler if dirty
o Check that the units and the screw fittings are tight and retighten if
necessary
o Check all hydraulic cylinders for leaks and tight fit
o Check the accumulator
o Replace the accumulator
o Lubricate the piston rods of all exposed cylinders
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7. MAINTENANCE
Service/Inspection
operating hours
by maintenance personnel by authorized qualified personnel
x one-off task x one-off task
4000 hrs / every 2 years
1000 hrs / half-yearly
o at regular intervals o at regular intervals

500 hrs / 3-monthly
2000 hrs / annually
+ as and when necessary + as and when necessary

Special intervals
40 hrs / weekly
every year at the start of the cold season every year at the start of the cold season
* *
8 hrs / daily
ELECTRICAL SYSTEM / CONTROL

o Test control system for any errors; dump error codes from memory
o Clean battery connections and lubricate with battery grease
o Check battery fluid and top up if necessary (using distilled water only)
o Check that all the EMERGENCY STOP switches are working
o Check all connectors in the switch cabinet for tight fit and tighten if
necessary
o Check cable guides and cable connections for chafing
o Check hoisting limit switches, boom limit switches and, if necessary, limit
switches of the piling and drilling unit to ensure they are working
properly
o Check that the mechanical inclinometer is working properly
o Check that the floodlights/additional floodlights are working properly
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7. MAINTENANCE
Service/Inspection
operating hours

500 hrs / 3-monthly
2000 hrs / annually

Special intervals
40 hrs / weekly
* *
8 hrs / daily
ROPES
o Check that the ropes are guided correctly over the rope pulleys and that
the rope winds correctly onto the drum
o Check ropes for wear, tight fit and lubricate if necessary
o Check for breakages in the rope suspensions (rope clamps), check that
the screw fittings are tight and free of rust
o Check the rope and pocket lock
o Check press end attachments for cracks and replace entire rope if
necessary
o Check the rope thimble connections
o Check the feed ropes and feed winch for wear, wire breaks, rust and
adequate lubrication, particularly around the feed winch
o Replace the feed ropes in conjunction with the capstan
o Check the feed ropes and replace if necessary
ROPE PULLEYS
o Check all rope pulleys for ease of movement, signs of wear and damage
o Lubricate all the rope pulleys in the lifting system (pulley block, boom
head, rope guides, etc.)
See the lubricant table for the grease type
o Lubricate all rope pulleys in the boom luffing system
o Lubricate all rope pulleys in the lifting system and feed system
o Check rope deflection pulley for tight fit
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7. MAINTENANCE
Service/Inspection
operating hours

500 hrs / 3-monthly
2000 hrs / annually

Special intervals
40 hrs / weekly
* *
8 hrs / daily
SLINGING EQUIPMENT
o o Check transportation belts and round slings for wear (according to EN
1492-2).
o o Check the round steel chains for wear and damage
LOAD HOOKS / PULLEY BLOCKS
o o Check all load hooks / pulley blocks for damage, wear, corrosion and
widening of the hook opening
o Load hooks (without pulleys): Lubricate the swivel
o o Pulley blocks (with pulleys): Lubricate the bearings and axles, check the
rope fixation, check for ease of movement and wear of the pulleys,
check that the rope guard and the retaining elements are present and
undamaged.
o Check that the safety latch is present and working properly
REAR / CENTRAL / ADDITIONAL COUNTERWEIGHT
o Check the fixation straps and round steel chains of the rear coun-
terweight for damage, wear and tight fit
o Check that the retaining elements are present, and check them for
damage and tight fit
o Check the bolting cylinders and the limit switches of the rear coun-
terweight if they are present
o Check the counterweight fixtures (bolts/straps) for damage
GENERAL
o Authorized qualified personnel have to check the machine
o o Check the steel construction of the machine for damage, cracks
o Check the seals and inspection dates on the fire extinguishers
o Check that all required safety signs are affixed to the machine and are
legible
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7. MAINTENANCE
Service/Inspection
operating hours

500 hrs / 3-monthly
2000 hrs / annually

Special intervals
40 hrs / weekly
* *
8 hrs / daily
DIESEL ENGINE D934; D936; D846; D9508

o Engine; check oil level and oil pressure
o Change the engine oil
Only E4, E6, E7 engine oil should be used
o Change the engine oil filter
o Checking that the oil sump and engine support fastening screws are
tight-fitting
o Checking the condition and tension of v-belts, replacing them if neces-
sary
o Check engine for leaks, damage and dirt and clean if necessary
x o Checking that the intake and exhaust systems have no leaks and are
tight-fitting
o Changing the oil separator filter element
Check flame starting system at the start of the cold season
o
* Lightly grease crown gear on the flywheel
o Checking the vibration damper every 3000 hrs for deformation (on
engine type D934/D936)
o Checking the charge air regulating valve/flap on the turbocharger
(wastegate)
o Exhaust gas recirculation (EGR): checking the stop valve (if present)
x o Check and if necessary adjust the valve clearance
Check the heating flange (except engine type D846)
*
o Change the heating flange (except engine type D846)
o Coolant circuit; check coolant level and top up if necessary
o Check antifreeze and DCA concentration (DCA-4), change water filter if
necessary
o Cooling circuit; change coolant
o Check radiator and fan wheel for dirt and clean if necessary
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7. MAINTENANCE
Service/Inspection
operating hours

500 hrs / 3-monthly
2000 hrs / annually

Special intervals
40 hrs / weekly
* *
8 hrs / daily
Continued: DIESEL ENGINE D934; D936; D846; D9508

o Change the filler cap on the compensation tank
o Fuel pre-filter, if necessary drain condensation water
o Replacing the fuel pre-filter (do this earlier in the event of an error
message/drop in performance)
o Replacing the fuel fine filter (do this earlier in the event of an error
message/drop in performance)
o Fuel tank; drain condensation water and sediments
o x Check coolant pump and replace if necessary
o Check dry air filter and test negative pressure indicator
o Emptying the dry air filter, dust collection container (earlier, if necessary)
o Replace the filter element in the dry air filter
DIESEL PARTICLE FILTER
o Checking the condensate trap
o Replace condensate trap
o Checking cables, hoses and screw connections
o Visually check the diesel particle filter
o Checking fixing lugs for tightening torque (12 Nm)
o Cleaning ash deposits from filter (if Liebherr
10W40 low ashengine oil is being used)
o Cleaning ash deposits from filter (if all other permissible engine oils are
being used)
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7. MAINTENANCE
Service/Inspection
operating hours

500 hrs / 3-monthly
2000 hrs / annually

Special intervals
40 hrs / weekly
* *
8 hrs / daily
POWER DIVIDER
o Check the oil level and venting valve
o Change oil
o Check fastening screws for tight fit
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7. MAINTENANCE
Service/Inspection
operating hours

500 hrs / 3-monthly
2000 hrs / annually

Special intervals
40 hrs / weekly
* *
8 hrs / daily
ALL WINCHES
o Check oil level of winch gearbox
o Checking winch gearbox for leaks and if necessary carrying out an oil
analysis
x o Change winch gearbox, oil
o Change crowd winch, oil
o Lubricate the counter bearing if possible
o Check rope end fastening for tight fit
o Checking the 3 rope windings limit switch for tight fit and correct
operation
o Check winches for tight fit (pin clearance, retainer)
o Check the fastening screws for tight fit and tighten if necessary
o Check the mechanical connection hydraulic motor/gearbox or drive
(pinion/sleeve) for wear, replace if necessary
o Checking the down time monitor for tight fit and correct operation
o Carrying out a visual check; recording the operating hours of the
winches
o Check that stopping brakes are working
o Checking that the free-fall brake is working (if present)
o Check that the constant tension of winches 1 and 2 operates correctly (if
present)
o Checking that the free-wheel is working properly (if present)
x o Hydraulic motor and drive planetary stage: Check toothed profile for
wear and change if necessary
o Checking that the line pull limitation is working properly
o Checking that the line pull limitation is working properly using test
weights
TAGLINE WINCH
o Check fixed-caliper disc brake for damage
o Lubricating the rope bracket on the boom base section and checking
pulleys for damage
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7. MAINTENANCE
Service/Inspection
operating hours

500 hrs / 3-monthly
2000 hrs / annually

Special intervals
40 hrs / weekly
* *
8 hrs / daily
CAB
o Check the windows of the cab for damage
o Check that the door and the door lock work properly
o Check the outside and inside mirrors for damage
o Check that the driver's seat works properly
o Check that the hydraulic cab tilting system is working properly.
o Check the adjustment cylinders, hydraulic hoses and connections of the
hydraulic cab tilting system for leaks and damage
o Hydraulic cab elevation:
- Check that the acoustic warning signal works properly
- Check that the controls (valves, displays, etc.) work properly
- Check that the safety chain is present and working properly
o - Hydraulic cab elevation:
- Check hydraulic hoses and connections for leaks and damage
- Check that the lowering device is present and working properly
- Check the attachment point on the cab for damage
- Check the emergency lowering system
- Check for presence of bolt retaining elements
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7. MAINTENANCE
Service/Inspection
operating hours

500 hrs / 3-monthly
2000 hrs / annually

Special intervals
40 hrs / weekly
* *
8 hrs / daily
HEATING / VENTILATION / AIR-CONDITIONING

o Check that the heating and the ventilation system are working properly
o
* Check that the air-conditioning works and that there are no leaks
o Replace fresh air filter at top rear of the cab
o Check the hoses of the hot water circuit for leaks or damage
o Start heating system and make sure sufficient antifreeze has been
added to the water
o Check the refrigerant level
o Check the dryer for mechanical damage and corrosion
o Exchange dryer
o Check coolant pipes and connectors for leaks and damage
o Check that the compressor does not leak and fits properly
o Check drive belts for damage
o Check the condenser and the evaporator for leaks and clean if neces-
sary
o Clean filter on heating/air conditioning device, exchange if necessary
o Clean condenser and evaporator
o Bring air-conditioner into operation monthly (grease plant parts)
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7. MAINTENANCE
Service/Inspection
operating hours

500 hrs / 3-monthly
2000 hrs / annually

Special intervals
40 hrs / weekly
* *
8 hrs / daily
SLEWING GEAR TRANSMISSION and ROTARY CONNECTION

o Check oil level and top up if necessary
o Check gearbox for leaks
x o Change the oil
o Gear box and oil motor: Check the fastening screws for tight fit
(fastening screws may only be used for a maximum of two more
mounting procedures)
o Rotary connection: Check fastening screws for tight fit
o Lubricate the exterior teeth of the rotary connection
o Lubricate the bearing races of the rotary connection via the central
lubrication point (preferably at the end of the shift)
o Visually inspect the slewing gear pinion and the crown gear
x o Measure bearing clearance of rotary connection
o Check that the slewing gear stopping brake works
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7. MAINTENANCE
Service/Inspection
operating hours

500 hrs / 3-monthly
2000 hrs / annually

Special intervals
40 hrs / weekly
* *
8 hrs / daily
CRAWLER DRIVE
o Checking the oil level
x o Change the oil (if the crawlers are used a lot, more than 15% of the
engine operating hours)
o Check fastening screws for tight fit
o Check tumbler wheel and crawler engine fastening screws for tight fit
o Check gearbox and hydraulic connections for leaks
CRAWLERS
o Visually check crawler components (carrying rollers, running rollers,
idlers, track pads)
o Clean the crawlers, earlier if necessary
o Checking screws, nuts and fixing pins for tight fit
o On telescopic undercarriages, check the locking screws on the chords of
the crawler side frames for tight fit and tighten if necessary (HS855 or
LR1100: always tighten them until there is absolutely no play)
o Check chain guides for wear and tight fit
o Check chain tension and re-tension if required (earlier if necessary);
note: re-tensioning must be done using the crawler control in the case of
hydraulic pretensioning
o Tighten track pad screws
o Check rope tensioning cylinders for leaks
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7. MAINTENANCE
Service/Inspection
operating hours

500 hrs / 3-monthly
2000 hrs / annually

Special intervals
40 hrs / weekly
* *
8 hrs / daily
PILING and DRILLING UNIT

o Check the lead joints
o Check that the screws on the lead joints are correctly seated (every 100
hours or sooner)
o Replace the screws on the lead joints with new original parts (lead joint
screws may only be used a maximum of 2 more mounting procedures)
o Lubricate the piling and drilling unit
o Check the piling and drilling unit for damage and wear (cracks and
notches, corrosion, plastic deformation, wear)
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7. MAINTENANCE
Service/Inspection
operating hours

500 hrs / 3-monthly
2000 hrs / annually

Special intervals
40 hrs / weekly
* *
8 hrs / daily
ACCESSORIES / OPTIONS
o Check that the refueling pump works properly and is not leaking
o Check the helicopter warning lights for damage and correct operation
- If present, check the mains cable and connection plug (230 V) for
damage
o Check that the rope length metering of all winches and height measure-
ments operates correctly
o Check that the personal protective gear is in place, intact and complete
o Check that the GSM service modem works properly
o Check that the diaphragm wall grab works properly
o Check that the hose winches, sump pans, cable winches, hose guides,
cable guides, rope pulleys and hose reels with scrapers are undamaged
and correctly fastened.
o Check that the rope pulleys and hose reels on the boom head run
smoothly
o Lubricate hose winch bearing at the central lubrication point
o Check the oil level of the hose winch gear
x o Change hose winch gear oil
o Check that the bolt retraction device is complete and fully operative
o Lubricate grab rope guide
o Check the grab rope guide for wear and damage
o Check that the safety harness and fall protection slide operate correctly
o Have the safety harness and fall protection slide inspected
o Check that the hydraulic oil heating is working properly
o Check that the auxiliary heating is working properly
o Check the function lock for correct operation
o Check that the central lubrication for the slewing ring is working correctly
o Check that the central lubrication for the tooth flanks is working correctly
o Check that the central lubrication for the lead runners is working
correctly
o Check that the central lubrication for the kinematics is working correctly
o Check that the PDE and printer are working properly
o Check that the vibrator cooling is working properly
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7. MAINTENANCE
1
7.3 Diesel engine
7.3.1 Engine; check oil level and oil pressure
Check the oil level
Always check engine oil levels with the machine level.
• Switch off the diesel engine and wait 2 to 3 minutes
until the oil has collected in the oil sump.
• Open middle maintenance door on the left of the
superstructure.
• Remove dipstick (Figure 1, item 3), wipe it with a

clean cloth and re-insert it as far as possible.
2
• Take out the dipstick again and check the oil level.
markings on the dip stick, otherwise top up with oil
(Figure 2).
- For the total oil quantity and grade of

oil to use, see Chapter 7 "Capacities" and
"Lubricant requirements".
Check oil pressure
• Start the diesel engine, see Chapter 5
• On the "Power unit monitoring" screen

(Chapter 4), check the oil pressure.
The following values must be indicated:
- Engine is cold and idling;
5 bar
- Engine is warm and idling;
3 - 4 bar
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7. MAINTENANCE
7.4 Fuel System
DANGER!
Do not smoke, handle open fire or open light near the fuel system!
Never let fuel drain into the ground, always use a suitable waste container!
3
7.4.1 Drain off condensate
The water separator (Figure 3, item. 3) and the fuel filter
(1) is mounted directly on the diesel engine.
• Open the rear maintenance door on the left of the
superstructure.
• Place a suitable container (approx. volume: 5 l) under
the water separator and fuel filter.
• Open the drain plug (Figure 3, item 4) on the bottom
(by turning it counter-clockwise) and drain off con-
densation water until only pure fuel flows out.
• Close the drain plug again.
4 7.4.2 Draining condensation and sediments from

the fuel tank
The fuel tank (Figure 4) has a water drain valve (3) on
its underside to allow condensation to be drained from
the fuel tank. It can also be used to drain off fuel.
To drain off water, unscrew the drain plug on the drain
valve by two turns until water-free fuel flows out, then
retighten the drain plug.
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7. MAINTENANCE
7.4.3 Bleeding the fuel system
CAUTION!
Any work on Common Rail System components should only be carried out by specially-
trained personnel.
It may be necessary to bleed the fuel system after the

following actions:
- Work was done until the fuel tank was empty.

- Fuel filter changed.
- Fuel tank cleaned.
- Fuel system repaired.
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7. MAINTENANCE
7.5 Cooling system

7.5.1 Check coolant level, top up if necessary
CAUTION!
Hot coolant can burn!

At operating temperature, the engine cooling system is very hot and pressurized.
Avoid touching parts carrying the coolant.
Do not check the coolant level until the system has cooled down.
5
• While the diesel engine is cold , the coolant should
come up to the center of the sight glass (Figure 5,
item 1). Top it up if necessary.
Topping up coolant
IMPORTANT!
The cooler cap with overpressure valve (Figure 5, item
2) on the equalizing reservoir (Figure 5) is lead-sealed
and must not be opened! It is used to bleed the cooling
system.
• If cooling system is cold

- Open the cooler cap with underpressure valve (Figure 5, item 3).
- Top up the coolant until it reaches the center of the sight glass.
• If cooling system is hot (Danger of burning, wear protective gloves)

If the level sensor trips during operation, check the coolant level and top it up.
- First turn the cooler cap and underpressure valve (Figure 5, item 3) carefully through 90° to
relieve any excess pressure.
- Top up the coolant until the sight glass is completely full.
NOTE!
The cooling system should be filled with a suitable antifreeze all year round. The coolant comprises
50% fresh water and 50% anticorrosive/antifreeze agent.
For specifications, see Chapter 7 "Capacities" and "Lubricant requirements".
On leaving the factory, the cooling system is filled with anticorrosive/antifreeze agent for tempera-
tures down to -37°C [-35°F].
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7. MAINTENANCE
6
7.6 Dry air filter
7.6.1 Arrangement on the central power unit
The dry air filter is accessible after opening the front
maintenance door on the superstructure.
Names of the components (Figure 6)
1 Plastic cover
2 Discharge gate of the dust collection container.
7
Names of the components (Figure7)
1 Main element
2 Safety element
8
The dry air filter is equipped with a pressure sensor for
the clogging indicator (Figure 8, item 1).
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7. MAINTENANCE
7.6.2 Emptying the dust collection container

• The dust collection container must be emptied if the error message "Air filter clogged" appears on
the "Power unit monitoring" screen.
• Press the discharge gate of the dust collection container and remove any dirt.
• Open metal straps and remove plastic cover (1).
• Remove the main element (Figure 7, item 1).
• Blow compressed air through the main element from the inside to the outside.
The pressure must not exceed 5 bar . Move the nozzle up and down inside the element, keeping
it at least 2 cm away from the element. Cleaning is finished when no more dust can be seen
escaping.
• Check the safety element (2) to ensure that it is seated firmly.
• Insert the main element.

