Bal 001 en PDF

Load capacity chart book EN
Type:
LRB 255
Serial number:
111 622
001 - 04.02.2010 / lwnfim2

LRB 255
Load Capacity Charts
The load capacities have been calculated according to:

DIN EN 996 Edition 1995
DIN EN 791 Edition 1995
The load capacities are only applicable to machines standing on horizontal, firm and
sufficiently supportive ground.
The machine operator must not drive into areas other than those specified in the tables. The
machine is not permitted to move into areas with no load capacity value.
This load capacity chart is only applicable to original LIEBHERR machine components and
equipment that are new and in perfect condition. Any form of damage, any modification or
addition that has not been approved by LIEBHERR invalidates the following load capacities,
which in such cases must not be applied.
The piling and drilling rig is approved for use in outside temperatures of -20°C [-4°F] to
+40°C [104°F]. Operation in other temperature ranges will necessitate a special modification
to the machine.
The load capacities were calculated with the following wind speeds:
Operating mode Maximum permissible wind speed in m/s [mph]

In use 20 [44.7]
Not in use, less than 20m [66ft] 36 [80.5]
Not in use, more than 20m [66ft] 42 [93.9]
The machine must not be used when wind speeds exceed those shown in the table.
Chapter 5 of the operating manual describes the permitted parking position of the machine.
If a wind speed of more than 36 m/s [80.5 mph] is expected or forecast, move the lead into the
transport position (see Chapter 6 of the operating manual).
The load capacity charts must not be used for offshore applications.
The operator must hold the qualifications stated in section 3.2 of the operating manual. The
operator of the machine and all other personnel who are involved with its operation must have
read and understood the national safety and accident prevention regulations.
Liebherr -Werk Nenzing GMBH 12.01.2004

LRB 255
When moving with a load, higher stability factors apply.
The machine must only be moved very slowly (travel gear level 1; v < 0.5 km/h [0.31 mph])
and only when the ground is level and firm (or on excavator mattresses). Any dynamic effects
must be reduced to the absolute minimum. The load must not be allowed to sway.
Drilling rigs must not be moved until the drilling tool has been completely emptied.
Pulling work may only be carried out with the lead supported (make sure that the ground has
an adequate load bearing capacity).
The pulling force required must not exceed the values shown in the load capacity chart.
The load capacities shown here are only representative of one of the many possible areas of
application of the machine.
It is vital that you consult the manufacturer if the machine is to be operated under conditions
other than those specified here.
The following conditions also apply with respect to the load capacity charts:
- LRB 255 carrier with 12.3t [27100lbs] counterweight

- Lower edge of lead no more than 0.5m [1.6ft] above the ground
- Lower edge of pile/drilling equipment no more than 0.5m [1.6ft] above formation
level
- Outreach measured from excavator pivot point to pile shaft (with lead facing straight
ahead)
- Max. slewing speed with load: 1 rpm, slewing gear level 1
- The weight of any additional equipment (such as a pile guide) must be deducted from
the load capacity
- Any extra load, e.g. the weight of concrete hoses, must also be deducted from the load
capacity.
- The superstructure can (unless stated otherwise) rotate through 360°
- No load on the auxiliary hoist
Liebherr -Werk Nenzing GMBH 12.01.2004

Load chart for piling rigs to EN996: Machine type: LRB255
ID no.: 10540403
Caution: the specified values only apply under the following conditions: Drg.No.: 509 001 2255 03 000
- carrier LRB255 670kW with 12.3 t + 1.4t rear counterweight and HD undercarriage extended
- leader bottom no more than 0.5m above the ground, ground firm and level
- bottom edge of pile no higher than bottom edge of leader
- Pile shaft 1200mm in front of centre of leader
- radius measured from excavator pivot point to pile shaft (along the ground)
- max. travel speed with load: 0.5 km/h, travel only permitted on firm ground or crane mats
- max. swing speed with load: 1 rpm
- the weight of a pile guide and any additional equipment must be deducted from the lifting capacity
- loads can (unless stated otherwise) be slewed through 360°
- leader vertical and facing straight ahead!
- including Rope crowd system
- including Auxiliary winch on the leader
- Optional leader top for the Kelly rope attached
- not for offshore applications
Hammer weight: max. 12500 kg H110 with 9.0 tonne drop weight
Hammer length: min. 6.000 m
Lead length [m]:
Support arm - 21.2m 24.2m 27.2m 30.2m
Radius [m]: angle [°] Max. pile weight [t]:
4.10 74.6 17.5 17.5 16.0 9.0
4.25 71.5 17.5 17.5 13.5 7.0
4.50 66.0 17.5 15.5 9.5 4.0
4.75 60.3 15.0 11.5 6.5 1.0
5.00 54.2 11.5 8.5 3.5
5.25 47.7 8.5 5.5 1.0
5.50 40.4 5.5 3.0
5.80 30.3 2.5
20.0
18.0
16.0
Pile weight [t]
14.0
21.2m
12.0
24.2m
10.0
27.2m
8.0
30.2m
6.0
4.0
2.0
0.0
4.10 4.25 4.50 4.75 5.00 5.25 5.50 5.80
Radius [m]
Max. ground pressure [kg/cm 2] with 900mm grousers:

Radius [m]:
Lead length: 21.2m 4.10 4.25 4.50 4.75 5.00 5.25 5.50 5.80
Load (front): 3.09 3.25 3.59 3.67 3.59 3.54 3.44 3.35
Load (lateral): 2.05 2.10 2.18 2.17 2.11 2.07 2.01 1.96
Load (diagonal): 3.58 3.77 4.14 4.22 4.13 4.06 3.95 3.85
Lead length: 24.2m 4.10 4.25 4.50 4.75 5.00 5.25 5.50 5.80
Load (front): 3.16 3.33 3.46 3.35 3.32 3.25 3.21
Load (lateral): 2.08 2.13 2.15 2.08 2.03 1.98 1.94
Load (diagonal): 3.66 3.86 4.00 3.88 3.84 3.75 3.70
Lead length: 27.2m 4.10 4.25 4.50 4.75 5.00 5.25 5.50 5.80
Load (front): 3.10 3.05 2.96 2.92 2.86 2.82
Load (lateral): 2.06 2.02 1.96 1.92 1.87 1.84
Load (diagonal): 3.60 3.54 3.43 3.39 3.32 3.27
Lead length: 30.2m 4.10 4.25 4.50 4.75 5.00 5.25 5.50 5.80
Load (front): 2.64 2.60 2.57 2.51
Load (lateral): 1.85 1.83 1.79 1.74
Load (diagonal): 3.03 2.99 2.96 2.89
For floor plates in other sizes, a rough estimate of the ground pressure can be derived from the relationship between the plate widths
! Consult the manufacturer for exact figures.
23.04.2010 LIEBHERR - Werk Nenzing A. Koller