• Replace the plastic cover and secure with metal clips.
NOTE!
The dry air filter is designed to provide maximum engine protection with long maintenance intervals.
It is recommended that the filter cartridges are only removed when the "Air filter clogged" warning
appears on the "Power unit monitoring" screen, although this should be done at least once per
year . Removing and replacing them too often may damage the seals between the filter element and
the housing.
The Main element must be renewed after 3 cleans or at the latest after one year .
If the main filter element is heavily soiled, it should be renewed.
Do not clean and reuse the safety element (Figure 7, item 2). It should be replaced with a new
one after 3 cleans of the main element.
Only original filter elements may be used.
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7. MAINTENANCE
9
7.7 Power divider
7.7.1 Checking the gearbox oil level
Check the gearbox oil level with the machine standing
on level ground. After turning off the diesel engine, wait
2 - 3 minutes for the oil to collect.
• Dipstick (Figure 9, item 1), wipe it with a clean cloth
and re-insert it as far as possible.
• Take out the dipstick and check the oil level.

markings on the dipstick, otherwise top up with oil
(Figure 10).
- For the total oil quantity and grade of 10
oil to be used, see Chapter 7 "Capacities" and
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7. MAINTENANCE
7.8 Crawlers
7.8.1 Cleaning and maintaining the crawlers
NOTE!
Dirt causes increased chain tension.
• Clean the crawlers regularly.
• Ensure the crawlers are kept clean.
NOTE!
• Use a suitable cleaning agent.
• Clean the undercarriage using a high-pressure cleaner.
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7. MAINTENANCE
7.9 Guide wheels

The guide wheels are located in the guides on the crawler side frame and are equipped with a
tensioning system.
7.9.1 Overview of the crawler tensioning systems
Grease Grease tensioner/ Grease tensioner/ Hydraulic

tensioner/ Nitrogen cylinder Elastomer cylinder tensioner
Spring
Chain tension X X X -
check
HS 825 X
HS 835 X
HS 845 X
HS 855 X
HS 875 X
HS 885 X
HS 895 X
LR 1100 X
LR 1130 X
LR 1160 X
LR 1200 X
LR 1280 X
LR 1300 X
LB 16 X
LB 20 X
LB 24 X
LB 28 X
LB 36 X
LRB 125 X
LRB 155 X
LRB 255 X
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7. MAINTENANCE
WARNING!
Explosion hazard!
The nitrogen cylinders are maintenance-free. Repairs on this pressure ves-
sel may only be carried out by authorised and qualified personnel.
WARNING!
The elastomer cylinders are maintenance-free. Repairs on this pressure vessel may only be
carried out by authorised and qualified personnel.
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7. MAINTENANCE
7.10 Checking the chain tension
NOTE!
Too high a tension causes increased wear.
Too little tension results in unwinding of the crawler chain.
• Move the machine forwards 3 m

• Move it back again in order to compensate for any play in the chain.
• Place the measuring rod on the crawler side frame (Figure 11).
• Measure the distance between the measuring rod and the chain (Figure 11, x), maximum permis-
sible distance: 40 mm [1.57 inch].
- value OK, no further action required.
- value too high, tension the chain.
11
7.10.1 Tensioning the chain

12
• Unscrew the cover (Figure 11, item 1) on the crawler
side frame.
• Connect the grease gun to the grease nipple on the
guide wheel rope tensioning cylinder (Figure 12).
• Apply grease until the pressure gauge in the grease
gun displays a pressure of approx. 160 - 180 bar .
• Check the chain tension again
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7. MAINTENANCE
13 7.10.2 Floor plates
NOTE!
Tighten the screws diagonally. (Figure 13)
Oil the thread and contact surface under the screw head slightly.
Turn-angle method
NOTE!
Pre-tension the bolts as indicated in the table. The turn the bolts another 120° to reach the maximum
pre-tension force.
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7. MAINTENANCE
Overview of tightening torques for the ground plate screws
Machine Screw Strength grade Torque method

type Nm
HS 825 M 20 x 1.5 12.9 750 +/-40
HS 835 3/4 x 16 UNF 12.9 640 +/-30
HS 845 3/4 x 16 UNF 12.9 640 +/-30
HS 855 7/8 x 14 UNF 12.9 1020 +/-50
HS 875 1 x 14 UNF 12.9 1560 +/-80
HS 885 1 1/8 x 12 UNF 12.9 2210 +/-110
HS 895 M30 x 2 13.9 2810 +/-140
LR 1100 7/8 x 14 UNF 12.9 1020 +/-50
LR 1130 1 1/8 x 12 UNF 12.9 2210 +/-110
LR 1160 1 1/8 x 12 UNF 12.9 2210 +/-110
LR 1200 -
LR 1280 -
LR 1300 -
LB 16 M 20 x 1.5 12.9 750 +/-40
LB 20 M 20 x 1.5 12.9 750 +/-40
LB 24 3/4 x 16 UNF 12.9 640 +/-30
LB 28 7/8 x 14 UNF 12.9 1020 +/-50
LB 36 7/8 x 14 UNF 12.9 1020 +/-50
LRB 125 M 20 x 1.5 12.9 750 +/-40
LRB 155 3/4 x 16 UNF 12.9 640 +/-30
LRB 255 7/8 x 14 UNF 12.9 1020 +/-50

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7. MAINTENANCE
Machine Screw Strength grade Torque method

type ft lb
HS 825 M 20 x 1.5 12.9 533 +/-30
HS 835 3/4 x 16 UNF 12.9 472 +/-22
HS 845 3/4 x 16 UNF 12.9 472 +/-22
HS 855 7/8 x 14 UNF 12.9 752 +/-37
HS 875 1 x 14 UNF 12.9 1151 +/-44
HS 885 1 1/8 x 12 UNF 12.9 1630 +/-81
HS 895 M30 x 2 13.9 2073 +/-103
LR 1100 7/8 x 14 UNF 12.9 752 +/-37
LR 1130 1 1/8 x 12 UNF 12.9 1630 +/-81
LR 1160 1 1/8 x 12 UNF 12.9 1630 +/-81
LR 1200 -
LR 1280 -
LR 1300 -
LB 16 M20 x 1.5 12.9 553 +/-30
LB 20 M20 x 1.5 12.9 553 +/-30
LB 24 3/4 x 16 UNF 12.9 472 +/-22
LB 28 7/8 x 14 UNF 12.9 752 +/-37
LB 36 7/8 x 14 UNF 12.9 752 +/-37
LRB 125 M20 x 1.5 12.9 553 +/-30
LRB 155 3/4 x 16 UNF 12.9 472 +/-22
LRB 255 7/8 x 14 UNF 12.9 752 +/-37
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7. MAINTENANCE
14
7.11 Slewing gear transmission/Rotary
connection
7.11.1 Slewing gear transmission, checking the oil

level
When checking the oil level, the machine must be stand-

ing on level ground.
• The two slewing gearboxes are at the front of the

superstructure.
• Dipstick (Figure 14, item 1), wipe it with a clean cloth
and re-insert it as far as possible.
markings on the dipstick. Top up oil if necessary.
- For the total oil quantity and specifications of the
7.11.2 Lubricating the crown gear/pinion
The pinion and crown gears must be sprayed with

graphite spray or greased daily.
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7. MAINTENANCE
15
7.11.3 Lubricating the rotary connection bearing
races
• Open the rear right maintenance door.

• Remove the protective cover. Lubricate the grease
nipple (Figure 15, item 2, marked "KUD").
CAUTION!
During rotation no one must be in the rotational area

of the machine!
• Turn the superstructure by 45° further and lubricate the grease nipples anew.
Repeat this procedure all the way round. Put the protective cover back on.
• To distribute the grease better, turn the superstructure through one complete revolution.
• A collar of grease should form at the lip of the seal, that is to say, grease should emerge evenly
around the whole circumference.
• Close the rear right maintenance door.
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7. MAINTENANCE
16
7.12 Winches
7.12.1 Component check
Check that the following components are seated cor-
rectly and work properly:
1 3-windings limit switch* /rope length metering sensor
2 Reversing winch
3 Auxiliary winch
4 Zero speed detector *
5 Kelly winch
6 Contact roller
17
Rope fastening (Figure 17)
1 Dipstick
2 Oil drain plug
3 Tightening roller
4 Screws
5 Rope fixation
6 Rope wedge
7 Rope
8 Rope bushing
18
7.12.2 Check the oil level
For correct checking the lead must be horizontal.
• Unscrew and then pull out the oil dipstick (Figure 18,
no 17.1), wipe it with a clean cloth and re-insert it as
far as possible.
markings on the dipstick. Top up oil if necessary.
- For the total oil quantity and specifications of the
Dipstick on the winches (Figure 18)

1 Dipstick
2 Oil drain plug
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7. MAINTENANCE
7.13 Ropes and pulleys

Ropes and pulleys are very susceptible to external mechanical damage and for this reason must be
regularly checked for all types of damage, deformation, etc.
7.13.1 Checking the rope against end of service life criteria

Due to the limited service life of wire ropes, ropes must be checked at regular intervals during use to
correctly identify when the rope has reached the end of its service life and to remove it from service
before it fails completely.
The following points are important when determining the inspection intervals and may shorten the
intervals:
- national and local regulations that apply in the country of use
- the environmental conditions to which the machine is exposed
- the first few weeks after a rope has been put on
- the results of earlier inspections
- the amount of time the rope has already been in use
NOTE!
.
Action following prolonged machine down time or incidents that could have resulted in damage:
Ropes and end attachments must be thoroughly checked.
These rope changing criteria form part of ISO 4309. They describe the most commonly occurring
types of rope wear.
DANGER!
Risk of rope rupture!

• The criteria listed below must be observed within the framework of the specified maintenance
intervals.
NOTE!
If there is any doubt about the continued operational safety of a rope, the rope must be withdrawn
from service or the advice of a qualified engineer sought.

- the engine has been switched off and secured against unauthorised starting
• Check ropes for all possible damage and deformation.
NOTE!
Check the rope in particular around the termination as it is subject to increased mechanical stresses
at this point.
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7. MAINTENANCE
7.13.2 Check the rope for diameter shrinkage

As a result of natural wear that occurs during use, ropes gradually become thinner and must
eventually be withdrawn from service. If the rope diameter has reduced over long sections by more
than 10% relative to the nominal dimension as a result of internal friction, corrosion, etc., the rope
must be changed regardless of whether or not wire breaks have occurred.
- a caliper gauge with wide jaws is available
Figure 19 shows the correct way to measure the diameter of the rope (left-hand side).
19
• To determine the rope diameter, take measurements at two separate points at least a meter apart
on the rope.
• Measure the diameter at these two separate points at least twice.
• Calculate the average of the four measurements. The average corresponds to the rope diameter.
- The rope diameter is up to 10% smaller than the nominal diameter: the rope diameter is OK and
no further action is required.
Troubleshooting:
.
Is the rope diameter is more than 10% smaller than the nominal diameter?
withdraw the rope from service and replace it with an intact one.
.
NOTE!
Always check the rope drive before using new ropes.
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7. MAINTENANCE
20 7.13.3 Check for rope deformations
Pockets: these can occur when the outer layer of wires

loosens or the outer wire strands are longer than the
inner ones. Movement of the outer wires or strands in
relation to the inner ones causes movement of the ex-
cess length at a particular location.
21
Loop formation: single wires or groups of wires emerge

from the rope structure. The loops usually lie in a series
of strands.
22
Necking: is a reduction in the diameter of the wire rope

over short lengths. Rope sections immediately before the
end attachment must be checked for necking with par-
ticular care. Necking is often difficult to recognise at
these points.
23
Knots: are deformations of the wire rope. They are

formed when a eyelet-shaped rope loop is pulled straight
without the wire rope being able to compensate by
turning on its axis.
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7. MAINTENANCE
24
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 increased 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.
• Check for rope deformations.
Troubleshooting:
..
Does the rope meet one of the criteria above or exhibit specific damage?
Stop using the machine and if possible determine the cause of the damage.
Change the rope or pair of ropes immediately.
7.13.4 Check ropes for corrosion
25
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 localised corrosion, such as pitting (forms deep
holes in places where the protective layer is missing or
damaged). The photographs both show atmospheric cor-
rosion.
26
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.
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7. MAINTENANCE
• Checking ropes for corrosion.
Troubleshooting:
..
7.13.5 Check ropes for abrasion
27
Abrasion: abrasion reduces both the static breaking

force of the rope due to reduction of the metallic cross-
section and its fatigue limit due to wear notches. If the
rope diameter has reduced by 10% or more relative to
the nominal dimension, the rope must be changed re-
gardless of whether or not wire breaks have occurred.
• Check ropes for abrasion.
Troubleshooting:
..
7.13.6 Check ropes for the effects of heat
28
Heat damage: if the temperature rises above 300 °C,

the tensile fibre structure of the wire rope caused by
cold deformation recrystallises and the wire loses around
2/3 of its original strength.
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29
An extreme form of heat damage is caused by lightning

strike. The rope may heat up at the point of the strike to
such an extent that the steel starts to melt. In all cases
of exposure to high temperatures, the rope must be
changed regardless of whether or not wire breaks have
occurred.
• Check ropes for significant heat damage.
Troubleshooting:
..
If there is evidence of external heat damage, such as recrystallisation, localised melting of steel, etc.:
.
NOTE!
For permitted operating temperatures for ropes and end attachments, please refer to EN 12385-3.
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7.13.7 Check the rope for number of permitted wire breaks

The table below shows the permitted number of wire breaks relative to a defined control section of
the rope.
Number of wire breaks at end of service life

Number of bearing wires in
the outer strands of the Cross lay Lang lay
wire rope 1) over a length of over a length of
n 6D 30 D 6D 30 D
50 2 4 1 2
51 to 75 2 6 2 3
76 to 100 4 8 2 4
101 to 120 5 10 2 5
121 to 140 6 11 3 6
141 to 160 6 13 3 6
161 to 180 7 14 4 7
181 to 200 8 16 4 8
201 to 220 9 18 4 9
221 to 240 10 19 5 10
241 to 260 10 21 5 10
261 to 280 11 22 6 11
281 to 300 12 24 6 12
2)
over 300 0.04 x n 0.08 x n 0.02 x n 0.04 x n
In the case of ropes that have particularly thick wires in the outer layer of the outer strands, round
strand ropes 6 x 19 Seale to DIN 3058 or round strand ropes 8 x 19 Seale to DIN 3062, the number of
visible wire breaks at the end of the service life is 2 lines lower than the values shown in the table.
D = diameter of wire rope
1
Filler wires are not considered to be bearing wires. In the case of wire ropes with several layers of strand, only the strands in
the outermost layer are deemed to be outer strands. In the case of steel-core steel ropes the inner strands are the
reinforcement.
2
The numbers calculated should be rounded up.
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7. MAINTENANCE
.
NOTE!
When putting on a new wire rope, the rope diameter must match the breaking load and the number
of bearing wires in the outer strands of the original rope. Likewise the wire rope must comply with
the relevant national and international regulations.
Contact Liebherr after sales service or the rope manufacturer to find out how many bearing wires
there are in the outer strands.
Example:
Rope diameter D is 30 mm
Number of wires in the outer strands: 210
This means that the number of permitted wire breaks on a control section measuring 6 x D = 180
mm [7"] may not be higher than 9. On a control section measuring 30 x D = 900 mm [2 12"] the
number may not be higher than 18.
• Check ropes for the number of wire breaks and compare with the values in the table.
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Troubleshooting:
..
Does the number of wire breaks exceed the number of permitted wire breaks?
7.13.8 Selecting a rope

When selecting a rope, make sure that only rope of the same type and strength equivalent to that
originally chosen is used. Ropes from manufacturers not approved by LIEBHERR may only be used
following consultation with the relevant manufacturer.
DANGER!
Using ropes that do not conform to the manufacturer's specifications poses a threat to life!
• Always use ropes that conform to LIEBHERR specifications.
DANGER!
Damage to the rope.

• The fitting of swivels to any of the ropes that are attached to the machine is prohibited!
• Exceptions to this are only permitted after special consultation with the manufacturer.
NOTE!
The actual rope diameter may be no more than 4% greater than the nominal rope diameter. Observe
the rope plan for the correct arrangement of the rope lay direction.
Rope lay direction

The correct choice of lay direction for the wire rope is critical to the correct operation of the rope
drive. Under stress any wire rope will tend to untwist. For this reason the rope lay direction must be
chosen so that this untwisting torque is not encouraged by the drum or the rope reeving, but is
compensated for by them instead. For example, a rope with a left-hand lay direction can be wound
around a left-hand drum, a right-hand drum, however, would counteract the untwisting torque of the
rope.
Rope lay direction in the case of multi-strand reeving

In the case of a multi-reeved rope drive, the influence of the angle of deflexion between the pulleys
is greater than the influence of the drum itself. In such situations, the rope lay direction should be
adapted to match the reeving. In addition, the lay direction of the reeving must always correspond to
the lay direction of the drum.
Right-hand lay direction reeving:
- rope with left-hand lay direction
Left-hand lay direction reeving:
- rope with right-hand lay direction
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7. MAINTENANCE
Start at the anchoring point of the rope on the drum and follow, with your finger, the winding of the
rope from the anchoring point to the uncoiled strand. If you are moving your finger in a clockwise
direction, the drum (the reeving) has a right-hand lay direction and requires a rope with a left-hand
lay direction (Figure 30). If you are moving your finger in an anti-clockwise direction, the drum (the
reeving) has a left-hand lay direction and requires a rope with a right-hand lay direction (Figure 31).
The lay direction of the drum or reeving is determined as follows:
• At the anchoring point of the rope on the drum, follow, with your finger, the winding of the rope
from the anchoring point to the running strand.
30
- If you are moving your finger clockwise: the drum (the

reeving) has a right-hand lay direction and requires a
rope with a left-hand lay direction.
31
- If you are moving your finger anti-clockwise: the drum

(the reeving) has a left-hand lay direction and requires a
rope with a right-hand lay direction.
Rope lay direction on a single layer drum

In the case of a single layer drum the choice of lay direction should be the opposite of the lay
direction of the drum.
Right-hand lay direction drum:
Drum with left-hand lay direction:
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Rope lay direction on a multi-layer drum

In the case of multi-layer spooling, where the lay direction of the drum changes from layer to layer,
the rope lay direction should match the layer that carries out the most rope work.
Right-hand lay direction:
Left-hand lay direction:
Rotation resistant (wire) ropes
.
NOTE!
Ropes described as "low twist" vary considerably with regard to the torque or twist when under
stress.
There are two types of rotation resistant (wire) ropes:

Rotation resistant (wire) ropes
Rotation resistant (wire) ropes include ropes with two layers of strands, twisted around an inner core.
The rope lay direction of the outer strands is opposite to that of the layer underneath.
WARNING!
Incorrect use. Damage to property, severe injury or death.

• With rotation resistant (wire) ropes, the use of a swivel is prohibited.
High performance rotation resistant ropes

The high performance rotation resistant ropes have a separate twisted steel core that is twisted in
the opposite direction to the outer layer, which nowadays consists of 15 and more outer strands.
Under stress, the steel core twists in one direction, while at the same time the outer strand layer
twists in the opposite direction. This largely compensates for the torque that occurs in the rope when
it is under stress.
Due to these special rope properties, only high performance rotation resistant ropes are used:
- for hoisting winches with high lifting heights
- when lifting unguided loads in one-fall operation
.
NOTE!
Despite this, the use of swivels is not recommended by Liebherr.
. Ropes onto which rotating parts are attached, e.g. Kelly ropes on drilling rigs, are excepted from
this.
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Non-rotation resistant ropes
..
NOTE!
Non-rotation resistant ropes generate high torques when under stress.
The ends of the ropes must therefore be secured to prevent them rotating.
Non-twist-free ropes may be used:

- for guided loads
- for paired use of similar right and left hand laid rope designs
Under these conditions non-rotation resistant ropes achieve a higher fatigue life compared with
rotation resistant (wire) ropes.
WARNING!
Damage to property, severe injury or death.

• Never combine several non-rotation resistant ropes with different lay directions in succession (e.g.
on retaining ropes)!
• Never use these rope designs with a swivel or having one or both rope ends without an
anti-rotation device.
Non-rotation resistant ropes for hoist winches:
In exceptional cases, non-rotation resistant ropes may be used for hoist winches in the following
applications:
- dragline bucket
- slurry wall grab
- handling two-rope grab (paired right and left hand laid ropes)
..
NOTE!
Distortion of max. 180° is desired with the slurry wall grab.
The pendant ropes are designed as non-rotation resistant ropes.
Decision table
In the following decision table, which uses an example of the choice of most suitable wire rope
design for the hoisting gear of a crane, the ten questions should be answered as far as possible with
yes or no. If there is no simple answer to a question then answer Yes/No.
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Decision Yes Yes/No No

1 Do you require a Special rope, rotation re- Special rope, rotation re- 6, 8 or 10-strand rope
rotation resistant sistant sistant
(wire) rope?
2 Is a high break- Special rope SES, poss. SES -
ing force re- sealed
quired?
3 Is a high number Multi-stranded, thin Multi-stranded, thin out- -
of bending cy- outer wires er wires
cles required?
4 Is a high degree Thick outer wires Thick outer wires -
of abrasion re-
sistance re-
quired?
5 Does the rope Lang lay, sealed - Cross lay
operate with
multi-layer
spooling?
6 Are structural Plastic intermediate lay- Plastic intermediate lay- -
changes expect- er er
ed?
7 Do large deflex- Plastic intermediate lay- Plastic intermediate -
ion angles oc- er layer
cur?
8 Does the drum Rope with right-hand lay - Rope with left-hand lay
have a left-hand direction direction
lay direction?
9 Does the reev- Rope with right-hand lay - Rope with left-hand lay
ing have a left- direction direction
hand lay
direction?
10 Will it be used in Galvanized version Galvanized version Exposed version
a corrosive envi-
ronment?
7.13.9 Storing ropes
.
NOTE!
Ensure that drums and ropes are not damaged during storage.
CAUTION!
There is a risk of ropes being mixed up.

• If the label is missing or is no longer clearly legible, label the affected drums immediately in
accordance with the delivery documentation.
• Check that the labeling of supplied ropes matches the material inspection documents and the
order.
• The material inspection documents must be filed away carefully.
• Store wire ropes in a dry, well-ventilated area. The rope and drum must be protected against the
effects of the weather and must not be stored directly on the ground.
• Storage out of doors for an extended period must be avoided at all costs!
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7.13.10 Transporting ropes
Ropes are very susceptible to external damage, therefore great care must be taken when they are
lifted, transported or unloaded.
32
Figure 32 shows a drum being transported correctly (left) and incorrectly (right) on a forklift truck.
Correct procedure to avoid damage to ropes during transport:

• Lift drums using textile slinging equipment (flat lifting slings or round slings).
• Ideally, drums should be lifted with a spindle through the centre of the drum.
• Lift drums using forklift forks Figure 32 .
7.13.11 Checking the rope drive
The service life of the rope depends to a large extent on checking of the rope drive. Any fault on the
rope drive will damage the rope. The rope will reach the end of its service life more quickly due to
increased wear. The grooves of the winching drums and the pulleys are therefore checked for wear
using test templates.
Test templates are related to the nominal groove base diameter.
A suitable test template is available.
The machine is switched off.
The machine is secured to prevent unauthorised operation.

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33
1 Test template
2 Winch drum
The diameter of the measuring device (test template 1 ) must be virtually identical to that of the
groove base so that it fits easily into the groove. The groove diameter of the winch drum 2 must be
4 % to 8 % larger than the diameter of the test template 1 .
Use the test template 1 to check each groove of the winch drum 2 .
Troubleshooting
Is the diameter of the test template not the same as the groove base of the winch drum? Is there a
crescent-shaped gap between the test template and the groove base?
34
1 Test template
2 Winch drum
• Impermissible result when testing the groove base using a test template
Remove the rope.

Smooth the surfaces of the grooves.
Contact Liebherr after sales service.
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Checking all pulleys for ease of movement, signs of wear and damage
Check all pulleys for ease of movement

Check pulleys for ease of movement.
If the pulleys do not move easily:
Lubricate the pulley bearings (for further information see: Lubricating the pulley bearings).
Check all steel pulleys for wear
The steel pulleys are checked in exactly the same way as the winch drum groove base, in other
words the radius of the grooves is checked using a test template.
The rope grooves often exhibit an imprint corresponding to the negative imprint of the rope in
question. The impressions of the individual strands in the rope grooves are normal and not
undesirable, since these produce a greater rope support surface, which increases the service life of
the rope. When the rope is changed, the ridges must be removed and any sharp edges on the
surface of the pulley smoothed.

35
1 Test template A Maximum permissible wear on pulley

2 Steel pulley
The maximum permissible wear A is 4 % of the nominal rope diameter.

Use the test template to check the radius of the groove in the pulley.
If the actual wear exceeds the maximum permissible wear: Replace the pulley.
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Checking plastic pulleys for wear
The rope grooves often exhibit an imprint corresponding to the negative imprint of the rope in
question. The impressions of the individual strands in the rope grooves are normal and not
undesirable, since these produce a greater rope support surface, which increases the service life of
the rope. When the rope is changed, the ridges must be removed and any sharp edges on the
surface of the pulley smoothed.

36
1 Test template A Maximum permissible wear on pulley

2 plastic pulley
The maximum permissible wear A is 50 % of the nominal rope diameter.

Use the test template to check the radius of the groove in the pulley.
If the actual wear exceeds the maximum permissible wear: Replace the pulley.
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37
Checking pulleys for damage
1 Crack
2 Nicks
.
NOTE!
Pulleys are very susceptible to external damage: Chafing must be avoided at all times and pulleys
must not be placed on the ground without protective equipment.
• Check pulley for all types of damage, such as nicks, wobble, cracks and notches, etc.
- If the 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 pulley shows any sign of damage:
replace the pulley immediately.
• Contact Liebherr after sales service.
Lubricating the pulley bearings
Manually lubricate the pulleys:
.
NOTE!
The grease must not leak from between the pulleys.

- A lever-type grease gun filled with the appropriate grease type as stated on the lubrication chart
is available
- The boom is lowered
Checking the bearing for proper seating and position
The position of the bearing and circlip must be correct to ensure optimum rope drive.
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7. MAINTENANCE
Cleaning plastic pulleys
When in use, plastic pulleys in particular can become very dirty, resulting in excessive wear. It is
therefore important to clean gum, etc. off plastic pulleys.
.
NOTE!
Only clean plastic pulleys with suitable cleaning agents.
Plastic pulleys are resistant to:

- crude oil
- petrol
- kerosene
- diesel
Plastic pulleys are not resistant or not fully resistant to:
- concentrated mineral acids (e.g. sulphuric acid, hydrochloric acid, nitric acid)
- concentrated organic acids (e.g. formic acid)
- concentrated bases (e.g. sodium, caustic potash solution or corrosive potassium salts)
- alcohol other than ethyl alcohol, methyl alcohol and propyl alcohol
- inorganic chlorides, e.g. calcium, lithium chloride, magnesium chloride and zinc chloride
• Clean plastic pulleys using a cleaning cloth and suitable cleaning agents.
7.13.12 Winding ropes
Hoisting ropes will only work smoothly if they are laid without twisting and without external damage.
..
NOTE!
The rope must be luffed under pretension when it is first wound onto the winch.
..
The pre-tensioning force should be 1 - 2% of the minimum breaking force.
This pre-tensioning force is obtained by braking the rope drum.
Direct braking of the rope is not permitted!
WARNING!
Damage can occur as a result of incorrect handling of wire ropes.

Damage to the crane, threat to life!
• Wind ropes in accordance with the following instructions.
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CAUTION!
Rope destruction.
• If the winding area of the rope is more in the upper rope layer when operating winches with
multiple-layer spooling, the lower rope layer may become loose.
• This results in a slight ovalisation of the rope that changes the winding diameter across the width
of the drum. This leads to gaps in the running rope layer, which impairs the spooling properties
and increases rope wear.
• To improve the spooling properties and to reduce rope wear, the rope should be completely
unwound at regular intervals and then re-wound under tension (1 - 2% of the rope's minimum
breaking force).
.
NOTE!
A rope works most economically when its entire length is used. It is therefore recommended that an
appropriate length of rope is used for lengthy operations.

- Protective clothing is being worn
.
NOTE!
Contamination: The rope must not be pulled over the ground (Figure 38).
38
• Unwind ropes from the drum in the winding direction (Figure 39).
Unwinding to the side causes the rope to twist until it is destroyed by kink formation.
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7. MAINTENANCE
• Unwind ropes from a jacked up drum (Figure 38).

39
• Unwind ropes from a drum that is braked (Figure 39).
Troubleshooting:
.
If the rope shows signs of damage, deformation, wear, etc.:
withdraw the rope from service and replace it with an intact one.
7.13.13 Luffing ropes
When luffing the new rope, ensure that the rope is not twisted or untwisted. The rope can be luffed
using the old rope or ideally using an auxiliary rope. If an auxiliary rope is used, it must have
sufficient permitted pull force (at least the weight of the rope). If the old rope is used as the luffing
rope, ensure that the new rope does not become twisted.
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7. MAINTENANCE
WARNING!
Risk of ropes fusing together! Breaks when running over pulleys, damage to crane or rope,
severe injury!
• Weld on eyelets to connect the two ropes.
• A rope stocking may be used (the rope stocking manufacturer's instructions must be followed).
CAUTION!
Risk of damage caused by an excessive rope deflexion angle (greater than 4°)!
• Position the pulley some distance away and, if possible. without any lateral deflexion.

- The machine is secured to prevent unauthorised operation.
- The boom is lowered
- The rope is checked before luffing for damage as a result of incorrect handling or storage
- Protective clothing is being worn
WARNING!
Risk of sudden and violent movements as the end of the rope comes off the rope drum.
• Wear protective clothing.
• Unreel the rope from the drum carefully and as slowly as possible.
• Weld on eyelets to connect the two ropes; a rope stocking may also be used (the rope stocking
manufacturer's instructions must be followed).
• Luff the rope using an auxiliary rope or an old rope.
• Before starting to use the rope, check that the new wire rope is laid correctly in the grooves of the
rope drums or the pulley.
• Have the rope limit switch checked and adjusted by personnel authorised by LIEBHERR.
• Hoist a light load (up to 10% of full load) several times to check that the wire rope is winding onto
the winch drum correctly.
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7.13.14 Lubricating ropes
Regular rope maintenance ensures safe operation of the crane and increases the service life of the
rope. Only lubricant equivalent to the original rope lubricant may be used. The rope must be
regularly lubricated in particular where it bends around the winch drums and the 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 followed). An alternative is to use solvent-
based lubricants that can be sprayed on the rope.
.
NOTE!
The intervals chosen for regular rope maintenance depend on the operating conditions.
7.13.15 Check rope suspension and rope fixation
If a rope lock is being used as a rope suspension, the free rope end must be secured to prevent it
being pulled through. This mechanism means that the free rope end must not be connected to the
bearing rope strand in such a way that a force is transmitted.
Fitting the wire rope
.
NOTE!
The end of the new wire rope must be made up in such a way that there is absolutely no possibility
of the rope structure loosening (e.g. as a result of flash-butt welding or hardening), assuming the
rope structure is not separated by the type of rope fixation (e.g. splicing or casting).
.
NOTE!
If a rope lock is being used as a rope suspension, the free rope end must be secured to prevent it
.
being pulled through.
This mechanism means that the free rope end must not be connected to the bearing rope strand in
such a way that a force is transmitted.
DANGER!
Incorrect fitting of a new wire rope. Rope damage.

• When fitting a new wire rope, no adjustments may be made or attachments added to the rope
suspension and rope fixation.
• The rope end should be inserted in the same way as for the original wire rope.
• After fitting a new wire rope, check the rope suspensions regularly for correct position of the wire
rope in the fastener and to ensure that it is correctly fastened to the adjacent structure (particularly
screw fastenings to the structure).
• Check the device used to attach the rope suspension to the structure for any cracks.
• Check the cast rope ends regularly for wire breaks and corrosion where the wire rope emerges out
of the cast metal.
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7. MAINTENANCE
Troubleshooting:
.
cut open the rope end and replace the cast.
• Check rope suspensions with ferrules for wire breaks near the ferrule, cracks in the ferrule material
and for slippage of the wire rope.
Troubleshooting:
.
shorten the wire rope and replace the connection.
• Check detachable rope suspensions (rope lock, rope clamps, drum) for wire breaks and corrosion
of the wire rope, slippage of the rope at the termination and loosening of the fastening screws.
Troubleshooting:
.
If the rope shows signs of wire break or corrosion:
shorten and refasten the rope.
Troubleshooting:
.
If there is rope slippage at the termination and the clamping bolts are loose:
tighten the connection.
7.13.16 Checking the pocket locks
WARNING!
Damage to the pocket lock.

• Damaged pocket locks must be replace immediately.
Replace the pocket lock at once if there are:

- cracks
- corrosion
- stiffness and sticking of the safety button
- removability of the wire clamp or ferrule
40
1 Locking pin
2 Pin
3 Wire clamp or ferrule
4 Pocket lock
5 Safety latch
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7. MAINTENANCE
• Check the pocket locks for cracks and corrosion.

• Check the pocket locks for the correct functioning of self-locking safety latch (Figure 40, item 5).
• Check the ease of movement of the safety button for the safety latch.
• Check for presence of the fastening pin (Figure 40, item 2).
7.13.17 Checking the rope fixation and rope thimble
Rope lock
41
1 Rope lock
2 Rope fixation
3 Intermediate connector
4 Hoist rope
• Check the rope lock for damage and proper operation.

• Check rope clamp for tight fit.
Troubleshooting:
.
If the rope shows signs of wire break or corrosion:
remove the rope.
Troubleshooting:
.
If the rope lock is cracked:
immediately replace the rope lock with an original LIEBHERR spare part.
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7. MAINTENANCE
Rope thimble with ferrule 42
1 Wire clamp
2 Ferrule
3 Rope thimble
• Check the ferrule for cracks and splitting.

• Check the ferrules on the pendant ropes and backstay pendants.
Troubleshooting:
.
If the ferrule is split or cracked:
remove the rope immediately.
• Check rope thimbles for corrosion, cracks and wire breaks.
Troubleshooting:
.
Does the rope thimble show any signs of corrosion, cracks or wire breaks?
If it does, replace the rope thimble.
• Check the wire clamps for cracks and corrosion.