ID no.: 10540403
- carrier LRB255 670kW with 27117lbs + 3087lbs rear counterweight and HD undercarriage extended
- leader bottom no more than 1.64ft above the ground, ground firm and level
- Pile shaft 3.94ft in front of centre of leader
- max. travel speed with load: 0.3 mph, travel only permitted on firm ground or crane mats
- including Rope crowd system
- including Auxiliary winch on the leader
- Optional leader top for the Kelly rope attached
Hammer weight: max. 27558 lbs H110 with 19841 lbs drop weight
Hammer length: min. 19.700 ft
Lead length [ft]:
Support arm - 70ft 80ft 90ft 100ft
Radius [ft]: angle [°] Max. pile weight [lbs]:
13.5 74.6 38581 38581 35274 19842
13.9 71.5 38581 38581 29762 15432
14.8 66.0 38581 34172 20944 8818
15.6 60.3 33069 25353 14330 2205
16.4 54.2 25353 18739 7716
17.2 47.7 18739 12125 2205
18.0 40.4 12125 6614
19.0 30.3 5512
45000
40000
35000
Pile weight [lbs]
30000 70ft
25000 80ft
20000 90ft
15000 100ft
10000
5000
0
13.5 13.9 14.8 15.6 16.4 17.2 18.0 19.0
Radius [ft]
Max. ground pressure [PSI] with 2.95ft grousers:
Radius [ft]:
Lead length: 70ft 13.5 13.9 14.8 15.6 16.4 17.2 18.0 19.0
Load (front): 44.0 46.2 51.1 52.2 51.1 50.4 48.9 47.6
Load (lateral): 29.2 29.9 31.0 30.9 30.0 29.4 28.6 27.9
Load (diagonal): 50.9 53.6 58.9 60.0 58.7 57.7 56.2 54.8
Lead length: 80ft 13.5 13.9 14.8 15.6 16.4 17.2 18.0 19.0
Load (front): 44.9 47.4 49.2 47.6 47.2 46.2 45.7
Load (lateral): 29.6 30.3 30.6 29.6 28.9 28.2 27.6
Load (diagonal): 52.1 54.9 56.9 55.2 54.6 53.3 52.6
Lead length: 90ft 13.5 13.9 14.8 15.6 16.4 17.2 18.0 19.0
Load (front): 44.1 43.4 42.1 41.5 40.7 40.1
Load (lateral): 29.3 28.7 27.9 27.3 26.6 26.2
Load (diagonal): 51.2 50.4 48.8 48.2 47.2 46.5
Lead length: 100ft 13.5 13.9 14.8 15.6 16.4 17.2 18.0 19.0
Load (front): 37.5 37.0 36.6 35.7
Load (lateral): 26.3 26.0 25.5 24.7
Load (diagonal): 43.1 42.5 42.1 41.1
For floor plates in other sizes, a rough estimate of the ground pressure can be derived from the relationship between the plate widths
! Consult the manufacturer for exact figures.

Operating instructions for drilling rigs to EN791 Machine type: LRB255
for Kelly drilling: ID no.: 10540404
Drg.No.: 509 001 2255 04 000
Caution: the machine may only be operated under the following conditions:
- carrier LRB255 670kW with 12.3 t rear counterweight and HD undercarriage extended
- drilling axis 1250mm in front of front edge of leader
- radius measured from excavator pivot point to drilling axis (along the ground)
- drilling pipe diameter max. 2200mm
- max. lead length: 24m
- Leader vertical and torque supports fitted at top and bottom!
This stability calculation applies to:

- vertical operation only!
- concrete supply line and ladder for leader access are not attached
- boom walkway is not attached to the drilling drive
- Kelly bar MD28/3/30 max. 5.9t completely compressed in its highest position
- Kelly guide is not attached from above
- BA250 Kelly transmission with attached drive adapter, damping and cardan without pressure pipe
- weight of drilling tool max. 1.5 t
- leader not supported
- Leader must be supported on the ground for extraction operations
- the loads specified for the various winches apply to the individual winch only
and must not be combined!
- a load on the auxiliary winch is only permitted when the drilling tool is completely empty!
21m vertical leader: Drilling gear Drilling gear Drilling gear

raised max. 2m raised max. 10m at very top
Radius: Radius: Radius:
Max. permitted line pull for: Min.: 4.5m max. 5.0m Min.: 4.5m max. 5.0m Min.: 4.5m max. 5.0m
Auxiliary winch [t]: 8.0 8.0 8.0 8.0 8.0 8.0
Kelly winch [t]: 20.0 20.0 20.0 20.0 20.0 19.0
Crowd winch [t]: 33.0 22.0 27.0 18.5 21.0 15.0
Max. ground pressure [kg/cm2] Load (front): Load (lateral): Load (diagonal):
with 900mm track pads for: Radius: Radius: Radius:
Min.: 4.5m max. 5.0m Min.: 4.5m max. 5.0m Min.: 4.5m max. 5.0m
Max. permitted load on auxiliary winch: 2.53 3.01 1.77 1.92 2.89 3.47
Max. permitted load on Kelly winch: 2.42 2.85 1.71 1.86 2.74 3.29
Max. permitted load on crowd winch: 4.59 4.09 2.48 2.25 5.15 4.61
24m vertical leader: Drilling gear Drilling gear Drilling gear

raised max. 2m raised max. 10m at very top
Max. permitted line pull for: Min.: 4.5m max. 5.0m Min.: 4.5m max. 5.0m Min.: 4.5m max. 5.0m
Auxiliary winch [t]: 8.0 8.0 8.0 7.0 8.0 6.0
Kelly winch [t]: 20.0 17.0 20.0 16.5 20.0 15.0
Crowd winch [t]: 29.0 19.0 23.0 15.0 17.5 12.0
Max. ground pressure [kg/cm2] Load (front): Load (lateral): Load (diagonal):
with 900mm track pads for: Radius: Radius: Radius:
Min.: 4.5m max. 5.0m Min.: 4.5m max. 5.0m Min.: 4.5m max. 5.0m
The machine may only be moved under the following conditions:

- drilling head and drill casing detached
- drilling tool completely emptied
- drilling drive and Kelly bar in lowest position
- leader vertical
- no load on the auxiliary hoist
- base arm cylinder fully retracted
- leader bottom just above the ground, ground firm and level
- travel only permitted when uppercarriage is parallel with the undercarriage!
- no dynamic effects whatsoever permitted, drive with extreme caution and think one step ahead!
Operating instructions for drilling rigs to EN791 Machine type: LRB255
for Kelly drilling: ID no.: 10540404
Drg.No.: 509 001 2255 04 000
Caution: the machine may only be operated under the following conditions:
- carrier LRB255 670kW with 27117lbs rear counterweight and HD undercarriage extended
- drilling axis 4.1ft in front of front edge of leader
- radius measured from excavator pivot point to drilling axis (along the ground)
- drilling pipe diameter max. 7.2ft
- max. lead length: 80ft
This stability calculation applies to:

- vertical operation only!
- concrete supply line and ladder for leader access are not attached
- boom walkway is not attached to the drilling drive
- Kelly bar MD28/3/30 max. 13007lbs is completely compressed in its highest position
- Kelly guide is not attached from above
- BA250 Kelly transmission with attached drive adapter, damping and cardan without pressure pipe
- weight of drilling tool max. 3307 lbs
- leader not supported
- Leader must be supported on the ground for extraction operations
- the loads specified for the various winches apply to the individual winch only
and must not be combined!
- a load on the auxiliary winch is only permitted when the drilling tool is completely empty!
70ft vertical leader: Drilling gear Drilling gear Drilling gear

raised max. 6.5ft raised max. 32.8 ft at very top
Max. permitted line pull for: Min.: 14.7ft max. 16.4ft Min.: 14.7ft max. 16.4ft Min.: 14.7ft max. 16.4ft
Auxiliary winch [lbs]: 17637 17637 17637 17637 17637 17637
Kelly winch [lbs]: 44092 44092 44092 44092 44092 41888
Crowd winch [lbs]: 72753 48502 59525 40786 46297 33069
Max. ground pressure [PSI] Load (front): Load (lateral): Load (diagonal):
with 2.95ft track pads for: Radius: Radius: Radius:
Min.: 14.7ft max. 16.4ft Min.: 14.7ft max. 16.4ft Min.: 14.7ft max. 16.4ft
80ft vertical leader: Drilling gear Drilling gear Drilling gear

raised max. 6.5ft raised max. 32.8 ft at very top
Max. permitted line pull for: Min.: 14.7ft max. 16.4ft Min.: 14.7ft max. 16.4ft Min.: 14.7ft max. 16.4ft
Auxiliary winch [lbs]: 17637 17637 17637 15432 17637 13228
Kelly winch [lbs]: 44092 37479 44092 36376 44092 33069
Crowd winch [lbs]: 63934 41888 50706 33069 38581 26455
Max. ground pressure [PSI] Load (front): Load (lateral): Load (diagonal):
with 2.95ft track pads for: Radius: Radius: Radius:
Min.: 14.7ft max. 16.4ft Min.: 14.7ft max. 16.4ft Min.: 14.7ft max. 16.4ft
The machine may only be moved under the following conditions:

- drilling head and drill casing detached
- drilling tool completely emptied
- drilling drive and Kelly bar in lowest position
- leader vertical
- no load on the auxiliary hoist
- base arm cylinder fully retracted
- leader bottom just above the ground, ground firm and level
- max. travel speed with load: 0.3mph, travel only permitted on firm ground or crane mats
- travel only permitted when uppercarriage is parallel with the undercarriage!
- no dynamic effects whatsoever permitted, drive with extreme caution and think one step ahead!
ID no.: 11250304
- carrier LRB255 670kW with 12.3 t + 1.4t rear counterweight and HD undercarriage extended
- pile shaft 1200mm in front of centre of leader
- including rope crowd system
- including auxiliary winch on the leader
- optional leader top for the Kelly rope attached
Hammer weight: max. 14500 kg H110 with 9.0 tonne drop weight, incl. helmet
Hammer length: min. 6.000 m
Leader length [m]:
Support arm - 21.2m 24.2m 27.2m 30.2m
Radius [m]: angle [°] Max. pile weight [t]:
4.10 74.6 15.5 15.5 15.5 10.4
4.25 71.5 15.5 15.5 14.9 8.3
4.50 66.0 15.5 15.5 11.0 5.1
4.75 60.3 15.5 13.2 7.6 2.2
5.00 54.2 13.0 9.8 4.7
5.25 47.7 9.8 6.8 2.1
5.50 40.4 6.9 4.1
5.80 30.3 4.0 1.4
18
16
14
Pile weight[to]
[t]
12 21.2m
Pfahlgewicht
10 24.2m
08 27.2m
06 30.2m
04
02
00
4.10 4.25 4.50 4.75 5.00 5.25 5.50 5.80
Radius
Ausladung
[m] [m]
Max. ground pressure [kg/cm2] with 900mm grousers:

Radius [m]:
Leader length: 21.2m 4.10 4.25 4.50 4.75 5.00 5.25 5.50 5.80
Load (front): 2.83 2.97 3.25 3.58 3.63 3.55 3.46 3.40
Load (lateral): 1.94 1.98 2.06 2.14 2.13 2.07 2.02 1.97
Load (diagonal): 3.28 3.45 3.77 4.13 4.17 4.07 3.97 3.89
Leader length: 24.2m 4.10 4.25 4.50 4.75 5.00 5.25 5.50 5.80
Load (front): 2.90 3.04 3.33 3.41 3.33 3.26 3.19 3.14
Load (lateral): 1.97 2.02 2.10 2.09 2.04 1.99 1.94 1.90
Load (diagonal): 3.36 3.53 3.86 3.94 3.84 3.76 3.68 3.62
Leader length: 27.2m 4.10 4.25 4.50 4.75 5.00 5.25 5.50 5.80
Load (front): 2.97 3.06 2.98 2.91 2.85 2.81
Load (lateral): 2.00 2.03 1.97 1.91 1.87 1.83
Load (diagonal): 3.44 3.56 3.46 3.38 3.31 3.25
Leader length: 30.2m 4.10 4.25 4.50 4.75 5.00 5.25 5.50 5.80
Load (front): 2.65 2.61 2.56 2.51
Load (lateral): 1.86 1.83 1.78 1.74
Load (diagonal): 3.04 3.00 2.94 2.89
For floor plates in other sizes, a rough estimate of the ground pressure can be derived from the relationship between
the plate widths! Consult the manufacturer for exact figures.

ID no.: 11250304
- carrier LRB255 670kW with 27117lbs + 3087lbs rear counterweight and HD undercarriage extended
- pile shaft 3.94ft in front of centre of leader
- max. travel speed with load: 0.3 mph, travel only permitted on firm ground or crane mats
- including rope crowd system
- including auxiliary winch on the leader
- optional leader top for the Kelly rope attached
Hammer weight: max. 31967 lbs H110 with 19841 lbs drop weight, incl. helmet
Hammer length: min. 19.700 ft
Leader length [ft]:
Support arm - 70ft 80ft 90ft 100ft
Radius [ft]: angle [°] Max. pile weight [lbs]:
13.5 74.6 34172 34172 34172 22928
13.9 71.5 34172 34172 32849 18298
14.8 66.0 34172 34172 24251 11244
15.6 60.3 34172 29101 16755 4850
16.4 54.2 28660 21605 10362
17.2 47.7 21605 14991 4630
18.0 40.4 15212 9039
19.0 30.3 8818 3086
40000
35000
Pile weight [lbs]
30000
70ft
25000
Pfahlgewicht
80ft
20000
90ft
15000 100ft
10000
5000
0
13.5 13.9 14.8 15.6 16.4 17.2 18.0 19.0
Radius
Ausladung
[ft] [ft]
Max. ground pressure [PSI] with 2.95ft grousers:
Radius [ft]:
Leader length: 70ft 13.5 13.9 14.8 15.6 16.4 17.2 18.0 19.0
Load (front): 40.3 42.2 46.2 50.9 51.6 50.5 49.2 48.4
Load (lateral): 27.6 28.2 29.3 30.4 30.3 29.4 28.7 28.0
Load (diagonal): 46.7 49.1 53.6 58.7 59.3 57.9 56.5 55.3
Leader length: 80ft 13.5 13.9 14.8 15.6 16.4 17.2 18.0 19.0
Load (front): 41.2 43.2 47.4 48.5 47.4 46.4 45.4 44.7
Load (lateral): 28.0 28.7 29.9 29.7 29.0 28.3 27.6 27.0
Load (diagonal): 47.8 50.2 54.9 56.0 54.6 53.5 52.3 51.5
Leader length: 90ft 13.5 13.9 14.8 15.6 16.4 17.2 18.0 19.0
Load (front): 42.2 43.5 42.4 41.4 40.5 40.0
Load (lateral): 28.4 28.9 28.0 27.2 26.6 26.0
Load (diagonal): 48.9 50.6 49.2 48.1 47.1 46.2
Leader length: 100ft 13.5 13.9 14.8 15.6 16.4 17.2 18.0 19.0
Load (front): 37.7 37.1 36.4 35.7
Load (lateral): 26.5 26.0 25.3 24.7
Load (diagonal): 43.2 42.7 41.8 41.1
For floor plates in other sizes, a rough estimate of the ground pressure can be derived from the relationship between
the plate widths! Consult the manufacturer for exact figures.