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7.14 Hydraulic system

7.14.1 General
It is particularly important for the hydraulic system to be absolutely clean. For this reason, it is
essential to adhere to the prescribed maintenance intervals for the hydraulic oil filters.
Condensate must be drained off regularly.
43
7.14.2 Check the oil level
• The oil level in the hydraulic tank should be checked
daily by means of the sight glasses (Figure 43).
IMPORTANT!
When checking the oil level or topping up hydraulic oil,
note the following:
- The machine must be horizontal.
- The oil level in the hydraulic tank depends on the
position of the cylinders.
• The upper sight glass (1) shows the maximum oil level
when all cylinders are retracted.
• The lower sight glass (3) shows the minimum oil level
when all cylinders are extended.
• The level must not be below the center of the lower sight glass or above the center of the upper
sight glass.
• Hydraulic fluid must always be topped up via the return filter (see Changing hydraulic oil).
NOTE!
Before changing to a different hydraulic oil (e.g.: synthetic hydraulic oil), inform Liebherr Customer
Service.
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7. MAINTENANCE
44
7.14.3 Topping up hydraulic oil
• Unscrew the aeration filter (Figure 44, item 1) by one
turn and release the pressure.
• Pour hydraulic oil in through the return filter (2) until oil
can be seen in the center of the lower sight glass.
• Retighten the aeration filter.
• Screw the filter cover back on again.
For specification, see Chapter 7 "Lubricant require-
ments")
45
• When refilling the tank, fill completely as far as the top
cover plate. When filling via the opening in the filter
cover, make sure that the return chamber (Figure 45,
item 2) around the filter centering pipe (1) is also
completely filled.
Drain off condensate

• Condensate must be drained off regularly. Place the
supplied drain hose on the drain valve (3) until water-
free oil runs out.
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7. MAINTENANCE
46
7.14.4 Suction pipe on the hydraulic tank
When carrying out repairs to the hydraulic system (e.g.:
suction hoses of the pumps), the shut off valve on the
suction pipe of the hydraulic tank must be closed.
Once the repairs are finished and before restarting,
re-open the shut-off valve on the hydraulic tank.
• The shut-off valve is open when the hand- lever is
parallel to the suction pipe (Figure 47, position 1).
7.14.5 Shut off valve on hydraulic tank

Before starting the diesel engine, check the position of
the shut off valve on the suction pipe.
The shut off valve has the following positions:
• Position 1 = shut off valve open (Figure 46)

• Position 2 = shut off valve closed (Figure 46)
CAUTION!
The diesel engine must not be started with the shut

off valve closed! Doing so will destroy the hydraulic
system.
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47
7.14.6 Cleaning the magnet plug
CAUTION!
For the first 250 operating hours clean the magnet

plug daily, thereafter weekly.
• Unscrew the aeration filter by one turn to relieve the

internal pressure in the tank. Retighten the aeration
filter.
• Undo the 4 fixing screws (Figure 47, item 6) on the
filter cover (5) and remove the lid with the magnet
plug.
• Carefully clean the magnet plug (4) to remove adher-
ing dirt and detritus. Check the sealing ring (3) and
renew if necessary. Replace the cover and tighten the
screws.
Names of the components (Figure47)

1 Filter element
2 O-ring (2)
3 Sealing ring (3)
4 Magnet plug
5 Filter cover
6 Screws
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7.14.7 Check the hydraulic system

All hoses and pipelines must be examined at regular intervals for leaks and possible chafing.
CAUTION!
Do not examine the machine for leaks with bare hands. A fine jet of fluid under pressure can
cause serious injuries.
• Do not remove any pipes, hoses or connectors while the hydraulic system is still under pressure.
Turn off the engine to depressurize the hydraulic system.
Defective hydraulic hoses must always be replaced immediately by LIEBHERR CUSTOMER SER-
VICE .
7.14.8 Special maintenance activities

• For transport over long distances or by sea or when putting into temporary storage, the machine
and equipment must undergo preservation measures. Such measures should be taken in consulta-
tion with LIEBHERR CUSTOMER SERVICE.
• Before prolonged shut-down periods, the hydraulic systems must be protected against corrosion.
Contact LIEBHERR CUSTOMER SERVICE.
• Before restarting after a prolonged shut-down, the preservation measures, such as coats of paint,
must be removed carefully.
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7.15 Electrical system

7.15.1 General
• The electrical system must be checked regularly to ensure it is in good working order.
• Faulty fuses and components must be replaced immediately with new original parts, once the
cause of the fault has been rectified.
• All terminal screws in the switch cabinets and terminal boxes should be checked once a year and
retightened if necessary. In addition, all emergency shut-down buttons must be checked at
regular intervals to ensure that they work properly.
• Turn the battery main switch off when working on the electrical system or when welding.
7.15.2 Wet cleaning

• The switch cabinet must not be subjected to wet cleaning!
When the machine is undergoing wet cleaning, it is absolutely imperative to ensure that no water
reaches switch cabinet X1. The valve connectors on the hydraulic pumps and solenoid valves and
all electrical components of the superstructure should not be directly exposed to the water jet.
7.15.3 Batteries
CAUTION!
When working on batteries, the wearing of working gloves and safety goggles is mandatory.
Battery acid is extremely corrosive. Never work on batteries in the presence of a naked flame.
Batteries must be transported or stored upright and secured to prevent them from toppling
over, as battery acid may otherwise escape.
General
Batteries must be kept clean and dry at all times. Battery posts and terminals must be cleaned
regularly upon first commissioning and regularly every 500 operating hours, and then smeared with
terminal grease (Vaseline). Do not allow oil and grease to come into contact with the battery casings.
Do not place tools on the batteries.
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48
Checking battery acid level
The battery acid level must be checked upon commis-
sioning and regularly every 500 operating hours. To
check the acid level, unscrew and remove the battery
cover. Unscrew the battery cell covers (Figure 47). The
acid level should be at the maximum acid level mark,
that is to say, approx. 15 mm [0.6"] above the top of
the plate. If the acid is too low, top up with distilled or
desalinated water .
Charging the battery
NOTE!
To protect the batteries against overcharging, an automatic charger must be used. (Follow the
operating instructions for the charger)
The automatic charger must be designed for 24V batteries.
• Before connecting the automatic charger, turn off the battery main switch (key can be removed).
• Connect the automatic charger to the batteries correctly.
The two 12V batteries are connected in series, resulting in a system voltage of 24V. This means that
the automatic charger must be connected in such a way as to charge both batteries simultaneously.
A single battery taken out of the machine must only be charged using an automatic charger
designed for a battery voltage of 12V.
The charging current (Amps) should not exceed 1/10 of the battery capacity. This value may be
briefly exceeded before gassing starts, but the acid temperature must not exceed 55 °C [131 °F].
• After charging, check the acid level and top up with distilled or desalinated water if necessary.
NOTE!
To ensure a long service life, the batteries must be charged as soon as possible after discharging.
The water consumption depends on the operating conditions and the charger that is used. Therefore
pay attention to the acid level, which must not fall significantly below the maximum acid level mark. If
necessary, top up with distilled water.
The batteries have central vents with flashback protection.
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7.15.4 Limit switch
NOTE!
Before starting work, check the operation of all limit switches by carefully approaching them.
49
Feed limit switches
Functional testing
The operation of the limit switches for the feed (Fig-
ure 49) can be checked first by operating the trip cam.
• After erecting the lead, move the accessory unit care-
fully to check the setting of the limit switches.
• If they are working properly, the top limit switch
should block the lifting movementand the bottom
limit switch should block the lowering movement.
50
Maximum outreach limit switch
Functional testing
The operation of the limit switches for maximum out-
reach (Figure 50) can be checked by operating the trip
cam.
• While or after erecting the lead, move the accessory
unit carefully to check the setting of the limit switch.
• Assuming the switch is working correctly, the "Maxi-
mum outreach" symbol is displayed and the warning
buzzer sounds.
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51
Hoisting limit switch
Check the fastening of the hoisting limit switch (Figure
51, item 1, 2).
Functional testing
• Raise the hoisting rope and carefully move the load
hook / add-on unit against the weight of the hoisting
limit switch.
• If it is working properly, hoisting with the winch
concernedshould be blocked.
• Check the smooth running of the limit switch fittings. If

required, spray with adhesive lubricant.
• Check that the indexing table is secure
52
3-windings limit switch* /rope length metering sensor
Check the fastening of the sensor (Figure 52, item 1).
Functional test for 3-windings limit switch (Kelly winch)*
• Lower the load hook until the winch stops. Take spe-
cial care with the last few windings.
• If it is working properly, the lowering movement of
the winch should be blocked at latest when there are
three windings left.
zero speed detector*

Check the fastening of the zero speed detector (Figure
52, item 2).
Functional testing
• The LED in the zero speed detector flashes when the
winch is turning.
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7.15.5 Checking displays, lights etc.
53
• Check that the following components are working properly:

- Work floodlights (Fig 53, item 1)
- Warning light (item 3)
- Interior lighting (item 2)
- Reading lamp (item 4)
- Fan (item 5)
- Hooter (item 7)
- Windshield wipers and windshield wash system at the front and above (item 9)
- Sound transmitter at front and back (item 6)
- Screen displays (item 10)
- Joysticks (item 8)
Components that are not functioning are to be repaired at once by LIEBHERR Service!
WARNING!
If faulty, the following components must be repaired before using the machine again:
- Sound transmitter (item 6)
- Work floodlight and warning light (items 1 and 3)
- Screen displays (item. 10).
- Joysticks (item 8)
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7.16 Heating and ventilation

The following checks must be carried out regularly, though at least once a year before the start of
the cold season.
• Check that the heating system works properly (See "Heating and air- conditioning system*"in
Chapter 5 ).
• Check all connections of the hot water circuit for leaks and tighten the connections (pipe clips) if
necessary. Always replace any worn or damaged hoses.
• Check that the fan motor works properly. Three speeds are available.
• Switch on the heating to ensure that the coolant contains sufficient antifreeze (50% by volume
prevents freezing down to - 37°C).
• Thoroughly de-scale the heat exchanger and flush it until clear water flows out (close water valve
on diesel engine).
For coolant specifications, refer to "Coolant" in Chapter 7.
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54
Switch cabinet filter mat
The filter mat in the cab must be replaced according to
the maintenance plan or whenever necessary. The fan
for ventilating the switch cabinet is located on the left
behind the driver's seat (Figure 54, item 1)
Procedure
• Remove the cover (Figure 55, item 1).
• Change the filter mat (2).
• Check the fan motor (4) and housing for damage.
• Fit the cover.
The fan should run when the Litronic control system is
switched on. 55
Heater fresh air filter

The filter mat in the cab must be replaced according to
the maintenance plan or whenever necessary. It is lo-
cated behind the driver's seat at the bottom.
IMPORTANT!
Maintenance of the optional air conditioning system is
described in Chapter 9.
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7.17 Drilling unit

Overall impression, noise, heat, etc.
If any abnormalities are discovered during inspection or in day-to-day work, these must be rectified
immediately. If you experience problems in the process, please contact the manufacturer.
Lubricating the drilling unit

The different components (lead guides, rope pulleys, cylindrical joint ends, locking bolts on the
universal slide etc.) must be lubricated regularly according to the lubrication chart.
Checking the guides

Excessive play in the guiding claws and bearings impairs the accurate and firm guidance of the
drilling elements. Therefore make sure this is rectified in good time.
56
If the phase is no longer visible, replace all 12 guides of the universal carriage.
Checking the polyamide scrapers

The polyamide scrapers for the feed ropes must be replaced when worn. If they are not material may
accumulate in the lower rope pulleys, eventually causing the rope to jump out of the pulleys.
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7.18 Lubrication chart

No. Lubrication Outside temperature Type: ISO VG/SAE Specification Liebherr lubricants
points
year-round to -20 °C SAE 10W-40 ACEA E4 Liebherr Motoroil 10W-40
below -20 °C with API CF
preheating
Engine, year-round to -20 °C SAE 10W-40 ACEA Liebherr Motoroil 10W-40
1. Oil bath air filter below -20 °C with E4/E6/E7 low ash required when
preheating API Using a soot particle filter
CF-4/CG-4/
CH-4/CI-4
year-round to -30 °C SAE 5W-30 ACEA E4 Liebherr Motoroil 5W-30
below -30 °C with API CF
preheating
2. Mech. gearbox to -20 °C SAE 85W-90 API GL-5 Liebherr Hypoid EP 90
and winches
3. Drive axles to -40 °C SAE 75W-90 API GL 4;GL 5; Liebherr Syntogear Plus
MT1 75W-90
to -25 °C +50 °C B ) ISO VG 32 - 46 DIN 51524/T3 Liebherr Hydraulic 37

SAE 10W-20 HVLP
ATFA ) 1. DEXRON II
D/E
Hydrostatic to -25 °C + 50 °C B ) ISO VG 46 (32-68) DIN 51524/T3 Liebherr Hydraulic Plus
4. Drive unit; SAE 10W-20 HVLPD HC
Hydraulic steer- biologically
ing
degradable
acc. to
CEC-L-33-A-93
to - 50 °C + 30 °C ISO VG 15-46 DIN 51524/T3 Liebherr Hydraulic Plus
SAE 0W-20 HVLPD HC Arctic
biologically
degradable
acc. to
CEC-L-33-A-93
5. Hydr. additive for DIN 51 757 Liebherr special additive
NL
Free-fall brake DIN 51 562
Roller, friction to -25 °C + 150 °C Lubricating grease, DIN 51502 Liebherr universal grease
9900
and ball bearings for lubrication system Lithium saponified KP 2 K-30

up to
or -20 °C + 150 °C KPF 2 N-25
Roller-bearing to -60 °C + 140 °C DIN 51502 Liebherr universal grease
6. rings, for lubrication system KPFHC 1N-60 Arctic
up to
Cardan pivots, - 55 °C + 140 °C
other grease lu-
brication
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No. Lubrication Outside temperature Type: ISO VG/SAE Specification Liebherr lubricants
points
to -25 °C + 150 °C Lubrication and DIN 51502 Liebherr universal grease
9900
For lubrication system Preservation OGPF 2
Open to -20 °C + 150 °C
Gear wheels and
7. crown gears,
Ropes to -60 °C + 140 °C OGPF 1 Liebherr universal grease
for lubrication system Arctic
up to
-55 °C + 140 °C
All areas OGPF 00 Liebherr paste spray
8. Telescopic All areas Special regulation DIN 51502 Liebherr grease for
boom KP 2 K-30 telescopic components
9613 Plus
9. Coolant to -37 °C DIN 51 757/4 Liebherr Antifreeze Mix
DIN 51 432/2
10. Screenwash to -80 °C Rala Klirr
fluid
Lubrication chart Table 7-02
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 can be about 10°C lower.
NOTE!
The familiar specifications listed above are minimum oil grades only.
High-quality Liebherr products have been developed and tested for compatibility. The correct function
of the machine can only be guaranteed with original Liebherr products. Products of other grades do
not carry this guarantee.
For more information contact the Liebherr Lubricant Hotline (+49 (0) 7354 806060 or lubricants@lieb-
herr.com).
Ordering data
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
Engine oil ordering data Table 7-03
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Gearbox oil
Liebherr Hypoid 90 EP 10 66 48 74 10 66 48 75 10 66 48 76 10 44 16 36
Liebherr Syntogear Plus 75W-90 10 33 02 85 10 33 02 87 10 33 02 88 10 29 64 77
Gearbox oil ordering data Table 7-04
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
Hydraulic oil ordering data Table 7-05
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
Grease ordering data Table 7-06
Coolant
Liebherr Antifreeze Concentrate 10 30 12 15 10 42 84 10 10 42 84 11
Liebherr Antifreeze Mix 10 65 18 38 10 30 12 13 10 45 54 46 10 35 90 77
Coolant ordering data Table 7-07

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Screenwash fluid
Liebherr screenwash -80°C 10 51 53 00 10 51 57 52
Screenwash fluid ordering data Table 7-08
Oil concentrate
Liebherr special additive NL 10 51 53 00 10 51 57 52
Oil concentrate ordering data Table 7-09
Oil analysis kit

Oil analysis kit: 88 56 018 14
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7.19 Hydraulic oil
7.19.1 Initial filling

The information sign on the hydraulic tank filler neck displays the hydraulic oil with which the
machine was first filled.
If the initial filling was carried out by Liebherr, the machine will have been filled with Liebherr 37 or
higher grade hydraulic oil as standard. In exceptional cases (low temperature package, bio applica-
tion) the machine is initially filled with a special hydraulic oil.
7.19.2 Mixing
CAUTION!
Mixing rapidly biodegradable third-party ester-based oils with mineral oils may result in damage to
the hydraulic system.
Liebherr recommends:
do not mix rapidly biodegradable third-party oils from different manufacturers.
Do not mix rapidly biodegradable third-party oils with mineral oils.
Third-party oils are oils from other manufacturers.
Use of a rapidly biodegradable hydraulic oil must be cleared in advance with Liebherr.
Plant-based oils must not be used because of their poor temperature stability.
Using Liebherr hydraulic oils ensures that none of the disadvantages listed above will occur.
Mixing Liebherr hydraulic oils
Liebherr oils with Liebherr oils Can be mixed in any ratio
Liebherr oils with biodegradable Liebherr Can be mixed in any ratio.

oils To ensure biodegradability, do not add more than 2%
mineral oil (as per regulations in most European coun-
tries).
Liebherr oils with third-party oils To ensure that oil properties are not altered, do not mix
in more than 10% third-party oil.
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7. MAINTENANCE
NOTE!
If replacing mineral oil-based hydraulic oil with synthetic oil-based hydraulic oil, contact Liebherr
after sales service.
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.
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7.20 Diesel fuels

Diesel fuel specification
Diesel fuels must satisfy the minimum requirements of the following diesel fuel specifications.
Permitted diesel fuel specifications:
- DIN EN 590
- ASTM D 975 (89a) 1D and 2D
Sulphur content of diesel fuel
1 See the "Lubricating oil change intervals depending on aggravating factors" table in the chapter
entitled "Lubricating oils for diesel engines".
2 Only use diesel fuels whose sulphur content is less than 1% (10000 mg/kg).
3 LIEBHERR recommends: In the case of diesel engines with external exhaust gas recirculation
(eEGR), use diesel fuels with a sulphur content of less than 0.005% (50 mg/kg).
4 If the diesel engine uses E6 engine oil and a standard lubricating oil change interval regime (500
Oh) is in operation:
Only use diesel fuels whose sulphur content is less than 0.005% (50 mg/kg).
NOTE!
According to the HFRR (60) test, the diesel fuel lubricity must not exceed 460 um [lubricity
korrigierter wearscar "diameter" (1,4) bei 60 °C].
Diesel fuel standard ASTM D 975 does not require diesel fuels to have passed a diesel fuel lubricity
test.
A written confirmation from the diesel fuel supplier must be provided. Additives should be added by
the diesel fuel supplier. The diesel fuel supplier is responsible for the quality of the diesel fuel. The
addition of secondary lubricity additives by the customer is not recommended.
Diesel fuel at low temperatures (winter operation)
According to ASTM D 975, a cetane number of at least 45 is required for diesel fuels. At
temperatures below 0 °C (32 °F), a cetane number of over 50 is required.
As the external temperature drops, paraffin crystals separate out from diesel fuel. Paraffin crystals
increase the flow resistance in the fuel filter and restrict the supply of fuel to the diesel engine.
NOTE!
The addition of petroleum or normal fuel is forbidden for safety as well as technical reasons.
Special diesel fuels are available for arctic conditions.
Use a starting aid (e.g. fuel filter heater) if the diesel fuel flow is sluggish or the temperature is below
-20 °C.
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7.21 Diesel engine lubricating oils

Lubricating oil specification
Modern diesel engines only use lubricating oils with a high additive content. Such lubricating oils
consist of basic oils mixed with additives.
The LIEBHERR diesel engine lubrication guide is based on the following specifications and require-
ments:
Designation Specification
ACEA classification (Association des construc- E4, E6, E7
teurs Européens de l'Automobile) Caution: Particle filter operation only permitted
with E6.
API classification (American Petroleum Institute) CH-4, CI-4
Caution: observe shorter oil change intervals.
Lubricating oil viscosity
The choice of lubricating oil viscosity is based on the SAE (Society of Automotive Engineers)
classification.
The critical factor for choosing the SAE class is the ambient temperature. The SAE classification
does not give any clue as to the quality of a lubricating oil.
If the lubricating oil is too viscous it will be difficult to start the engine, if the viscosity is too low
lubricating efficiency may be lost.
The temperature ranges shown in the following chart are guideline values only. Each end of the
temperature range may be violated briefly.
Temperature-dependent selection of SAE classification
For ambient temperatures in the range -20 °C to +45 °C (-4 °F to +113 °F) LIEBHERR recommends
the following lubricating oils:
- LIEBHERR Motoroil 10W-40, specification ACEA E4
- LIEBHERR Motoroil 10W-40 low ash, specification ACEA E6
For ambient temperatures in the range -30 °C to +30 °C (-22 °F to +86 °F) LIEBHERR recommends
the following lubricating oils:
- LIEBHERR Motoroil 5W-30, specification ACEA E4
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Lubricating oil change intervals
Lubricating oil change intervals: See "Maintenance list" chapter.

If the specified number of operating hours during the year is not reached:
Change the lubricating oil and filter at least once a year.
Various aggravating factors change the maintenance interval.
Aggravating factors:
- frequent cold starts
- sulphur content of diesel fuel
- operating temperature
If aggravating factors are present:

change the lubricating oil and filter according to the following table.
Aggravating factor Lubricating oil grade

CH-4, CI-4 E4, E6, E7
Operating temperature Sulphur content of diesel fuel Interval
to -10 °C up to 0.005% 200 Oh 400 Oh
from 0.005% to 0.05% 100 Oh 200 Oh
from 0.05% to 0.1% prohibited 100 Oh
below -10 °C up to 0.005% 100 Oh 200 Oh
from 0.005% to 0.05% prohibited 100 Oh
from 0.05% to 0.1% prohibited prohibited
Lubricating oil change intervals depending on aggravating factors

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7.22 Diesel engine coolant

The coolant is a mixture of water and anticorrosion and antifreeze additives.
Coolant
- can be mixed with the following products.
- is available in a pre-mixed form (Permix).
General recommendations
The cooling system only works reliably when under pressure. Keep the cooling system clean and
free of leaks. The coolant shut-off and working valves must be in good working order. Maintain the
required coolant level.
The anticorrosion/antifreeze agents approved by LIEBHERR
- guarantee adequate protection against freezing, corrosion and cavitation.
- do not attack seals and tubes.
- do not foam.
Coolants cause cavitation or corrosion damage in the cooling system if they contain unsuitable
anticorrosion/antifreeze agents or are prepared incorrectly. Thermally-insulating deposits on heat-
conducting components will result in overheating and failure of the diesel engine.
NOTE!
Emulsifiable anticorrosion oils are prohibited.
Anticorrosion agents without any antifreeze (e.g. DCA) are generally never used. Their use is
possible under certain circumstances (see "Permitted anticorrosion agents (inhibitors) without anti-
freeze").
Water (fresh water)
Colourless, clear, free from mechanical contamination, potable tap water with the following restricted
analysis values is suitable.
Sea water, brackish water, brine or industrial waste water are not suitable.
Designation Value
Total alkaline earths (water hardness) 0.6 mmol/dm³ to 3.6 mmol/dm³ (3 °d to 20 °d)
Ph value at 20 °C 6.5 to 8.5
Chloride ion content max. 80 mg/dm³
Sulphate ion content max. 100 mg/dm³
Fresh water quality
Designation Value
Total alkaline earths (water hardness) 0.6 mmol/dm³ to 2.7 mmol/dm³ (3 °d to 15 °d)
Ph value at 20 °C 6.5 to 8.0
Chloride ion content max. 80 mg/dm³
Sulphate ion content max. 80 mg/dm³
Fresh water quality when using DCA 4
Ask the relevant municipal authority for their water analysis results.
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Coolant mixing ratio
The coolant must contain at least 50% anticorrosion/antifreeze agent throughout the year.
Outside temperature Mixing ratio

Water Anticorrosion/anti-
freeze agent
to -37 °C to -34 °F 50% 50%
to -50 °C to -58 °F 40% 60%
A = Proportion of anticorrosion/antifreeze agent in coolant in %

Temperature-dependent mixing ratio of water and anticorrosion agent
Approved anticorrosion/antifreeze agents
Product description Manufacturer

LIEBHERR Antifreeze Concentrate LIEBHERR
NOTE!
If LIEBHERR coolant is not available locally:
Use a coolant that conforms to the "Coolant specification for LIEBHERR diesel engines 10652041"
(contact customer service).
Mixing different anticorrosion/antifreeze agents will degrade the properties of the coolant.
Approved pre-mixed coolants

LIEBHERR Antifreeze Mix (ready-mixed: 50% LIEBHERR
water, 50% anticorrosion/antifreeze agent)
NOTE!
If LIEBHERR coolant is not available locally:
Use a coolant that conforms to the "Coolant specification for LIEBHERR diesel engines 10652041"
(contact customer service).
Mixing different anticorrosion/antifreeze agents will degrade the properties of the coolant.
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Approved anticorrosion agents (inhibitors) without antifreeze
If it can be demonstrated that no approved anticorrosion agent is available:

In exceptional cases and where the ambient temperature is always above freezing point mix the
water with the following anticorrosion agents:
- Product DCA 4 (Diesel Coolant Additives 4)
- Product Caltex / Chevron / Havoline / Total
Change the coolant every year in this case.
Check the concentration during maintenance work.
NOTE!
Drain off the coolant when changing from anticorrosion/antifreeze agent to anticorrosion agent (or
vice versa).

DCA 4 Diesel Coolant Additives Fleetguard / Cummins Filtration
Caltex XL Corrosion Inhibitor Concentrate Chevron Texaco
Chevron Heavy Duty Extended Life Corrosion Chevron Texaco
Inhibitor Nitrite Free (ELC)
Havoline Extended Life Corrosion Inhibitor (XLI) Chevron Texaco
Total WT Supra Total, Paris
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7.23 Capacities
NOTE!
The volumes listed below in the table are recommendations. The actual capacity is determined by
the dipstick and the sight glass.
Object V V Remarks
[l] [gal] US
Diesel engine 33 8.70 Liebherr D 846 A7 (6 cylinder)
Power divider 12 3.16 including cooling system
Travel gear transmission 8 2.11 per item
Slewing gear transmission 11 2.90 -
Reversing winch 10 2.64 20t rope pull
Auxiliary winch* 3 0.79 10t rope pull
Kelly winch* 21 5.54 25t rope pull
Hydraulic tank 800 210.97 -
Diesel tank 700 184.60 -
Cooling system 98 25.88 Only fill with coolant with antifreeze and
DCA concentrate.
* Option
IMPORTANT!
Further data for the built-in components are listed under "Technical data" in Chapter 2 of this
operator's manual.
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7.24 Lubrication chart

The lubrication chart below gives an overview of all the lubrication points. Adhere to the indicated
maintenance intervals.
Lubrication and maintenance plan Figure 7- 01
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Lubrication and maintenance plan Figure 7- 02
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Lubrication and maintenance plan Figure 7-03
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7. MAINTENANCE
7.25 Repair welding

7.25.1 General
In the event that faults, e.g. cracks or permanent deformations are determined in the steel construc-
tion, this is to be immediately reported to the LIEBHERR-WERK Nenzing GMBHcustomer service
department.
In addition, the fault is to be immediately inspected by an authorized inspector in accordance with
technical regulations. This person must immediately determine whether or not the machine can be
operated until it is repaired.
7.25.2 Requirements for welding
Repair welding may only be undertaken by the following persons or companies:
• Qualified specialist personnel, or LIEBHERR authorised personnel with the relevant welding
qualifications according to EN 287-1 for the respective material (W 03) and welding procedure.
• Companies in possession of an excellent indication of suitability according to DIN 18800, Part 7,
DIN 15018, and DIN 4132 with the annexe for cranes, crane tracks and the following high and
super high-strength fine-grain structural steel:
Plate S690QL1 W. No. 1.8988
Plate S690QL W. No. 1.8928
Plate S700MC W. No. 1.8974
Pipe S770QL W. No. 1.8938
Plate S960QL W. No. 1.8933
Plate S960MC W. No. -
• Experience in the repair of load-bearing steel components on construction equipment with the
respective materials and application of welding procedure MAGM (135), as well as especially
manual metal arc welding E (111) are unconditional requirements.
• Before undertaking the repair, a set of repair instructions, detailing the base material and the
associated welding fillers and auxiliary materials must be requested from LIEBHERR. The required
non-destructive tests are to be carried out and documented.
• The repair welding work must correspond to EN 25817-B. The specifications of the welding
instructions are to be maintained during the welding process.
• The repaired component is subsequently to be subjected to stress testing:
The required test loads are to be requested from the customer service department! The success-
fully undertaken testing is to be documented!
• In addition, we would like to emphasise accident prevention regulation "Principles for the testing of
cranes by authorized inspectors or experts according to accident prevention regulation ´Cranes´
BGV D6 and BGG 905", (previously: VBG 9)!
NOTE !
In countries where these accident prevention regulations do not apply, the applicable national
regulations are to be maintained!
DANGER !
Failure to observe these instructions, especially disregard of the welding regulations can lead to
serious injuries and property damage!
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8. REPAIR
8.1 General
This chapter describes activities in which parts of the machine are replaced. In contrast to main-
tenance, these activities are not carried out at defined intervals.
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8. REPAIR
8.2 Change cables
DANGER!
Risk of lethal injury and damage to equipment by improper changing of cables!
• When repairing cables, generally observe the instructions for handling cables (see Chapter 7
"Cables and Rollers").
• At least 2 people are required to carry out repair work on cables.
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8.3 3-windings limit switch *

8.3.1 General
The 3-windings limit switch (Figure 0, item 1) is a safety precaution to prevent the whole rope
unwinding from the winch unintentionally. The 3-windings limit switch is set so that at least three
"safety windings" remain on the winch.
8.3.2 Setting the 3-windings limit switch

Setting of the 3-windings limit switch is necessary when a rope is changed or when the complete
rope is wound onto the winch during transport and the winch has been moved (operated) in this way.
Procedure
• The machine must be in assembly mode. .
• Unwind the rope from the winch until only three windings are left on the winch. Then remove the
cover of the 3-windings limit switch and adjust the 3-windings limit switch until it trips.
• Wind the hoisting rope through several windings and be sure to re-check the operation of the
3-windings limit switch. .
NOTE!
When changing the rope, run the winch in the lowering direction until the 3-windings limit switch
trips. Then press the "Bypass limit switch" selection button on the right-hand control panel (X23),
lower the winch further and change the rope.
DANGER!
• If the winch "runs empty" (no rope on the winch or the rope is fully wound onto the winch
for transport), the 3-windings limit switch will go out of adjustment.
Check for correct adjustment upon start-up by slowly tripping the 3-windings limit switch.
• As the load is being lowered, the rope can be pulled out of the rope fixation on the winch!
• It is a mandatory requirement that there are always at least three so- called safety windings
remaining on the winch.
• The length of rope needed for this purpose depends on the type of use.
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1
8.4 Changing the auxiliary rope
8.4.1 General
When changing a rope on the auxiliary winch, ensure
that a wire rope of the same type and strength is fitted,
in accordance with the winch pulling force and the safety
regulations.
DANGER!
Risk of falling!
Ropes must only be changed by appropriately
trained personnel.
8.4.2 Procedure
• Lay down the load on the auxiliary rope
• Lay down the lead
See "Laying down the lead" in Chapter 6.
• Unwind the auxiliary rope (Figure 1, item 2)
Unwind the old auxiliary rope completely from the
winch. The optional 3- windings limit switch must be
bypassed by pressing the "Bypass limit switch"
preselect key (see "Right-hand control panel (X23)" in
Chapter 4).
Note: the auxiliary rope must be unwound from the
winch (3) in such a way that it does not become entan-
gled on the winch drum.
• Pull out the auxiliary rope
Detach the auxiliary rope from the rope fixation and pull it out fully.
• Threading in the auxiliary rope
Luff the auxiliary rope as far as the winch
Note: the rope must run correctly in the rope pulley
• Fasten the auxiliary rope to the winch
Before fastening the new auxiliary rope to the winch, the optional 3-windings limit switch must be
set. Then insert the rope end in the rope fixation of the winch and fix with fastening screws.
• Wind up the auxiliary rope
Slowly wind the auxiliary rope on to the winch.
During the winding process, constantly check to ensure that:
- the auxiliary rope runs correctly in the rope pulleys
- the rope does not become entangled on the winch drum,
- the pre-tension on the rope reel is correct
• Fit the hoisting limit switch (1) (see Chapter 6)
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2
8.5 Changing the feed ropes
DANGER!
Risk of falling!
Ropes must only be changed by authorized per-
sonnel.
3
Procedure:
• Dismantle drilling unit
• Lay the lead down
(see "Laying down the lead" in Chapter 6)
• Relieve the tensioning cylinder
• Remove old rope
• Reeve the feed ropes according to the rope reeving
plan (Figure 3)
When changing the rope, observe the following:
- Use only original ropes
- In either case (top or bottom), change both ropes
- install both ropes as follows:
the longer rope is fastened to the tensioning cylinder,

the shorter one to the support.
- On the rope fixation at the bottom, mount both plates
using all screws
- Fit a rope clamp at each rope end
- Tighten the tensioning cylinders
- Check the running and operation of the rope
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8.6 Changing the Kelly rope
DANGER!
Risk of falling!
Ropes must only be changed by appropriately trained personnel.
8.6.1 General
When changing a rope on the Kelly winch, ensure that a wire rope of the same type and strength is
fitted, in accordance with the winch pulling force and the safety regulations.
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4
8.6.2 Procedure
• Lay down the lead
Any load must be set down to change the rope. Then
lay the lead down (see "Laying down the lead" in
Chapter 6).
• Unwind the Kelly rope
Then wind all of the old Kelly rope (Figure4, item 2)
off the winch. The optional 3-windings limit switch
must be bypassed by pressing the "Bypass limit
switches" preselect key (see "Right-hand control panel
(X23)" in Chapter 4).
Make sure that the Kelly rope is taken off the winch in
such a way that it does not become entangled on the
winch drum.
• Pull the Kelly rope out
Release the Kelly rope at the rope fixing point on the
winch (2) and pull it all off.
• Thread up the Kelly rope
Thread in the new rope according to the reeving dia-
gram (Figure4 ).
Thread the Kelly rope in as far as the winch, making
sure that it runs correctly through the pulleys.
• Fasten the Kelly rope to the winch
Before fastening the new rope to the winch, the op-
tional 3-windings limit switch must be set. Then
insert the rope end in the rope fixation of the winch
and fix with fastening screws.
• Wind up the Kelly rope
Slowly wind the rope on to the winch. The rope layer
switch and the rope length metering system must
be reprogrammed (see "Kelly winch operation" in
Chapter 5).
During the winding process, constantly check to en-
sure that:
- the Kelly rope runs correctly through the rope pul-
leys,
- the rope does not become entangled on the
winch drum,
- the pre-tension on the rope reel is correct.
The first layers of rope, in particular, must be correctly
wound on the winch drum.
• Fit the hoisting limit switch (1) (see Chapter 6)
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8.7 Diesel engine

Only authorized personnel may maintain and repair the engine.
During repairs always shut off the engine and remove the ignition key.
The following table should help rectify malfunctions. Do not attempt to perform repairs that are
beyond your ability.
NOTE!
Flame starting system only on Liebherr engines!
Problem Cause Remedy
1) The engine Fuel tank is empty Fill fuel tank and bleed fuel system
does not start
Water separator blocked Change filter
Fuel filter is blocked, in winter due to Replace fuel filter and bleed fuel system.
paraffin precipitation Use winter fuel
Fuel line leaks Check line for leaks and tighten connec-
tions
Starter faulty Remove and have it repaired or over-

hauled
Battery flat Check and recharge battery
Electrical connections to the battery, Check and tighten cables

starter or ignition lock are loose
Flame starting system faulty (at low tem- Check and if necessary replace solenoid
peratures) valve and flame glow plug
2) Engine starts All causes listed under point 1) except the See point 1)
but stops imme- electrical and flame starting system
diately
Ventilation of the fuel tank cap is blocked Clean the fuel tank cap
3)Engine runs ir- all causes listed under points 1) and 2), See points 1) and 2)
regularly, stut- except the electrical and flame starting
ters, or system.
does not run at
full
power Air filter dirty Clean air filter
Valves in the fuel pump leak Have the fuel pump repaired or if neces-
sary replaced
Charge air cooler dirty Clean the charge air cooler
Diesel engine troubleshooting table Table 8-01
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3) Engine runs Boost pressure too low Check exhaust turbo charger
irregularly,
stutters Wrong fuel injection start Check injection start and settings
or does not run
at
full power Injection pump, wrong fuel quantity in- Have injector pump checked professionally
jected or throttle stuck
Throttle linkage not at full load stop Check and set throttle linkage
Engine compression too low Check and if necessary replace valves,

pistons and cylinders
4) Exhaust gas- Air filter dirty Clean air filter

es are
black
Air intake system leaks Check and replace hoses and pipes
Wrong fuel injection start Check and set start of fuel injection
Injection pump delivers too much fuel Have injector pump checked professionally
5) Exhaust gas- Too much lubricating oil in the engine Correct oil level
es are
blue
Oil gets into the combustion chamber and Overhaul cylinder heads or change them,
is burnt. Play between the valve stem and change pistons and cylinder liners
stem guide too large, piston rings worn,
broken or stuck, scuffs on pistons and
cylinder liners.
Defective seal on the compressor of the Check and if necessary replace exhaust
exhaust gas turbo charger gas turbo charger
6) Exhaust gas- Cylinder head gasket defective and cool- Replace cylinder head gasket
es are white ing water getting into the combustion
chamber
Cylinder head is cracked or leaks Replace cylinder head
7) Engine pings Injector nozzle leaks or vaporization in- Check injector nozzle and if necessary
complete replace it
Wrong fuel injection start Check fuel injection start and if required,
correct the setting
8) Engine Injector nozzles are damaged or blocked Check and replace injector nozzles
knocks
Piston rings are worn or broken, pistons Check and replace pistons and cylinder
scored liners
Main or connecting rod bearing defective Replace engine bearings or overhaul the
engine
Diesel engine troubleshooting table, continued Table 8-02
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9) Cooling water Not enough cooling water in the cooling Top up cooling water
system
temperature
too high Air in the cooling system Bleed the cooling system
Radiator dirty on the outside Clean cooling grill
Radiator dirty on the inside or calcified De-scale the radiator
Thermostats defective Check and if necessary replace thermo-

stats
Cooling water pump defective Check, overhaul or replace cooling water

pump
Fan defective Check and if necessary replace the fan
10) Lubricating Oil level in the oil sump too low Top up oil to the specified level
oil pressure too
low
Oil is too fluid Drain oil, refill with specified oil grade
Oil pressure gauge or pressure sensor Check oil pressure and replace faulty pres-
faulty sure gauge or pressure sensor
Oil pressure pump faulty Replace the oil pressure pump
Oil pressure pump blocks in open position Check control valve of oil pressure pump
Too much play in the bearings due to wear Replace engine bearings or overhaul the
or bearing damage engine
11) Oil Oil cooler or oil cooler plate leaks Squeeze and if it leaks replace
in the cooling
system
Cylinder head gasket leaks Replace cylinder head gasket
12) Cooling wa- Cylinder head gasket leaks Replace cylinder head gasket
ter
in oil
O-rings on the cylinder liners leak Replace O-rings
Diesel engine troubleshooting table, continued Table 8-03
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5
8.8 Fire extinguishers
There are two fire extinguishers (Figure 5) of type GS6
according to ÖNORM EN 3 in the machine. One is
placed in the cab, the other is on the left of the inside of
the first doors. (Figure6)
The fire extinguisher can be used within a temperature
range of -20 °C to +60 °C [-4 °F to +140°F] . When
filled with an extinguishing agent (Intermon CEN pow-
der), the fire extinguisher is suitable for fighting class A
(ordinary combustibles), B (flammable liquids) and C
(energized electrical equipment) fires.
Fire extinguishers are to be inspected at the prescribed
intervals (observe national regulations) by a professional
maintenance company (in the EU every two years). Ad- 6
ditional instructions issued by the specialist must be
adhered to. After use, fire extinguishers must be refilled
by a professional maintenance company.
8.9 Personal protective gear