Operating manual EN
Type:
LRB 255
Serial number:
111 622
ORIGINAL 001 - 04.02.2010 / lwnfim2

111 622
LIEBHERR
INTRODUCTION .................................................1
PRODUCT DESCRIPTION .................................2
SAFETY GUIDELINES .......................................3
CONTROL AND OPERATING ELEMENTS .......4
OPERATION .......................................................5
CHAPTER INDEX
ASSEMBLY AND DISASSEMBLY .....................6
MAINTENANCE ..................................................7
REPAIR ...............................................................8
OPTIONS ............................................................9
LRB255_V001 (mf) LWN - TD4/2/2010
APPENDIX ....................................................... 10
111 622
LIEBHERR
111 622
LIEBHERR
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
1.3 Legal notice 1-4
1.4 Conversion tables 1-5
1.4.1 Length 1-5
1.4.2 Surface area 1-5
1.4.3 Weight (Mass) 1-6
1.4.4 Volume 1-6
1.4.5 Pressure 1-6
1.4.6 Temperature 1-7
1.4.7 Speed 1-7
1.4.8 Force 1-7
1.4.9 Torque 1-7
1.4.10 Performance 1-8
1.5 Explanation of conformity 1-9
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 Ranges of use for the machine; Leader 2-2
2.2.1 Machine classification; Leader 2-2
2.3 Machine summary; Leader 2-3
2.4 Piling rig and drilling device 2-4
2.4.1 Kelly jib * 2-5
2.4.2 Auxiliary jib * 2-5
2.4.3 Leader ladder 2-5
2.4.4 Leader 2-6
2.4.5 Leader extension * 2-7
LRB255_V001 (mf) LWN - TD4/2/2010
2.4.6 Feed system * 2-9

2.4.7 Universal carriage 2-9
2.4.8 Vibrator adapter * 2 - 10
2.4.9 Hammer adapter * 2 - 10
2.4.10 Drilling gear carriage Kelly drilling * 2 - 10
2.4.11 Auxiliary winch * 2 - 11
2.4.12 Hook fixture point * 2 - 11
2.4.13 Swing and inclination device 2 - 12
0-5
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LIEBHERR
INDEX
2.4.14 Supporting arm 2 - 13

2.4.15 Supporting arm base 2 - 13
2.4.16 Rope guide Kelly rope * 2 - 13
2.4.17 Basic arm 2 - 14
2.4.18 Kelly winch * 2 - 14
2.4.19 Torque stay rods * 2 - 14
2.4.20 Leader foot plate * 2 - 15
2.4.21 Hydraulic leader foot * 2 - 15
2.4.22 Hose package 2 - 15
2.4.23 LRB-quick assembly system 2 - 15
2.5 Uppercarriage 2 - 16
2.5.1 Central power unit 2 - 19
2.5.2 Diesel engine 2 - 20
2.5.3 Pump components 2 - 21
2.6 Undercarriage 2 - 22
2.7 Counterweight 2 - 24
2.7.1 Rear counterweight 2 - 24
2.7.2 Additional ballast * 2 - 24
2.8 Summary of the hydraulic cylinders 2 - 25
2.9 Technical data 2 - 26
2.9.1 Nominal data 2 - 29
2.9.2 Application requirements 2 - 30
2.9.3 Emissions 2 - 30
2.9.4 Vibrations 2 - 30
2.9.5 Engine aggregates 2 - 31
2.9.6 Hydraulic system 2 - 31
2.9.7 Winches 2 - 32
2.9.8 Swing gear 2 - 33
2.9.9 Travel gear 2 - 33
2.9.10 Control 2 - 34
2.9.11 Load chart for piling rig and drilling equipment 2 - 35
2.10 Equipment - Summary 2 - 36
3. SAFETY PRECAUTIONS 3-1

3.1 General 3-1
3.1.1 Use as directed; Leader 3-2
3.1.2 Examples of use not as directed; Leader 3-3
3.1.3 Danger symbols 3-4
3.1.4 Areas of responsibility 3-5
3.2 Personal attributes required of the machine operator 3-6
3.3 Personal protective wear 3-7
3.4 Work area 3-8
3.5 Safety and monitoring devices 3-9
3.5.1 Safety devices 3-9
3.5.2 Monitoring devices 3 - 11
0-6
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LIEBHERR
INDEX
3.6 Safety signs on the machine 3 - 12

3.6.1 Safety signs on the machine, USA 3 - 16
3.6.2 Meaning of the safety signs 3 - 19
3.7 Machine-specific dangers 3 - 22
3.7.1 Injuries resulting from operating machinery 3 - 22
3.7.2 Injuries due to hydraulic energy 3 - 24
3.7.3 Risk of burns 3 - 25
3.7.4 Risk of chemical burns 3 - 26
3.7.5 Fire and explosion hazards 3 - 27
3.7.6 Risk of poisoning and asphyxiation 3 - 30
3.7.7 Electromagnetic influences 3 - 31
3.7.8 Endangering the environment 3 - 32
3.7.9 Hazardous area 3 - 33
3.8 Additional dangers 3 - 36
3.8.1 Effects from wind and storm 3 - 36
3.8.2 Ground composition at the site 3 - 42
3.8.3 Snow and ice loads 3 - 43
3.8.4 Lightning strikes 3 - 44
3.8.5 Overhead power lines 3 - 45
3.8.6 Underground pipes and cables 3 - 54
3.9 Safety precautions for the machine operator 3 - 59
3.10 Safety precautions for maintenance and repair personnel 3 - 59
3.11 Safety precautions for construction site personnel 3 - 60
3.11.1 Signalman 3 - 60
3.11.2 Rigger 3 - 62
3.11.3 Hand signals 3 - 62
4. CONTROL AND OPERATING ELEMENTS 4-1

4.1 General 4-1
4.2 Operating elements on the undercarriage 4-2
4.3 Operating elements on the uppercarriage 4-3
4.4 Cab 4-4
4.4.1 Cab overview 4-4
4.4.2 Overview of the control stand 4-6
4.4.3 Overhead view of control stand 4-8
4.5 Switch levers, pedals, handwheel 4 - 11
LRB255_V001 (mf) LWN - TD4/2/2010
4.6 Left control panel (X11) 4 - 13

4.7 Left-hand control panel (X12) 4 - 15
4.8 Right-hand control panel (X23) 4 - 17
4.9 Auxiliary panel (X25) 4 - 21
4.10 Auxiliary panel (X26) * 4 - 26
4.11 Overview LCD-display screen 4 - 32
4.11.1 Display screen-prime data area 4 - 32
4.11.2 Description of display screen prime data areas 4 - 33
4.11.3 Order of display screen pages 4 - 35
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4.12 Page "Operation diagram" Leader 4 - 38

4.13 Page "Preselect operating mode" 4 - 54
4.14 Page "Monitoring of components" 4 - 57
4.15 Motor error message 4 - 61
4.15.1 Serious motor error message 4 - 61
4.15.2 General motor error message 4 - 62
4.16 Page "Error displays" 4 - 63
4.17 Page "Adjustments" 4 - 65
4.18 Litronic service panel on the LCD screen 4 - 67
4.18.1 Menu bar 4 - 67
4.18.2 Keyboard menu 4 - 68
5. OPERATION 5-1
5.1 General 5-1
5.2 Notes on operation 5-1
5.2.1 Working safely with the LRB 255 5-1
5.2.2 Emergency-Off-switches 5-2
5.2.3 Actuating the safety lever 5-3
5.3 Inspections before start-up 5-3
5.3.1 Tour of inspection 5-4
5.3.2 Inspection duties 5-4
5.4 Start-up 5-5
5.4.1 Switch on ignition 5-5
5.4.2 Checking the fuel level 5-6
5.4.3 Refuelling the machine 5-6
5.4.4 Selecting operating mode 5-7
5.4.5 Starting the diesel engine 5-9
5.4.6 Setting the engine speed 5 - 10
5.4.7 Lower safety lever (access lever) 5 - 12
5.5 Operating the machine - Main functions 5 - 13
5.5.1 Checks before commencing operation 5 - 14
5.5.2 Actuating the crawler 5 - 15
5.5.3 Activating the swing gear 5 - 20
5.5.4 Swing gear free-swing 5 - 23
5.5.5 Swing gear limitation * 5 - 26
5.6 Litronic 5 - 30
5.6.1 Properties 5 - 30
5.6.2 General 5 - 30
5.6.3 Starting the Litronic 5 - 31
5.6.4 The menus 5 - 32
5.6.5 Main menu 5 - 32
5.6.6 INPUT/OUTPUT menu 5 - 33
5.6.7 MEMORY menu 5 - 33
5.6.8 SELECT menu 5 - 34
5.6.9 CORRECTION menu 5 - 37
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5.6.10 MESSAGES menu 5 - 38