Personal protective gear should be regularly cleaned,
maintained and if necessary replaced.
You yourself are responsible for wearing the personal
protective gear. When working on the machine, tight-
fitting protective clothing should usually be worn, as well
as the personal protective gear suited to the particular
activity (see section 3 "Personal protective gear").
8.10 Conservation regulations

If the machine is to be shut down for a prolonged period,
the lead must be laid down and the hydraulic cylinders
retracted. Turn off the battery main switch.
Depending on the environmental conditions (temperature
variations, proximity to the sea), relevant precautions for
storage must be taken.
8.11 Resale – Decommissioning

LIEBHERR-CUSTOMER SERVICE must be notified if
the machine is to be resold or decommissioned.
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9. OPTIONS
9. OPTIONS
9.1 General
This chapter
- provides an overview of the retrofit kits and special equipment available
for this machine,
- refers the user to parts of the standard operator's manual in which the
option is already described,
- contains important information and safety notices that supplement those of the standard
operator's manual.
IMPORTANT !
The standard operating manual remains valid even after adding options to the machine, and must
still be adhered to.
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9. OPTIONS
1 9.2 Orthopaedic driver's seat
With an orthopaedic driver's seat, the weight (air cush-

ioning) and the backrest can be electronically and appro-
priately adjusted, in addition to the functions described in
Chapter 5, using the operating device (image 1, no. 1).
Additional extras are optionally available

- a seatbelt and
- a heated seat.
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9. OPTIONS
9.3 Heating and air conditioning system

9.3.1 General
The air conditioning system is combined with the heating and ventilation of the driver's cabin. The
heating and air conditioning only work when the diesel engine is running.
The cooling performance of the air conditioning unit depends on the speed of the diesel engine.
Technical Data
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air heating unit with water heat exchanger and evaporator
Thermal output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 kW
Rated voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V
Blower output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1280 m³/h (freely blowing)
Blower motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . three-stage
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R134 A without CFC
9.3.2 Air conditioning system units
2
1 Condenser 3 Air conditioning box with heating and evap-

orator
2 Compressor 4 Coolant collector
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9.3.3 Operation
The adjustment of the heating and air conditioning system takes place at the left control panel (Fig.
9-01).
Button for blower setting heating
Three blower settings for the heating or air

conditioning system can be set using this
button. A corresponding number of LEDs
indicates the current blower setting. The
next higher blower setting is activated by
pressing the button once again.
Button air conditioning on/off
This button serves for switching the air

conditioning on and off. For this, the heat-
ing must be switched on to at least setting
1.
Temperature controller heating/air con-

ditioning
The rotary switch serves for adjusting the

temperature for the heating and/or air con-
ditioning. The temperature is electronically
controlled.
Left control panel (X11) Fig. 9-01
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3
Heating mode
The rotary switch (Fig 3, no. 1) for the ventilation flap of

the heating
- is situated underneath the driver's seat,
- has two settings for circulating air and fresh air opera-
tion (Fig. 3, no. 2 and 3).
For heating mode, set the rotary switch for the ventila-
tion flap underneath the driver's seat to circulating air
mode (Fig. 3, no. 2).
Turn the potentiometer for the temperature setting on the
left control panel (Fig. 5-09) to the desired temperature
(blue = cold, red = hot).
Set the button for the pre-selection of the blower level by
repeatedly pressing the required setting. The LED opti-
cally indicates the current pre-selection.
The blower directs the sucked in air to the discharge
vents on the driver's seat and the front side of the
driver's cabin (Fig. 3, no. 4).
For quick de-icing of the windscreen, close the discharge
vents underneath the driver's seat.
Fresh air mode
For fresh air operation, the rotary switch must be in

fresh air position (Fig. 3, no. 3).
Turn the potentiometer for the temperature setting on the
left control panel (Fig. 9-01) right to the left (to cold).
Set the button for the pre-selection of the blower level by
repeatedly pressing the required setting. The LED opti-
cally indicates the current pre-selection.
Anti-condensation heater*
The optional anti-condensation heater* is activated via a separate timer which is not dependent on
the Litronic control unit. The anti-condensation heater* can be actuated via this timer.
9.3.4 Information on the use of the heating and air conditioning system
• The maximum heating or cooling effect is achieved

- in circulating mode,
- at the highest blower level,
- with closed sliding door and windscreen.
• If the heating and the air conditioning systems work together in circulating mode, the air in the
driver's cabin is dehydrated. Therefore faster drying of fogged-up cabin windows is possible.
• Close all discharge vents underneath the driver's seat in cooling mode. This prevents the
discharged cold air from unnecessarily heating up at the windscreen.
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NOTE!
For the air conditioning system, make sure to

- only switch it on when the diesel engine is running, in order not to unnecessarily draw on the
batteries while starting,
- switch it on at least once a month so that the compressor is lubricated.
In case of suddenly occurring high coolant concentration, e.g. in the event of a tube breakage, leave
the driver's cabin or a closed room immediately and provide sufficient ventilation before starting any
repair work.
Immediately remedy and leakages in the air conditioning system!

A leakage not only impairs the function of the air conditioning system, it can also lead to a
dangerously high coolant concentration in the air in the driver's cabin.
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9.4 Auxiliary heating
9.4.1 General
The auxiliary heating
- is installed into the driver's cab (accessible from underneath),
- is operated with the timer switch on the right-hand control panel,
- is supplied with diesel via the fuel tank,
- works without the Litronic control system being switched on,
- is functional at outside temperatures down to -40°C,
- is used to heat the cab and deice the windows.
Right-hand control panel (Figure 4)

4
1 Litronic service panel
2 24 VDC socket
3 Heating timer
4 Radio
IMPORTANT!
The operating instructions for the heating timer are given
in the "Appendix" in Chapter 10.
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9.5 Cold weather kit

9.5.1 General
DANGER!
Operating the machine at temperatures below -25°C [-13 °F] will wreck the machine!
For operation at outside temperatures down to -25°C [-13 °F], additional equipment is provided to
preheat the machine and ensure safe and reliable operation of the machine and the diesel engine.
The cold weather kit has the following functions:
- Heating the diesel engine coolant
- Heating the cab and switch cabinet X1
- Heating the hydraulic oil at an oil temperature below -20°C [-4 °F]
- Heating the diesel
Coolant heating
The auxiliary heating system heats the diesel engine coolant to the operating temperature. This is
done electrically without the diesel engine running. The circulating pump for the diesel engine coolant
is activated electrically via the auxiliary heating control system.
The auxiliary heating can be programmed with a presetting timer to switch on at the required time
and for the required duration.
Heating the cab

The cab and switch cabinet X1 are heated via the auxiliary heating.
When the auxiliary heating is switched on, the fan in the cab comes on at speed 1.
Turn the temperature regulator on the left control panel (X11) fully to the right (warm).
Hydraulic oil heating (Option)

The hydraulic oil heating is automatically activated via the Litronic control system if the diesel engine
is running and the temperature of the hydraulic oil is below -20°C [-13 °F].
The hydraulic oil heating goes off automatically as soon as the hydraulic oil temperature reaches
-15°C [5 °F].
NOTE!
The hydraulic oil heating only works if the safety lever is lowered.
Diesel filter heating

The diesel filter heating
- serves for preheating of the fuel,
- is switched on at a fuel temperature of 5 °C [41 °F] and turned off at 15 °C [59 °F].
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9.5.2 Auxiliary heating

General
The auxiliary heating
- is installed in the superstructure behind the cab,
- is supplied with diesel via the fuel tank,
- is operated with the presetting timer on the right control panel,
- works without the Litronic control system being switched on,
- is functional at outside temperatures down to -40°C [-40 °F],
- is used to preheat the diesel engine, heat the cab and deice the windows.
5
Components of the auxiliary heating system (Figure 5)
1 Diesel heater (DBW 2010)
2 Exhaust pipe
3 Fuel filter
4 Cooling water hoses
5 Circulating pump
6 Presetting timer on the right control panel
6
Right control panel (Figure 6)
1 Litronic service panel
2 24 VDC socket
3 Presetting timer
4 Radio
IMPORTANT !
The operating instructions for the heating timer are given
in the "Appendix" in Chapter 10.
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9. OPTIONS
9.5.3 Hydraulic oil heating

Function
As soon as the hydraulic oil temperature falls below -20°C [-4 °F], the heating is automatically put
into operation by the Litronic control system.
- the flow rate of LPV pump 2 is reduced,
- the hydraulic oil is led over a pressure limiter and in that way it is heated,
While the hydraulic oil heating is active, the "Hydraulic oil temperature too low"
symbol appears in the status display of the LCD screen.
- all movements and functions can be actuated,

- speed and pressure are reduced.
As soon as the hydraulic oil temperature rises above -15°C [5 °F], the heating is automatically turned
off by the Litronic control system and all functions are enabled without limitation. The "Hydraulic oil
temperature too low" symbol disappears.
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9. OPTIONS
9.6 Function lock

For safety reasons, all functions of the machine are locked below an outside temperature of -25°C.
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9. OPTIONS
7
9.7 Compressor
9.7.1 General
The machine has a compressor, which allows pneumatic
tools to be driven.
The compressor (Figure 7, item 1)
- is located on the right of the superstructure,
- is driven by the diesel engine,
The quick-fitting union for the air hose connection is
located on the bulkhead plate at the front right of the
superstructure (Figure 7, item 2).
Compressor type: LE- 10-10 UV B S
Connection: 1/2 '
Standard pressure: 7 bar
max. pressure: 10 bar
Nominal power output: 7.5 kW
NOTE!
The description of the compressor is included in Volume "Technical Information". Technical details,
safety guidelines and maintenance guidelines are also included.
Maintenance and repair on the compressor may only be carried out by qualified personnel.
9.7.2 Commissioning
• Start the compressor according to the manufacturer's instructions in Volume "Technical Informa-
tion" (check oil level etc.).
The compressor only works when the diesel engine is running,
9.7.3 Operating the compressor

The compressor is turned on and off from the left-hand control panel (X11).
"Compressor on / off" button

Switches the compressor on and off.
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9. OPTIONS
9.8 Refueling the machine from a refueling pump

Refueling pump (symbolic representation, actual location may differ) Figure 5-01
Names of the components:

1 Fuel tank 6 Sealing cap
2 Refueling pump 7 Emergency shut-down switch
3 Additional "pump on/off" switch 8 Red "pump off" button
4 Pipe to fuel tank 9 Green "pump on" button
5 Connection for suction hose 10 Control panel
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9. OPTIONS
General
The refueling pump is
- located on the right side of the superstructure directly beside the fuel tank,
- accessible after opening the side door on the fuel tank.
Technical data
Suction height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 4 m [13 ft]
Flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 l/min [13,2 gal/min]
Operating time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 20 min
Idling time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 30s.
Refueling
WARNING!
When refueling, the safety precautions in Chapter 3 "Fire and explosion hazards" must be
strictly adhered to.
CAUTION!
Only use the refueling pump

- to pump diesel fuel,
- with the supplied suction hose, which is equipped with a fuel filter.
Observe the notes on diesel fuel quality in Chapter 7 under "Diesel fuels".
In case of danger, interrupt fuelling by pressing the emergency shut-down button on the
operating panel
The emergency shut-down button on the operating panel is not only for switching off the refueling
pump in emergency, but can also be used to stop the machine if other dangerous situations should
arise.
Do not let the refueling pump run dry. As soon as the fuel container runs dry, stop the
refueling pump with the red button on the control panel.
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Procedure:
• Switch off the diesel engine and then switch the ignition back on again.
• Get the fuel tank ready for refueling and open the middle, right-hand side door.
• Remove the cap from the refueling pump.
• Attach suction hose to the refueling pump connector.
• Totally immerse the other end of the hose with the fuel filter in the diesel fuel.
• Press the green button on the control panel - the pump starts running.
A level monitor checks the fuel level in the fuel tank. As soon as the maximum fill level is reached,
the refueling pump shuts off automatically.
• After filling, remove the suction hose from the refueling pump and hold it up to let the remaining
diesel fuel flow back into the fuel container.
• Let the fuel filter drain off and then wipe it clean.
• Roll up the suction hose and stow it away.
• Replace the sealing cap on the refueling pump.
CAUTION!
Wipe up any spilled diesel fuel, especially from the metal tray under the refueling pump.
Keep the fuel filter on the suction hose clean.
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9. OPTIONS
9.9 GSM Service Modem

A GSM telephone modem is attached to the Litronic system. The modem is located in the switch
cabinet of the machine and works with an antenna on the cab roof. This allows the current operating
data and the stored machine data to be transmitted to the Liebherr service department. The Liebherr
service department is then able to identify the causes of faults with a diagnostic system, arrange
engineer visits accordingly and organize the procurement of spare parts both quickly and efficiently.
The SIM card is not included with the machine and must be provided by the operator.
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9.10 Process data acquisition (PDE)

9.10.1 General
PDE is used to record and log work processes electronically. The recorded data can be used both
for QA purposes for the customer and for internal company evaluations.
PDE records both operating data from the Litronic control (e.g. pressure or rope length measure-
ments) as well as data from external sensors (e.g. frequency encoders or concrete pressure
sensors).
Depending on the process, the recorded data are collated and saved together with general data such
as contracting company, job site, workplace, date, time, etc. on a memory card.
As soon as recording is finished, a report can be printed out in the cab. The data are stored in a
standard format on the memory card (Compact Flash) and can therefore be easily processed,
evaluated and visualized on a desktop PC or notebook.
External sensors
Litronic PDE overview
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Litronic PDE components
1 Control computer, switch cabinet X1 4 Printer for PDE

2 Control computer PDE, cab 5 PDE monitor
3 Compact flash card (customer card)
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9.10.2 PDE monitor

The PDE monitor is split into four main areas. These main areas apply to all screen pages, unless
stated otherwise.
Home screen
10
Kelly drilling
Job site 12.49/4
Pile number 5
Overview of PDE monitor, main page
1 Symbol bar 3 Operator's panel

2 Status bar 4 Error bar
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Description of symbol bar
"PDE" symbol
Tap on this symbol to go to the PDE home page.
"Error messages" symbol

Tap on this symbol to go to the "Error messages" page.
"Additional inputs" symbol

By tapping on this symbol inputs can be made independently of the operating
mode (not yet available).
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"Start recording" symbol

Tap on this symbol to start recording data.
"Pause recording" symbol

Tap on this symbol to pause recording.
"Stop recording" symbol

Tap on this symbol to stop recording data.
"Select operating mode" symbol

Tap on this symbol to view the selection independently of the operating mode.
"Settings in submode" symbol

Tap on this symbol to adjust settings in the current submode. This function is
dependent on the selected operating mode (not yet available).
"Vertical increase" symbol

Tap on this symbol to adjust the scale of the vertical axis (pile depth), i.e. the
display of both diagrams are changed (currently only applies to double rotary
drilling and CFA drilling modes).
"Horizontal increase" symbol

Tap on this symbol to adjust the scale of the horizontal axis (concrete pressure),
i.e. the display of the right- hand diagram is changed (currently only applies to
double rotary drilling and CFA drilling modes).
"Test system" symbol

Tap on this symbol to switch to the test system.
"PDE Settings" symbol

Tap on this symbol to go to the PDE settings page. This is where you make any
PDE settings that are needed.
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Description of the status bar
"Status card" symbol

Indicates the used space on the memory card.
"Buffer memory status" symbol

Indicates the used space in the buffer memory when the printer is switched off.
"Hourglass" symbol
The system is at full capacity.
"Protocol" symbol
The protocol is generated.
"Print job" symbol

Displays the number of buffered print jobs and, if the symbol changes, whether
printing is in progress.
Description of the error bar
"Memory card full" symbol

Indicates that the memory card is full.
"Buffer memory full" symbol

Indicates that the buffer memory for the printer is full.
"Connection interrupted" symbol

Indicates that the connection between PDE and machine control has been
interrupted.
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Description of the operator's panel
Kelly drilling
Job site Nenzing
Pile number A12.43/3
Kelly drilling mode
Kelly drilling
Pile number
A12.43/3
Enter pile number

Alphanumeric keypad
(lower case including digits)
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Alphanumeric keypad
(upper case including special characters)
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"Down arrow" symbol

Switch to the next page.
"Up arrow" symbol

Switch to the previous page.
Keypad
To enter the required values.
On the keypad:
Back
Delete or correct entry.
Enter
Confirm input.
Increase digit
To increase the value of the last sequential digit.
Lower digit
To decrease the value of the last sequential digit.
Alphanumeric keypad
For switching to the alphanumeric keypad.
On the alphanumeric keypad:
Enter
Confirm input(s) from the keypad.
Shift lock
For switching the keypad between upper and lower case.
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On the operator's panel

- the mode that is currently set is displayed,
- the required submode is selected,
- the data (e.g.: job site or pile number) are entered,
- error messages are displayed,
- technical details are displayed (e.g. pile geometry),
- the next logical, recommended input possibility is displayed with a green border (in the
documentation this is shown as shaded).
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PDE settings page
11
"Depth trigger" symbol

Tap on this symbol to switch to the depth trigger. The value displayed can be
changed by tapping the value range.
"Time trigger" symbol

Tap on this symbol to switch to the time trigger. The value displayed can be
changed by tapping the value range.
"Chart on card" symbol

Tap on this symbol to show the recording as a graphic on the customer card.
"Print-out" symbol
Tap on this symbol to create the record as a print-out.
"Select protocol style" symbol

Tap on this symbol to select the protocol style. The available protocol style
selection depends on the operating mode.
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9.10.3 Compact flash card
CAUTION!
Do not remove the compact flash card whilst data are being accessed. Data will be lost.
Shut down the machine and turn off the ignition. The customer card can now be removed.
The customer card can only be removed in order to evaluate the data.
Function of the PDE configuration card:

- Loading the PDE configuration
- Loading customer logos
- Loading the fonts files for the PDE control panel
- Storing the graphic if the printer is not ready
(no paper loaded, or printer switched off;
only if output of graphic to printer selected)
Function of the customer card:

- Storing data in directory PDE\xxxx\data.txt and head.txt
- Storing the BMP graphic in directory PDE\xxxx\page1.bmp
(only if output of graphic to card selected)
9.10.4 Recording and printing

Data can be handled in SI or US units. The type of documentation can be dictated by the machine
operator. A choice can be made from the following options:
- Chart output to printer (assuming a printer is installed)
and/or
- Chart on customer card
Use the PDE settings page on the PDE monitor to select or make entries.
Once the process is complete, the following events take place automatically:
- a printout or
- a BMP graphic is generated on the customer card.
If the printer is not ready (no paper or switched off), then all printouts are stored and can be printed
later.
This print-out includes:
- The customer's or Liebherr's logo and letterhead
- Description of operating mode
- Date
- Start and stop time
- Site number
- Plank/pile number
- Chart of selected measured values (depth, pressure, frequency)
- Description of measured values below the windows
- Scaling of measured values in meters [ft] or seconds
in the left-hand edge of the window
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9.10.5 Operating modes

Different operating modes are provided for operating PDE.
The main operating modes are:
- Kelly drilling
- CFA drilling
- Double rotary drilling
- Soil mixing
- Vibrator
- Hammer
- Push&Pull
- Hydraulic grab
- ramming control
During vibrator operation, the machine operator can preselect so-called 'submodes on the PDE
monitor:
Recording while lifting
Recording while lowering
Recording while lifting and lowering
Recording over time
Selection of main operating mode
The main operating mode is selected automatically depending on which operating mode the machine
operator has chosen. The preselected operating mode is displayed on the PDE monitor.
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The following information is displayed in all operating modes :

1. Job site
2. Pile/slot number
3. Start/finish date
4. Start/finish time
5. US units*
6. Maximum depth in cm [ft]
Kelly drilling mode

The following data are recorded when Kelly drilling:
1. Depth in cm [ft]
2. Drilling pressure in bar [bar]
3. Drilling progress* in revolutions per meter [rpft]
4. Pressing force in kN [lbs*1000]
5. Drilling torque* kNm [ft.lbs*1000]
6. Interruption ¹
7. Time (per PDE trigger)
Torque display ²
The data are recorded when lowering. Drilling progress is optional and is only recorded if the drilling
drive is equipped with a tachometer.
CFA drilling mode

The following data are recorded when CFA drilling:
1. Depth in cm [ft]
2. Drilling pressure in bar [bar]
4. Concrete pressure in bar [bar]
5. Feed speed in m/min [ft/min]
6. Drilling progress in revolutions per meter [rpft]
7. Drilling torque* kNm [ft.lbs*1000]
8. Interruption ¹
10. Concrete volume in m³ [yd³]
Style ²
Pile diameter* cm [ft]
Total concrete volume* in m³ [yd³]
Number of pulses* (concrete pump)
Liters/pulse* (concrete pump)
Data are recorded while lifting and lowering. Drilling progress is optional and is only recorded if the
drilling drive is equipped with a tachometer.
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Double rotary drilling mode

The following data are recorded when Double rotary drilling:
1. Depth in cm [ft]
2. Auger drilling pressure in bar [bar]
5. Pipe drilling pressure in bar [bar]
7. Interruption ¹
Style ²
Data are recorded while lifting and lowering. The concrete pressure is optional and is only recorded if
a concrete pressure sensor is fitted.
Depth recording grid (PDE trigger)

Depending on the mode, data are recorded when lifting and/or lowering on a 10 cm [0.33 ft] grid.
The grid can be adjusted to any value between 2 and 200 cm [0.06 to 6.5 ft].
Soil mixing mode

The following data are recorded when in soil mixing mode:
1. Depth in cm [ft]
2. Auger drilling pressure in bar [bar]
5. Pipe drilling pressure in bar [bar]
7. Interruption ¹
Style ²
10. Number of tools (augers)
11. Auger height [cm]
Data are recorded while lifting and lowering. The concrete pressure is optional and is only recorded if
a concrete pressure sensor is fitted.
* optional, the corresponding sensor must be fitted

¹ a horizontal line is used to indicate the interruption
² supporting recording(s) to ensure the chart is generated correctly
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Vibrator mode
The following data are recorded when in vibrator mode:
1. Depth in cm [ft]
2. Vibrator pressure in bar [bar]
3. Frequency * in Hz [Hz]
5. Amplitude * in mm [inch/100]
6. Interruption ¹
7. Concrete volume * in m³ [yd³]
8. Concrete pressure * in bar [bar]
Style ²
Depending on which submode has been selected, the data are recorded when lifting and/or lowering.
The frequency and amplitude are optional and are only recorded if the optional frequency sensor is
fitted.
Hammer mode
The following data are recorded when in Hammer mode:
1. Depth in cm [ft]
2. Blows / depth step
3. Energy/blow in kNm [ft.lbs*1000]
4. Energy/depth step in kNm [ft.lbs*1000]
5. Blows/min
6. Number of blows
7. Interruption ¹
Drop weight in kg [lbs]
Total blows
Total energy in kNm [ft.lbs]
Depth step in mm [ft]
The data are recorded when lowering.
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Push&Pull mode
The following data are recorded when in Push&Pull mode:
1. Depth in cm [ft]
2. Ram pressure. in bar [bar]
3. Vibrator unit [EIN/AUS]
4. Interruption ¹
Data are recorded while lifting and lowering.
Hydraulic grab operating mode

The following data are recorded when Kelly drilling:
1. Depth in cm [ft]
2. Deviation X in cm [ft]
3. Deviation Y in cm [ft]
4. Maximum depth in cm [ft]
The data are recorded when lowering.
Ramming control operating mode

The following data are recorded when in ramming control mode:
1. Beat number
2. Preset lifting height in m [ft]
3. Compaction in m/beat [ft/beat]
4. Absolute compaction in m [ft]
6. Preset braking height in m [ft]
7. Max. speed of winch 1 in m/min [ft/min]
8. Max. speed of winch 2 in m/min [ft/min]
9. Date dd:mm:yy
10. Time hh:mm:ss
11. Compaction
12. Total beats
13. Winch 1 active
14. Winch 2 active
No graphics are generated in this operating mode.
Depth recording grid (PDE trigger)

Depending on the mode, data are recorded when lifting and/or lowering on a 10 cm [0.33 ft] grid.
The grid can be adjusted to any value between 2 and 200 cm [0.06 to 6.5 ft].
* optional, the corresponding sensor must be fitted

¹ a horizontal line is used to indicate the interruption
² supporting recording(s) to ensure the chart is generated correctly
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9.10.6 Operation
General
When the control has started up (ignition on), the PDE system carries out a self-test. Potential errors
are indicated by the Litronic control system on the error page as an error message.
Operating the PDE monitor

To operate the monitor, tap fields with a gray background or fields in a box.
When you tap a field, a beep is heard.
To simplify operation, a green guide is provided in the menu navigation. A green box appears
around fields or symbols that have been tapped (in the documentation they are shown hatched).
Selecting the operating mode

The operating mode is indicated by the mode selected on the LCD screen.
The submode is selected by tapping the relevant field on the PDE monitor.
Kelly drilling
Job site Nenzing
Kelly drilling mode
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Entering job site and pile number

Values are entered on the keypad on the PDE monitor.
Kelly drilling
Pile number
Enter pile number
Start recording
Tap this symbol to start recording data (the plank/drill is placed on the ground).
The depth of the recording and the rope length metering display are set to zero.
Interrupting recording
Tap on this symbol to pause recording (e.g. to extend a pile). A horizontal line is
used to indicate the interruption on the display.
No data are recorded while recording is interrupted.
The depth (PDE depth) is stored and shown on the LCD screen underneath the
rope length metering figure.
Recording then restarts from this depth.
Use: Redress or lengthen Kelly bar, etc.
Stop recording
Tap on this symbol to stop recording data. A print-out is produced, assuming the
printer is ready.
Error messages
Error message are indicated by the relevant symbol flashing on the home page.
Tap on this symbol to go to the Error messages page where the error message
will be displayed in text form.
Tap on an error message to acknowledge it.
The symbol is red for unacknowledged error messages and yellow for acknowl-
edged error messages.
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Real time pile display
The real-time pile display is used as a graphic support to the double rotary drilling and CFA drilling
modes.
12
Real-time pile display, pile not yet at work
1 Automatic hoisting: desired additional con- 5 Current position

sumption (adjustable with potentiometer on
additional control panel X25)
2 Nominal drilling tool diameter (green line) 6 Maximum drilling depth (white line)
3 Drilling depth display with linear scaling 7 Ground surface (white line)
4 Concrete pressure display with logarithmic
or linear scaling
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13
Correctly set-up pile
If the pile is withdrawn correctly, the corresponding area is displayed in gray.

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14
Incorrectly set-up pile
If the pile is pulled too quickly, the corresponding area is displayed as yellow if the deviation is minor
(Figure 14, item 1) or as red if it is severe (Figure 14, item 2). The concrete pressure scaling is
displayed logarithmically (Figure 14, item 3).
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15
Limit value not quite reached
If the pile is withdrawn too quickly and if the reference value (= nominal drilling tool diameter) is not
quite reached (range between 97.5% and 100% of the nominal diameter), the corresponding area is
displayed yellow (Figure 15, item 1). The concrete pressure scaling is displayed on a linear basis
(Figure 15, item 2). Switching the concrete pressure scaling is done with the "Horizontal increase"
button (Figure 15, item 3).
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Turn off the machine

The machine can be switched off at any time. The current status is stored and generated again
when the machine is next switched on.
If the machine is switched off while recording a cycle, all the data are stored and recording will
resume at the same place when the machine is started again.
The machine reverts to the status it was in when it was switched off.
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9.10.7 Data organization

Directories on the customer card
Data are stored on the customer card in the PDE/ directory.
A new directory, e.g. VIBRxxxx (in raise/lower vibrator mode) is created at the start of each cycle,
where xxxx is a sequential number. When xxxx reaches the value 9999, it starts again at 0000.
Files
HEAD.TXT
A HEAD.TXT file is created for every cycle; it contains general information:
Example:
Operating mode Lower vibrator
Start date 14.10.2004
Start time 10:08:06
End date 14.10.2004
End time 10:12:14
Job site 2725.2
Pile number 2.22
Maximum depth [cm] 2083.9
DATA.TXT
A DATA.TXT file is created for every cycle; this contains the actual data.
Example:
Depth [cm] Vibrator pressure [bar]Frequency [Hz] Feed speed [m/min]Amplitude [mm] Interruption Time [hh:mm:ss]
0 27.9 0.0 0.0 0.0 0 10:08:06
10 152.9 19.8 0.8 8.9 0 10:08:14
21 179.7 29.3 5.8 6.0 0 10:08:15
31 170.7 32.9 4.3 5.2 0 10:08:17
41 178.7 33.7 4.6 4.8 0 10:08:18
51 180.4 34.0 5.1 4.2 0 10:08:19
File contents
This file contains data and name in a general table format that can be read by most spreadsheet
programs.
- a horizontal tab is used to separate the columns (ASCII code 09Hex)
- Lines are separated by carriage return,
Line feed = Carriage Return + Linefeed (ASCII Code 0D Hex, 0A Hex )
Each column contains the values from a recording; the name of each recording is in the first row.
All data and text are stored in ASCII code.
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PAGE1.BMP
If this option was selected, a "PAGE1.BMP" file is created for every cycle; this contains the chart
showing the recorded data.
A second page "PAGE2.BMP" can be produced if required(e.g.: concrete flow measurement *).
16
HEAD.TXT
Interrupting recording
Operating mode
9.10.8 Printer
The printer is turned on using the switch in the top left corner. The "Power" light comes on. If the
printer is not ready, data can be stored on the memory card. If the printer is ready when the control
is next switched on, the data will be printed.
The printer operating manual is included in "Technical Information".
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9.10.9 Protocol style

At present the following protocol styles can be selected:
17
Soil Mixing, 1
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18
Vibrator, 0
19
Vibrator, 1
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20
Vibrator, 2
21
CFA, 0
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22
CFA, 1
23
CFA, 2
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24
Double rotary drilling 0
25
Double rotary drilling, 1
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26
Double rotary drilling, 2
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9.11 Central lubrication system for lead runner

9.11.1 General
The central lubrication system lubricates the bearings and guides in the drilling unit.
IMPORTANT!
The central lubrication system only works when the diesel engine is running and the safety lever of
the control system is in the down position.
The lubrication process starts when the feed and "Slide lubrication" preselection key are pressed.
27
The grease pump for lubricating the drilling unit is at the
right of the superstructure in the middle (Figure 27, item
1).
28
When the grease pump is switched on, grease is carried
from the grease container to the various lubrication
points on the drilling equipment.
CAUTION!
The overpressure valve (Figure 28, item 2) is set by

the manufacturer and must not be adjusted! It pro-
tects against overpressure and must not be used to
set the working pressure!
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9.11.2 Filling the grease container

The grease container (Figure 28, item 1) may only be filled via the grease nipple (3).
CAUTION!
Ensure maximum cleanliness when filling the container! Otherwise the system can easily
become blocked by dirt.
Approved lubrication grease

The system is designed for all commercial multi-purpose greases of classes NLKI-KL. 2 for summer
and winter operation.
When it leaves the factory it is filled with lubricating grease of type: AVIALITH 2 EP multi-purpose
grease .
9.11.3 Function
When the feed and the "Slide lubrication" preselection key are pressed, the lubrication process starts
automatically.
The lubrication process continues as long as the feed is actuated.
CAUTION!
If the central lubrication system does not work properly, the machine will be insufficiently
lubricated and may be damaged!
Regularly check operation and ensure that sufficient lubrication is taking place.
9.11.4 Maintenance of the central lubrication system

The central lubrication system is of maintenance-free design and requires no special maintenance.
To ensure long-lasting operation, check the following points on a weekly basis:
• Check for adequate lubrication of the drilling unit. See also Chapter 7 "Maintenance of drilling unit"
• Check the lubrication pipes for leaks
• Check the level of the grease container and top up if necessary
A steam cleaner can be used to clean the central lubrication system.
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29
9.12 Central lubrication for the kinematics
and rotary connection
9.12.1 General
The central lubrication system lubricates the kinematics,
the crown gear bearings and the tooth flanks.
The central lubrication system works,
- if the diesel engine is running and
- the safety lever of the control unit is in the down
position.
The lubrication process runs automatically according to
the programmed lubrication and pause time.
The grease pump is at the right of the superstructure in
the middle (Figure 30, item 3).
When the grease pump is switched on, grease is carried
from the grease container to the various lubrication
points on the kinematics (Figure 29 and Figure 30, item
1) and crown gear (Figure 29 and Figure 30, item 2).
30
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31
The time intervals for the lubrication time and pause time
can be set with the switch unit (Figure 31, item 5).
CAUTION!
The overpressure valve (Figure 31, item 2) is set by

the manufacturer and must not be adjusted! It pro-
tects against overpressure and must not be used to
set the working pressure!
1 Grease container
2 Overpressure valve
3 Grease nipple for topping up
4 Pushbutton for intermediate lubrication
5 Switch unit
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9.12.2 Filling the grease container

The grease container (Figure 31, item 1) may only be filled via the grease nipple (3).
CAUTION!
Ensure maximum cleanliness when filling the container! Otherwise the system can easily
become blocked by dirt.
Approved lubrication grease

The system is designed for all commercial multi-purpose greases of classes NLKI-KL. 2 for summer
and winter operation.
When it leaves the factory it is filled with lubricating grease of type: AVIALITH 2 EP multi-purpose
grease .
9.12.3 Function
After the diesel engine is switched on, the yellow control lamp (Figure 32, item 4) comes on for
approximately 1.5 seconds, indicating readiness for operation.
To carry out a function test , press the red pushbutton (Figure 31, item 4) on the side of the pump
housing. As a result, interim lubrication is carried out with the programmed lubrication time. After this
lubrication time has expired, the lubrication process is switched off and the programmed pause time
commences. All further lubrication processes are automatically initiated with the preset times.
When the diesel engine is switched off, the lubrication process stops.
When it is switched on again, the lubrication process continues automatically via the control system.
Interim lubrication can be carried out at any time by pressing the pushbutton (Figure 31, item 4) with
the diesel engine running.
CAUTION!
If the central lubrication system does not work, the machine will be insufficiently lubricated
and may be damaged!
The grease container must always contain enough grease.
Frequently slew the superstructure or change the position of the undercarriage.
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9. OPTIONS
32
9.12.4 Time interval programming
The switch unit (Figure 32, item 1) is mounted directly on
the grease pump. To adjust the time, first remove the
guard frame. Then take off the protective cover.
Setting the lubrication time

• The lubrication time in minutes can be programmed by
adjusting the switch (2) with a screwdriver.
Adjustment range: 1 - 16 min
Factory setting: 6 min.
Setting the pause time

• The pause time in hours can be programmed by
adjusting the switch (3) with a screwdriver.
Adjustment range: 0.5 - 8 h
Factory setting: 8 h
CAUTION!
If the central lubrication system is not properly programmed, the machine will be insufficiently
lubricated and may be damaged!
NOTE!
After making the settings, re-attach and fasten the protective cover so that no water can get into the
switch unit.
9.12.5 Maintenance of the central lubrication system

The central lubrication system does not need any special maintenance.
To ensure long-lasting operation, check the following points on a weekly basis:
• Check for adequate lubrication of the kinematics, the pinion and the slewing ring bearings (grease
collar can be seen from the outside). See also "Slewing gear transmission / Rotary connection" in
Chapter 7.
• Check the lubrication pipes for leaks
• Check the level of the grease container and top up if necessary
A steam cleaner can be used to clean the central lubrication system.
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9. OPTIONS
33
9.13 Counterweight loader
9.13.1 General
The counterweight loader enables the counterweight and
additional counterweight to be loaded and removed with-
out having to use an auxiliary crane.
The counterweight is loaded or removed when the lead
is erected or set down respectively.
9.13.2 Loading/removing the counterweight
DANGER!
Risk of injury when loading the counterweight.