5.6.11 SPECIAL FUNCTIONS menu 5 - 39
5.7 Operating the machine - Auxiliary functions 5 - 44
5.7.1 Adjusting operating elements 5 - 44
5.7.2 Operator's seat 5 - 45
5.7.3 LCD-display screen adjustments 5 - 46
5.7.4 Windshield wiper 5 - 46
5.7.5 Inside lighting in uppercarriage 5 - 48
5.7.6 Cab lighting 5 - 48
5.7.7 Radio 5 - 48
5.7.8 Horn 5 - 48
5.7.9 Cigarette lighter / socket in the cab 5 - 48
5.8 Adjusting piling rig and drilling system 5 - 49
5.8.1 Adjusting the leader via auxiliary panel (X25) 5 - 49
5.8.2 Adjusting the leader via the switch levers 5 - 61
5.8.3 Leader inclination display 5 - 67
5.8.4 Automatic vertical alignment 5 - 68
5.8.5 Automatic parallel shifting 5 - 70
5.8.6 Actuating the auxiliary winch * 5 - 71
5.8.7 Feed system * 5 - 73
5.8.8 Actuating the kelly winch * 5 - 77
5.8.9 Rope length measurement * 5 - 78
5.8.10 Drilling free-fall * 5 - 82
5.8.11 Mooring for assembly and dismantling * 5 - 85
5.8.12 Parallel operation * 5 - 87
5.8.13 Pile locking 5 - 90
5.9 Notes on operation 5 - 91
5.9.1 General 5 - 91
5.10 Drilling operation * 5 - 94
5.10.1 General 5 - 94
5.10.2 Kelly drilling 5 - 97
5.10.3 CFA drilling 5 - 101
5.10.4 Double rotary drilling 5 - 106
5.10.5 Soil Mixing operation 5 - 112
5.11 Vibrator * 5 - 115
5.11.1 General 5 - 115
LRB255_V001 (mf) LWN - TD4/2/2010
5.11.2 Pre-selecting vibrator operation 5 - 116

5.11.3 Setting the vibrator 5 - 117
5.11.4 Operating the vibrator 5 - 119
5.12 Special vibrator * 5 - 124
5.12.1 General 5 - 124
5.13 Hammer * 5 - 125
5.13.1 General 5 - 125
5.13.2 Pre-selecting hammer operation 5 - 126
5.13.3 Setting the hammer 5 - 127
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5.13.4 Operating the hammer 5 - 128

5.13.5 Additional hammer control 5 - 129
5.13.6 Hammer operation with energy measurement 5 - 130
5.13.7 Hammer operation with serial communication 5 - 131
5.13.8 Hammer operation with hoist cylinder 5 - 131
5.14 Casing oscillator * 5 - 132
5.14.1 General 5 - 132
5.14.2 Connect the casing oscillator 5 - 132
5.14.3 Setting the casing oscillator 5 - 133
5.14.4 Switch on the casing oscillator 5 - 135
5.14.5 Operating the casing oscillator 5 - 136
5.14.6 Saver circuit 5 - 137
5.14.7 Switching off the casing oscillator 5 - 137
5.15 Shutting down the machine 5 - 138
5.15.1 Parking position boom 5 - 138
5.15.2 Parking position leader 5 - 139
5.15.3 Switch off diesel engine 5 - 140
5.15.4 Parking position of ignition start switch 5 - 141
5.15.5 Checks when leaving machine 5 - 141
5.16 Catch belt and fall protection runner 5 - 142
5.16.1 Securing the catch belt 5 - 142
5.16.2 Function of the fall protection runner 5 - 143
6. ASSEMBLY AND DISASSEMBLY 6-1

6.1 General 6-1
6.2 Application planning 6-2
6.3 Safety guidelines for assembly and disassembly 6-3
6.3.1 Requirements of the assembly team 6-3
6.3.2 Requirements of the set-up site 6-3
6.3.3 Performance guidelines 6-4
6.4 Assembly of basic machine 6-5
6.4.1 Prerequisites 6-5
6.4.2 Summary of assembly stages 6-5
6.4.3 Prepare basic machine 6-6
6.4.4 Driving the machine down from the flat-bed-trailer 6-8
6.4.5 Removing uppercarriage locking 6-9
6.4.6 Adjusting the crawler track carrier to operating track width 6 - 10
6.4.7 Mounting the rear counterweight 6 - 15
6.5 Assembly of the piling rig and drilling system 6 - 17
6.5.1 Prerequisites 6 - 17
6.5.2 Summary of assembly stages 6 - 17
6.5.3 Assembly stages with piling rig and drilling system laid down 6 - 18
6.5.4 Mounting the piling rig and drilling system 6 - 22
6.6 Assembly stages with mounted piling rig and drilling system 6 - 33
6.6.1 Mounting/dismantling the foot plate 6 - 33
0 - 10
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6.6.2 Mounting/dismantling the piling rig or drilling device 6 - 33

6.6.3 Mounting/dismantling the torque stay rods * 6 - 36
6.7 Dismantling the piling rig and drilling device 6 - 38
6.7.2 Summary of disassembly stages 6 - 38
6.7.3 Disassembling the counterweight 6 - 39
6.7.4 Setting down the piling rig and drilling device 6 - 40
6.7.5 Disassembly stages with piling rig and drilling device set down 6 - 51
6.8 Dismantling the basic machine 6 - 52
6.8.2 Summary of disassembly stages 6 - 52
6.8.3 Adjusting the crawler track carrier to transport width 6 - 52
6.8.4 Driving the machine onto the flat-bed trailer 6 - 52
6.8.5 Mounting uppercarriage locking 6 - 53
6.8.6 Shut down the basic machine 6 - 54
6.8.7 Transport position of the LRB 255 on the flat-bed trailer 6 - 55
6.9 Initial assembly of the piling rig and drilling device 6 - 56
6.9.1 Mounting the piling rig and drilling device 6 - 56
6.9.2 Dismantling the piling rig and drilling device 6 - 57
6.9.3 Pin retraction device basic arm 6 - 58
6.9.4 Extracting pins 6 - 59
6.9.5 Inserting pins 6 - 60
6.10 Transport 6 - 61
6.10.1 Safety guidelines for loading and unloading 6 - 61
6.10.2 Transporting basic machine with flat-bed trailer 6 - 62
6.10.3 Transporting the attachment 6 - 64
6.10.4 Loading basic machine with auxiliary crane 6 - 65
6.10.5 Transporting overseas 6 - 67
7. MAINTENANCE 7-1
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
LRB255_V001 (mf) LWN - TD4/2/2010
7.3 Diesel engine 7 - 17

7.3.1 Engine; Check oil level and oil pressure 7 - 17
7.4 Fuel system (MAN engine) 7 - 18
7.4.1 Check the water separator on the fuel prefilter, drain off the condensate if necessary 7 - 19
7.4.2 Draining condensate from the fuel filter 7 - 21
7.4.3 Draining condensate from the fuel tank 7 - 23
7.4.4 Cleaning the fuel prefilter 7 - 25
7.4.5 Replacing the fuel filter 7 - 27
7.4.6 Bleeding the fuel system 7 - 29
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INDEX
7.5 Cooling system 7 - 31

7.5.1 Coolant, check filling level and fill as required 7 - 31
7.6 The dry-air filter 7 - 32
7.6.1 Arrangement of the central assembly 7 - 32
7.6.2 Emptying the dust collection container 7 - 32
7.7 Splitterbox 7 - 33
7.7.1 Checking gear oil level 7 - 33
7.7.2 Gear oil cooler 7 - 33
7.8 Travel gear 7 - 34
7.8.1 Cleaning the travel gear 7 - 34
7.8.2 Check chain tension, tighten as required 7 - 34
7.8.3 Releasing tension in the chain 7 - 35
7.8.4 Track pads 7 - 35
7.8.5 Track adjustment of the crawler track carrier 7 - 35
7.9 Swing gear / Rotary connection 7 - 36
7.9.1 Swing gear, Check oil level 7 - 36
7.9.2 Lubricating the spur gear / pinion 7 - 36
7.9.3 Lubricating the rotary connection, ball tracks 7 - 36
7.10 Winches 7 - 37
7.10.1 Winches 1 and 2 and main boom adjusting winch; Check oil level 7 - 37
7.10.2 Main boom adjusting winch; Lubricate 7 - 37
7.10.3 Main boom adjusting winch and A-frame; 7 - 37
7.11 Auxiliary winch * 7 - 38
7.11.1 Check oil level 7 - 38
7.12 Feed winch * 7 - 38
7.13 Kelly winch * 7 - 39
7.14 Ropes and pulleys 7 - 40
7.14.1 Checking the rope against end of service life criteria 7 - 40
7.14.2 Check the rope for diameter shrinkage 7 - 41
7.14.3 Check for rope deformations 7 - 42
7.14.4 Check ropes for corrosion 7 - 43
7.14.5 Check ropes for abrasion 7 - 44
7.14.6 Check ropes for the effects of heat 7 - 44
7.14.7 Check the rope for number of permitted wire breaks 7 - 46
7.14.8 Selecting a rope 7 - 47
7.14.9 Storing ropes 7 - 51
7.14.10 Transporting ropes 7 - 52
7.14.11 Checking the rope drive 7 - 52
7.14.12 Winding ropes 7 - 56
7.14.13 Luffing ropes 7 - 58
7.14.14 Lubricating ropes 7 - 60
7.14.15 Check rope suspensions and fastenings 7 - 60
7.14.16 Checking the pocket locks 7 - 61
0 - 12
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7.14.17 Check the rope fixation and rope thimble 7 - 62

7.15 Load hooks 7 - 64
7.15.1 Load hooks with one or more pulleys 7 - 64
7.15.2 Individual hooks 7 - 64
7.16 Maintenance boom 7 - 65
7.16.1 Boom pivot piece 7 - 65
7.16.2 Boom intermediate pieces 7 - 65
7.16.3 Main boom head 7 - 65
7.16.4 Inspection of boom threaded unions and retaining rope connections 7 - 66
7.16.5 Overtopping guard struts on the pivot piece 7 - 67
7.17 Maintenance of the hydraulic system 7 - 68
7.17.1 General 7 - 68
7.17.3 Topping up hydraulic oil 7 - 69
7.17.4 Suction pipe on the hydraulic tank 7 - 70
7.17.5 Shut off valve on the hydraulic tank 7 - 70
7.17.6 Clean the magnet plug 7 - 71
7.17.7 Check the hydraulic system 7 - 72
7.17.8 Special maintenance activities 7 - 72
7.18 Electrical system 7 - 73
7.18.1 General 7 - 73
7.18.2 Wet cleaning 7 - 73
7.18.3 Batteries 7 - 73
7.18.4 Boom limit switch 7 - 75
7.18.5 Hoist limit switches 7 - 75
7.18.6 Slip ring unit * 7 - 75
7.19 Personal protective equipment 7 - 76
7.20 Maintenance piling rig and drilling device 7 - 77
7.20.1 Limit switch feed 7 - 78
7.20.2 Lower limit switch leader height adjustment 7 - 78
7.20.3 Maximum outreach limit switch 7 - 78
7.21 Lubricant requirements 7 - 79
7.21.1 Rapidly biodegradable hydraulic oils 7 - 80
7.22 Hydraulic oil (initial filling) 7 - 81
7.23 Diesel fuels 7 - 82
7.24 Diesel engine lubricating oils 7 - 83
LRB255_V001 (mf) LWN - TD4/2/2010
7.25 Coolant 7 - 85
7.25.1 Fresh water guidelines: 7 - 85
7.26 Filling amounts 7 - 86
7.27 Lubrication chart 7 - 87
7.28 Repair welding 7 - 91
7.28.1 General 7 - 91
7.28.2 Requirements for welding 7 - 91
8. REPAIR WORK 8-1
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INDEX
8.1 General 8-1

8.2 Changing ropes 8-2
8.2.1 Safety instructions 8-2
8.2.2 Unwinding wire ropes from the reel 8-2
8.2.3 Laying ropes 8-3
8.3 Changing cable winches 1 + 2 8-4
8.3.1 General 8-4
8.3.2 Procedure 8-4
8.4 Replacing the feed rope 8-5
8.4.1 General 8-5
8.4.2 Procedure 8-7
8.5 Changing auxiliary ropes 8-9
8.5.1 General 8-9
8.5.2 Procedure 8-9
8.6 Changing kelly ropes 8 - 10
8.6.1 General 8 - 10
8.6.2 Procedure 8 - 10
8.7 Diesel engine 8 - 11
8.8 Fire extinguishers 8 - 14
8.9 Personal protective equipment 8 - 14
8.10 Preservation guidelines 8 - 14
8.11 Resale - taking out of service 8 - 14
9. OPTIONS 9-1
9.1 General 9-1
9.2 Heating and air conditioning system 9-2
9.2.1 General 9-2
9.2.2 Air conditioning system units 9-2
9.2.3 Operation 9-3
9.2.4 Information on the use of the heating and air conditioning system 9-4
9.3 3-coil-limit switch 9-6
9.3.1 General 9-6
9.3.2 Adjusting 3-coil-limit switch 9-6
9.4 Cold weather kit 9-7
9.4.1 General 9-7
9.4.2 Auxiliary heating 9-8
9.4.3 Hydraulic oil heating 9-9
9.5 GSM Service Modem 9 - 10
9.6 Function lock 9 - 10
9.7 Refuelling pump 9 - 11
9.7.1 General 9 - 12
9.7.2 Refuelling 9 - 12
9.8 Process data acquisition (PDE) 9 - 14
9.8.1 General 9 - 14
9.8.2 PDE monitor 9 - 16
0 - 14
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INDEX
9.8.3 Compact flash card 9 - 25

9.8.4 Recording and printing 9 - 25
9.8.5 Operating modes 9 - 26
9.8.6 Operation 9 - 31
9.8.7 Data organization 9 - 38
9.8.8 Printer 9 - 39
9.8.9 Protocol style 9 - 40
9.9 Pile/pipe guide 9 - 46
9.9.1 General 9 - 46
9.9.2 Mounting/dismounting pipe guide 9 - 46
9.9.3 Operating the pipe guide 9 - 47
9.10 Counterweight mounting device 9 - 48
9.10.1 General 9 - 48
9.10.2 Mounting/dismounting the counterweight 9 - 48
9.11 Air compressor 9 - 50
9.11.1 General 9 - 50
9.11.2 Start-up 9 - 50
9.11.3 Operating the air compressor 9 - 50
9.12 Cooler for vibrator gearbox oil 9 - 51
9.13 Optional floodlights on the superstructure 9 - 52
9.13.1 Location 9 - 52
9.13.2 Operational controls 9 - 52
9.14 Central lubrication for the kinematics and roller slewing ring 9 - 53
9.14.1 General 9 - 53
9.14.2 Filling the grease container 9 - 54
9.14.3 Function 9 - 54
9.14.4 Programming time intervals 9 - 55
9.14.5 Maintenance of the central lubricating system 9 - 55
9.15 Central lubrication for the lead slide 9 - 56
9.15.1 General 9 - 56
9.15.2 Filling the grease container 9 - 57
9.15.3 Function 9 - 57
9.15.4 Maintenance of the central lubricating system 9 - 57
9.16 Additional ballast 1.4 t 9 - 58
9.17 Additional ballast 7.3 t 9 - 60
9.18 Sheet pile feeder 9 - 61
LRB255_V001 (mf) LWN - TD4/2/2010
9.18.1 General 9 - 61
9.18.2 Operating the sheet pile feeder 9 - 62
9.19 Line pull limitation 9 - 63
9.19.1 General 9 - 63
9.19.2 Line pull limitation winch 2 to 10 t 9 - 63
9.20 Concrete feed line 9 - 64
9.21 Roof railing 9 - 65
9.21.1 General 9 - 65
0 - 15
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9.21.2 Mounting 9 - 66
10. APPENDIX 10 - 1
10.1 General 10 - 1
0 - 16
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INDEX
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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.
1.3 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