Precautions:
- Carry out movements slowly and with great care.
- Standing between the counterweight and base machine
or underneath the counterweight is forbidden.
34
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9. OPTIONS
General
• Always load the counterweight separately
• Load the additional counterweights(s) first, then the main counterweight.
Loading the counterweight

• The lead must be set down.
• Fasten the tackle (Figure 33, item 1) to the top lugs on the leader using an eyebolt (2).
• Erect the lead (See Chapter 6 "Assembly and dismantling").
• Position the counterweight immediately behind the machine.
• Fasten the bottom end of the suspension gear to the eyebolts in the counterweight with a
turnbuckle (3) and shackle.
• Tighten the suspension gear slightly, adjusting the lead so that it is as near as possible to the
vertical.
DANGER!

- Move the universal slide fully down.
- Lift and set down the counterweight immediately behind the machine,
Position transport vehicle accordingly.
- The superstructure must be parallel to the undercarriage.
Do not slew the superstructure.
Do not operate the travel gear.
• Carefully lift the counterweight and position it at the rear of the superstructure.
• Tighten the counterweight screws underneath (removing the cover plate).
• Slacken the tackle and detach it from the bottom ballast.
• Lay the lead down again and remove the suspension gear.
Removing the ballast

Remove the ballast in the reverse sequence.
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9. OPTIONS
9.14 Diesel particle filter
9.14.1 Product description
The diesel particle filter is installed instead of the silencer. It reduces sooty particles, hydrocarbons
and carbon monoxide in the exhaust gas.
The diesel particle filter self-regenerates as soon as the temperature exceeds 250 °C [482 °F].
The diesel particle filter system is monitored and supervised via the monitoring and display unit in
the operator's cab. The pressure, speed and temperature values displayed indicate the diesel particle
filter operating status.
Optical and audible warning messages are issued. It is then possible to respond quickly to any faults
in the filter system and prevent potential damage to the filter or diesel engine.
CAUTION!
Hot surface of the diesel particle filter!

Risk of crushing of limbs.
Touch the diesel particle filter exclusively when it has cooled down.
NOTE!
• If the machine is operated for a lengthy period in a low exhaust gas temperature range (low
engine speed), particles are only deposited in the filter and not burned immediately.
• Avoid engine idling and operating under low load as these shorten the service life of the filter.
• Use Liebherr 10W 40 low ash engine oil; for all other permissible engine oils the maintenance
interval is reduced by half (see maintenance chart)!
• Use EN 590 diesel fuel with a maximum sulphur content of 0.005% (50 ppm)!
• Fuel must not contain any additives (except dryer).
• The diesel particle filter holds the following certification (as of 30.11.2009): VERT, TRGS, BAFU
and LRV
• Note the exhaust gas counter pressure. Filter regeneration should take place at the latest when
maximum pressure (warning signal) is reached.
Accessories:
Use exclusively Liebherr accessories or additional equipment that are included in the operation
manual accessories list. Using other tools or accessories will result in loss of warranty and liability
claims!
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9. OPTIONS
Assembly:
35
Diesel particle filter system, design
1 Particle filter 3 Condensate trap

2 Data logger 4 Display/control unit
Regenerating the filter in operation:

• Oxidize deposited soot particles through continuous passive regeneration (exhaust temperature
above 250°C for at least 50% of period of operating time).
• Regeneration frequency depends on the operating conditions of the machine.
• The monitoring unit (in the operator's cab) emits a visual and audible signal when regeneration is
required.
• If the exhaust gas temperature during operation is not high enough, the machine operator can
boost the regeneration process by loading the machine.
• The input and output temperature and the input pressure are measured and displayed; these
values provide the machine operator with information on the current status of the filter.
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9. OPTIONS
Technical data:
Filter type Weight [kg] Diameter [mm] Length [mm] Monolith diameter x
length [inches]
5001 21.5 216.0 768.0 7.5 x 12.0
5002 28.0 254.4 768.0 9.0 x 12.0
5003 37.3 293.0 814.0 10.5 x 12.0
5004 46.4 332.5 839.0 12.0 x 13.0
5005 69.9 409.0 942.0 15.0 x 15.0
9.14.2 Controls and operating elements
36
Display/control unit (Figure 36):
The displays are explained in the table below.
1 LED red = warning (pressure)
2 LED yellow = system error
3 LED green = in operation
4 LCD display
5 OK button
6 DOWN button
7 UP button
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9. OPTIONS
9.14.3 Operating the monitoring and display unit

When the ignition is switched on, the message "Data logger ready for operation" appears on the
LCD display (Figure 36, item 4). After starting the diesel engine the display switches to the last menu
used. There is a choice of seven menus. The monitor displays different combinations of operating
data depending on the selected menu. The display is changed by pressing the UP and DOWN
buttons.
Press UP or DOWN button (approx. two seconds)
The display changes to the next menu.
The following information may be accessed:

• Pressure in mbar [psi] - appears after the engine starts
Displays the exhaust gas counter pressure only.
• Pressure in mbar [psi]/temperature 1 in °C
Also displays the exhaust gas temperature before the filter (engine side).
• Pressure in mbar [psi]/temperature 2 in °C
Also displays the exhaust gas temperature after the filter (exhaust side).
• Pressure in mbar [psi]/speed in rpm
Also displays the diesel engine speed.
NOTE!
The particle filter is most efficient and self-regenerates when the exhaust gas temperature is higher
than 250 °C [482 °F] for at least 50 % of the total operating time.
Function check:
The display/control unit monitors the particle filter and reports any undesirable operating conditions or
malfunctions. It also indicates when inspection of the particle filter is due. Where appropriate, a
warning signal (buzzer) is sounded when text is displayed and LEDs light up. The text will remain on
the screen until the cause of the problem has been rectified.
The warning signal can be switched off.
Press the OK button (approx. one second).

The warning signal is switched off.
The error message continues to be displayed.
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9. OPTIONS
Display LED Cause Trouble shooting

Inspection due - Number of operating Contact Liebherr after
hours until service sales service. Arrange
deadline. service and filter clean-
ing.
Thermocouple 1 (or 2) yellow Fault or interruption of Check temperature
faulty a temperature sensor sensor. In the event of
a fault, contact Liebherr
after sales service.
Idling/temperature yellow Operation for too long Increase load on ma-
fault at low exhaust gas chine/engine (full load
temperature (low en- operation).
gine load). Danger of
exhaust gas counter
pressure increasing as
a result.
Idling for too long. Operate machine at

higher speed.
Pre-boost pressure red Diesel particle filter is Regenerate diesel par-
reached dirty, exhaust gas ticle filter: operate ma-
counter pressure is chine under full load
slightly too high and until the pressure falls.
threatens to rise fur- If pressure does not
ther. Diesel engine can fall: Switch off machine,
be damaged. contact Liebherr after
sales service and ar-
range for filter to be
cleaned.
Explanation of the display fields Table 9-01 Part 1

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9. OPTIONS
Display LED Cause Trouble shooting

Main boost pressure red (flashing) Diesel particle filter too Switch off machine,
achieved dirty, exhaust gas contact Liebherr after
counter pressure too sales service and ar-
high. Diesel engine can range for filter to be
be damaged. cleaned.
Filter broken or pres- All LEDs flash Faulty diesel particle fil- Switch off machine and
sure pipe blocked. ter, blocked pressure contact Liebherr after
line or leakage in pres- sales service. Arrange
sure line. for filter and pressure
line to be checked.
Offset pressure yellow Exhaust gas pressure Contact Liebherr after
is the only measured sales service.
value (no engine RPM
or charge voltage val-
ues).
Pressure and charge yellow No measured values Contact Liebherr after
voltage error for exhaust gas pres- sales service.
sure and charge volt-
age.
Charge voltage error yellow No charge voltage val- Contact Liebherr after
ue. sales service.
Voltage threshold er- yellow Charge voltage is the Contact Liebherr after
ror only measured value sales service.
(no exhaust gas pres-
sure or engine RPM
measured values).
Clamp W interrupt er- yellow No engine RPM value. Contact Liebherr after
ror. sales service.
Explanation of the display fields Table 9-01 Part 2
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9. OPTIONS
9.14.4 Maintenance
NOTE!
• Rectify faults or defects immediately!

• Observe applicable safety regulations and accident prevention regulations!
• Maintenance work must be carried out exclusively by Liebherr maintenance personnel!
• Cleaning must be carried out exclusively by authorized Liebherr service stations!
• Observe the intervals defined in the maintenance chart!
37
The exhaust gas counter pressure is measured by a

pressure pipe that is connected to the particle filter
housing. A condensate trap (Figure 36, item 3 and Fig-
ure 37, item 1) is built into this pipe. The machine oper-
ator may only carry out maintenance work on this
component.
1 Condensate trap
2 Drain plug
3 Drain plug CLOSED
4 Drain plug OPEN
Drain off condensate:

Drain off condensate regularly.
Turn the drain plug (Figure 37, item 2) approx. 90° anti-clockwise (Figure 37, item 4) and drain the
condensate into a suitable container.
Close the drain plug by turning it clockwise (Figure 37, item 3).
Check for leaks.

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9. OPTIONS
NOTE!
The counter pressure monitoring system will not function correctly unless the system and the
condensate trap are sealed.
It is essential, therefore, to ensure that the drain valve is closed and there are no leaks!
CAUTION!
Exceeding the maintenance interval!
Damage to the diesel engine.
If the specified maintenance interval or maximum load is reached (warning LED on the control unit
lights up and warning signal sounds):
clean the diesel particle filter
Continued operation of the machine when the filter is clogged will result in damage to the
engine and invalidates the manufacturer's warranty!
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9. OPTIONS
38
9.15 Kelly bar guide
9.15.1 General
The Kelly bar guide (Figure 38, item 1)
- stabilises the Kelly bar (4)
- is bolted onto the Kelly bar via a spacer tube (3),
- has a ball slewing ring (2)
CAUTION!
Risk of falling!
39
9.15.2 Mounting the Kelly bar guide
• Bolt the Kelly bar guide and spacer tube onto the
Kelly bar
• Unfold the brackets
- Remove the linch pin (Figure 39, item 3), disc (2) and
bolt (1)
- Fold the brackets (4) outwards
- Fit the bolt (Figure 39, item 1), disc (2) and linch pin
(3)
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9. OPTIONS
40
• Fixing the Kelly bar guide
- Remove the spring plug (Figure 40, item 3), and bolt
(1)
- Push the plate (2) up to the Kelly bar
- Fit the bolt (Figure 40, item 1) and spring plug (3)
The Kelly bar guide can be turned with the Kelly bar.
This is necessary for further assembly.
• Place the Kelly bar in the drilling drive
• Turn the Kelly bar until the Kelly bar guide is correctly
positioned
41
• Folding the brackets together
- Remove the linch pin (Figure 41, item 3), disc (2) and
bolt (1)
- Fold the brackets (1) outwards
- Fit the linch pin (Figure 41, item 3), disc (2) and bolt
(1)
Do not turn the Kelly bar!
42
• Loosening the Kelly bar guide
- Remove the spring plug (Figure 42, item 3) and bolt
(1)
- Push the plate (2) away from the Kelly bar
- Fit the spring plug (Figure 42, item 3) and bolt (1)
The Kelly bar can be turned
Dismantling is carried out in reverse order.
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9. OPTIONS
9.16 Kelly extension

9.16.1 General
The Kelly extension is used when CFA drilling to achieve a greater drilling depth.
43
Overview of Kelly extension
1 Torque bracket 5 Drilling gear

2 Concreting head 6 Kelly damping
3 Kelly bar 7 Concrete delivery pipe
4 Drilling gear slide
9.16.2 Installing the Kelly extension

Procedure:
• Fit the concreting head (2) to the Kelly bar (3)
• Fit the torque bracket (1) to the drilling gear slide (4)
• Thread the Kelly bar (3) into the drilling drive
• Connect the concrete delivery pipe segments
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9. OPTIONS
Checks before operating the Kelly extension

Before using the Kelly extension, check that:
- the bolts are secured,
- fastening screws are secure,
- there is no mechanical damage
- or other damage
If anything is damaged, the Kelly extension must not be used.
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9. OPTIONS
9.17 Roof railing
9.17.1 General
An optional railing can be installed on the roof of the superstructure.
It is prohibited for anyone to stay on the roof without the roof railing!
The installation as well as the removal of the roof railing may only be carried out by authorized
personnel.
DANGER!
Danger of falling!
Work on the superstructure is only permitted with sufficient safety equipment.
44
1 Roof railing 2 Cotter pin
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9. OPTIONS
9.17.2 Mounting
The roof railing consists of segments. They are placed on the superstructure on special retainers,
subsequently secured via cotter pins (fig. 44, No. 1).
NOTE!
The railing segments, retainers and fixtures must be visually inspected once a week. If any damage
is found on the subject parts, then it must be remedied immediately!
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9. OPTIONS
9.18 Noise reduction cover
WARNING !
Danger of falling if standing on the noise reduction cover.

Do not stand on the noise reduction cover!
45
Noise reduction cover (Fig. 45, No. 1)

- Lift the noise reduction cover (Fig. 45, no. 1)
- by the four hangers (Fig. 45, no. 2) with an auxiliary crane

- hang it on the three bolts (Fig. 45, no. 4) at the rear right hand side of the superstructure
- fasten it underneath with the two star-headed screws (Fig. 45, no. 3).
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9. OPTIONS
9.19 Video surveillance system

46
Reversing camera
1 Video surveillance system monitor 3 Headlight

2 Rotary switch 4 Reversing camera
The rotary switch (2) is used to switch between the cameras.
The operating instructions for the monitor, the camera and the change-over box are included under
"Additional descriptions" in the "Technical information" manual.
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9. OPTIONS
47
Camera winches
1 Camera winches 2 Headlight
The operating instructions for the monitor, the camera and the change-over box are included under
"Additional descriptions" in the "Technical information" manual.
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9. OPTIONS
NOTES:
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10. APPENDIX
10. APPENDIX
10.1 General
The Appendix contains documents and information relating to third-party components and suppliers.
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10. APPENDIX
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Operating Manual EN

ORIGINAL 003 - 27.08.2010 / lwnfim2

Type of Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BA 280

1.2 Overview of Drilling Drive

1 Drilling Gear Slide 7 Oil Insert

1.3 Check Oil Level

• The oil level must be between the MIN. and MAX.

• Twist the dipstick out in an anticlockwise direction.

• Pull the dipstick out again and check oil level.

• First twist out the cover screw (Fig 2, No. 4) anticlockwise.

Driver bar wear

The maintenance of the hydraulic buffer (Fig 6, No. 1) is

The measures that are taken when a hydraulic buffer no

Bearing of the Kelly shock absorber

The bearing (Figure 6, No. 2) must be replaced when it

Check Before Operating the Drilling Drive

ORIGINAL 003 - 27.08.2010 / lwnfim2

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

SAFETY INSTRUCTIONS ..................................3

ASSEMBLY AND DISMANTLING ......................6

2. PRODUCT DESCRIPTION 2-1

2.6.1 Safety devices 2-6

2.11.2 Machine in operation 2 - 26

3. SAFETY INSTRUCTIONS 3-1

4.7 Left control panel (X12) 4 - 16

4.14 "Power unit monitoring" page 4 - 46

5.5.6 INPUT/OUTPUT menu 5 - 53

5.10.3 Operating the vibrator 5 - 100

6. ASSEMBLY AND DISMANTLING 6-1

6.3 Safety regulations for assembly and dismantling 6-3

7.1 General 7-1

7.13.2 Check the rope for diameter shrinkage 7 - 35

7.13.12 Winding ropes 7 - 52

8.5 Changing the feed ropes 8-5

9.10.4 Recording and printing 9 - 28

9.11.4 Maintenance of the central lubrication system 9 - 50

Liebherr-Werk Nenzing GmbH

The documentation for this machine is handled customer-specific.

1.2 Handling of documentation

Spare parts catalogue

• The entire documentation is provided in digital form on the CD-ROMs.

1.2.1 How are the Operating instructions set up?

1.2.2 System requirements of the computer for use of CD-ROMs

1.2.3 Storage of documentation

1.2.4 Current status of documentation

1.2.5 Danger symbols

The safety sign DANGER

The safety sign WARNING

The safety sign CAUTION

Carry out task

1.3 Legal notice

Litronic® is a registered trademark of the LIEBHERR company.

1.4 Conversion tables

Length conversion Table 1-01

1.4.2 Surface area

Surface area conversion Table 1-02

1.4.3 Weight (Mass)

Weight conversion Table 1-03

Volume conversion Table 1-04

Pressure conversion Table 1-05

Temperature conversion Table 1-06

Speed conversion Table 1-07

Force conversion Table 1-08

1 Optional xenon floodlight , superstructure 7 Rotating beacon