LRB255_V001 (mf) LWN - TD4/2/2010
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
LRB255_V001 (mf) LWN - TD4/2/2010
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 Explanation of conformity

The valid explanation of conformity upon delivery of the machine to an EEC country is filed in this
section. Furthermore, documents for a type approval or a national acceptance inspection can be
enclosed.
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1. INTRODUCTION
NOTES:
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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.
LRB255_V001 (mf) LWN - TD4/2/2010
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 Ranges of use for the machine; Leader

This piling rig and drilling machine is suitable for the many various application possibilities in civil
engineering and special foundation tasks.
A multitude of options enable special applications such as:

• Vibrator operation
• Hammer operation
• Drilling operation
- Kelly drilling
- Double rotary drilling (Vor-der-Wand drilling)
- CFA drilling (Continuous flight auger drilling)
• Casing oscillator (in combination with kelly drilling)
2.2.1 Machine classification; Leader

The machine has been designed as a piling and drilling rig and dimensioned accordingly.
The steel structure was calculated in accordance with DIN 15018, part 1.
Machine classification is resulted in accordance with DIN 15018, part 1 in dependence of application
types for:
- Piling operation (Vibrator or Hammer),
- Drilling operation.
Depending on the application the machine complies with the following norms:
- EN 996 Piling equipment - Saftey Requirements
- EN DIN 791 Drilling rigs
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2.3 Machine summary; Leader

LRB255_V001 (mf) LWN - TD4/2/2010
Main components LRB 255 Fig. 2-01
1 Piling rig and drilling system 3 Undercarriage

2 Uppercarriage 4 Counterweight
These main components of the LRB 255 are described in detailed order over the following pages.
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2.4 Piling rig and drilling device
Piling rig and drilling device LRB 255 Fig. 2-02
1 Kelly jib * 10 Swing and inclination device

2 Auxiliary jib * 11 Leader sliding locking carriage
3 Leader 12 Basic arm
4 Universal carriage 13 Supporting arm base
5 Drilling device / piling rig (not included in 14 Supporting arm
delivery scope)
6 Leader height adjustment carriage 15 Supporting arm guide carriage
7 Leader extension 16 Leader guide carriage
8 Torque stay rod * 17 Auxiliary winch
9 Leader foot plate/ Leader foot hydraulic * 18 Feed winch
* Option
not represented: Leader ladder, hose package
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1
2.4.1 Kelly jib *
For Kelly drilling, the Kelly rope (fig. 1, no. 2) is directed
via the Kelly jib (3) to the Kelly rod (1).
The Kelly jib can be folded to the rear during transport.
Rope guides have been provided on the Kelly jib to
guide the Kelly rope.
2.4.2 Auxiliary jib *

The auxiliary rope (fig. 1, no. 4) is guided from the
auxiliary winch (6) over the auxiliary jib (5). The auxiliary
jib is
- hydraulically rotate able,
- can be set to three different positions during operation
(carry out adjustments with piling rig and drilling device
resting on ground),
- can be pushed inwards for transport.
2
2.4.3 Leader ladder
The leader ladder
- allows access to the side of the leader for inspection
and maintenance tasks,
- can be folded into the leader for transport
(fig. 2, no. 1),
- features a safety rail (2) in the centre for fall protection.
Access via the leader ladder is only permitted with catch
belt secured.
Further prerequisites: Diesel engine switched off, leader
positioned vertically and all segments of the leader lad-
der bolted together.
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3
2.4.4 Leader
On the leader supporting arm the leader is guided
through
- the leader sliding locking carriage (fig. 3, no. 2),
- the leader height adjustment carriage (3) and the
- leader guide carriage (4).
The basic length of the leader with head section (5) and
foot piece (1) comprises 21.2 m.
The inclination sensor (6) for the leader is mounted on

the leader sliding locking carriage. The control shows the
values of the inclination sensor (leader inclination) on the
LCD-display screen.
4
Bolting cylinders (upper and lower)
Both bolting cylinders (fig. 4, no. 1) on the leader locking
and leader height adjustment carriage, as well as the
leader height adjusting cylinder allow higher or lower
adjustment (setting) of the leader.
Insertion of the connecting pin is verified via two limit
switches (2) respectively and displayed on the LCD-
display screen. Responsibility for proper pinning how-
ever, lies with the operator, independent of the display !
The connecting pins (5) are inserted in the leader rear
wall (6). A nut (4) has also been provided for securing
the pin.
Before a pin can be extracted, the leader must first be
raised or lowered approx. 25 mm [1''].
The pins are spring-loaded and are extracted via the
bolting cylinders. Only one pin may be extracted at a
time (hydraulic locking).
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5
Piling rig locking
When working on or below the leader or piling rig (lead-
er device), the piling rig must always be locked or set
down on the ground. Two piling rig lockings have been
provided on the right-hand side of the leader at different
heights (the second piling rig locking is optional).
If the leader length has been modified, the piling rig
locking which corresponds to the leader length must be
adjusted.
2.4.5 Leader extension *

The leader can be extended to up to 30.2 m [100'] by mounting up to three leader extensions (3 m
[10'] in length each).
The corresponding leader ladder is also provided with the leader extensions.
When mounting a leader extension,
- the corresponding feed cable is to be mounted,
- the second piling rig locking is to be added.
Leader combinations (fig. 6)

Head section (fig. 3, no.5) and foot piece (1) together have a length of 4.4 m [14.5'].
6
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Leader impact (fig. 7)

The leader head section and the leader foot piece, the optional auxiliary and Kelly jib and the
optional leader extensions are pinned together.
The screws of the leader clamp pieces (fig. 7, no.1) are secured via a slip and screw locking piece
(2) respectively.
The rear slip and screw locking pieces also prevent the pins of the bolting cylinder intervening during
impact.
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8
2.4.6 Feed system *
Due to the feed system, the universal carriage (fig. 8, no.
6) and thus, the piling rig or drilling device is moved up
and down and along the leader. The feed system allows
retraction as well as application of pressure for the de-
sired alignment.
It comprises of
- the feed winch (1),
- the three upper deflection pulleys (2),
- the feed cable (3),
- the universal carriage (4) with tensioning cylinder and
- the two lower deflection pulleys (5),
The length of the feed cable depends on the leader
length (number of leader extensions). The feed cable is
guided to the side via plastic collars.
The feed features high and low speed.
Movement of the universal carriage is limited upwards
and downwards via a limit switch.
The tensioning cylinder tensions the feed cable and
guarantee safe operation.
The feed winch can be fitted with a rope length mea-
surement as an option.
9
2.4.7 Universal carriage
The piling rig or drilling device is mounted to the univer-
sal carriage (fig. 9, no. 1) via the respective adapter.
It features an upper and lower deflection pulley for the
feed cable and is moved up and down along the leader
via the feed system.
The third guide claw (2) is optional.
10
Locking pins (fig. 10)
LRB255_V001 (mf) LWN - TD4/2/2010
The locking pins on the universal carriage

- are retracted or extended via a crank,
- allow quick mounting and dismantling of the respective
adapter.
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11
2.4.8 Vibrator adapter *
The vibrator adapter (fig. 11, no.1)
- is necessary for the mounting of a vibrator,
- is mounted on the universal carriage,
- can be configured to the specifics of the customer,
independent of the vibrator.
For the mounting of a vibrator, a corresponding adapter
(3) is also required (two pieces).
A fixture has been installed with the diaphragm on the
vibrator adapter for the hydraulic connections (2).
12
2.4.9 Hammer adapter *
The hammer adapter (fig. 12, no.1)
- is necessary for the mounting of a hammer,
- features two upper and lower rubber buffers respec-
tively (2),
independent of the hammer.
hammer adapter for the hydraulic connections (3).
13
2.4.10 Drilling gear carriage Kelly drilling *
The drilling gear carriage Kelly drilling (fig. 13, no.2)
- is necessary for the mounting of a drilling drive (1),
independent of the drilling drive.
drilling gear carriage Kelly drilling for the hydraulic con-
nections (3).
The drilling drive is pinned to the drilling gear carriage
Kelly drilling via four pins.
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14
2.4.11 Auxiliary winch *
The auxiliary winch (fig. 14, no. 1)
- serves to pick up the sheet pile,
- is mounted on the leader via guide claws,
- is equipped with a 3-coil-limit switch (2) for the lower
shut-off,
- is combined with a hoist limit switch (3) for the upper
shut-off on the auxiliary jib.
- is provided with an optional rope length measurement
as an option.
The minimal clearance (X= 2385 mm) may not be fallen
short of.
15
2.4.12 Hook fixture point *
The hook fixture point (fig. 15, no. 1)
- serves to secure the auxiliary rope,
- is located on the left-hand side of the foot piece,
- is folded into the leader in the transport position
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16
2.4.13 Swing and inclination device
Lateral inclination device
The lateral inclination device allows compensation of
ground unevenness.
Both lateral positioning carriages are adjusted respec-
tively via a dual working cylinder.
17
Leader rotational device
The leader can be rotated 90° to the left and right
respectively.
The leader rotary cylinders (fig. 17, nos. 1 and 2) must
thus be switched over.
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18
2.4.14 Supporting arm
The supporting arm (fig. 18, no. 4) is guided over the
supporting arm guide carriage (2) from the supporting
arm base (3). Movement of the supporting arm guide
carriage is limited at the top via the supporting arm
guide carriage (1). This locking is folded up when setting
down the piling rig and drilling device in the transport
position.
Redirection of the hoses for the hose package is moun-
ted on the upper part of the supporting arm.
The supporting arm is connected to the basic arm at the
lower end.
For drilling operation, the optional torque stay rods be-
tween leader and supporting arm must be mounted.
2.4.15 Supporting arm base

The supporting arm base (fig. 18, no. 3)
- is telescopic,
- is pivoted on the uppercarriage,
- can be optionally fitted with a pin retraction device for
quick assembly/disassembly.
- allows inclination of the leader to the front and rear.
19
2.4.16 Rope guide Kelly rope *
For Kelly drilling the optional rope guides must be moun-
ted
- on the lateral inclination device (fig. 19, no. 1),
- on the leader guide carriage (2),
- on the supporting arm base (3,4).
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20
2.4.17 Basic arm
The basic arm (fig. 20, no. 3)
- is pivoted on the uppercarriage,
- is adjusted via two basic arm adjusting cylinders (2),
- is connected with the supporting arm and
- supports a part of the leader hydraulics,
- supports the cooler for the vibrator gear oil *.
2.4.18 Kelly winch *

The Kelly winch (fig. 20, no. 1)
- is mounted in the uppercarriage,
- is used as a Kelly winch, as hammer winch or for
vibrator operation,
- is fitted with a 3-coil-limit switch for the lower shut-off,
- is combined with a hoist limit switch for the upper
shut-off on the Kelly jib.
- can be provided with a rope length measurement as an
option,
- is designed as a free-fall winch or optionally as a crane
winch.
21
2.4.19 Torque stay rods *
Two torque stay rods are prescribed for drilling opera-
tion.
Lower torque stay rod
The torque stay rod is mounted between the leader and
supporting arm.
22
Upper torque stay rod
The upper torque stay rod is comprised of two butt
straps (fig. 22, no.1), which are pinned between the
leader guide carriage and the supporting arm.
An adjustable torque stay rod (+/- 25°) is also avail-

able as an option (see chapter 1 under "Machine pass"
or chapter 9 "Options").
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23
2.4.20 Leader foot plate *
The leader foot plate allows setting down of the leader
on the ground for pulling the piling rig element.
24
2.4.21 Hydraulic leader foot *
A cylinder (fig. 24, no. 1) can be installed in the leader
foot piece as an option. The leader foot plate can thus
be hydraulically extended.
2.4.22 Hose package

The hose package establishes connection of the hydraulic system in the uppercarriage to the piling
rig and drilling system. Furthermore, the piling device or the drilling drives are also supplied.
The hose package is guided from the bulkhead plate on the front right-hand side of the uppercar-
riage via the hose guide on the side of the supporting arm, to the piling rig or drilling device. Strain
relief of the hoses is resulted via chains secured to the fixtures on the leader.
In the transport position, the hose package is positioned in the hose mounting on the right-hand side
of the uppercarriage (or at the front) and the rods by the basic arm.
2.4.23 LRB-quick assembly system

A quick assembly and disassembly of the piling rig and drilling device is possible due to the pin
extraction device on the basic arm and the quick-release couplings on the hydraulic lines.
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2.5 Uppercarriage
25
Uppercarriage from the front left , LRB 255
1 Operator's cab 7 Winch 1 *

2 Central power unit 8 Pivot points piling rig and drilling device or
A-frame *
3 Platform 9 Kelly winch (Winch 2) *
4 Leader support / Pivot point A-frame * 10 Hose support
5 Main boom adjusting winch / auxiliary 11 Pivot points basic arm or main boom foot *
winch *
6 Hose supports 12 Platforms
The uppercarriage of the LRB 255 is

- a torsion-free welded construction,
- mounted on the undercarriage via a rotary connection.
Die Operator's cab (1)
- includes all required control and operating elements,
- is equipped with reinforced glazing.
The central power unit (2)
- is comprised of the diesel engine, the splitterbox and the hydraulic aggregate with the cor-
responding pump components,
- supplies all drives of the machine via the hydraulic cable system.
The splitterbox is flanged on the diesel engine via a coupling and drives the majority of the hydraulic
pumps.
The platform (3)
- serves for inspection, maintenance and assembly purposes
- gets folded up.
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The piling rig and drilling device

- is mounted to the basic arm pivot points (11) and the pivot points (8) on the uppercarriage,
- is mounted on the leader supports (4) in the transport position,
- is electrically and hydraulically supplied via the connections on the bulkhead plate.
In boom operation on these points the A-frame (with the help of a bracket) or the main boom foot is
mounted.
The design of the Kelly winch (9) and winch 1 (7) is determined more precisely in the "Machine
pass".
In the transport position of the piling rig and drilling device, the hose package is in the hose supports
(15) on the right-hand side of the uppercarriage or on the hose support (6) on the front right-hand
side of the uppercarriage. Thus, rotation of the uppercarriage is not hindered by the hose package.
The main boom adjusting winch / auxiliary winch (5) is used
- in boom operation for adjusting the main boom,
- with mounted piling rig and drilling device as auxiliary winch,
- for mounting the counterweight.
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26
Uppercarriage from the back right , LRB 255
1 Hydraulic oil coolers 6 Shut off valve hydraulic tank

2 Fuel tank 7 Swing gear
3 Platform 8 Hydraulic cooler
4 Access ladder 9 Bulkhead plate
5 Hydraulic tank 10 Plugs
The hydraulic oil coolers (1) and (8)

- cool the hydraulic oil.
The swing gear (7) is standard equipment and swings the uppercarriage around 360°.
A second swing gear can be optionally mounted on the left-hand side of the uppercarriage.
The platform (3)

- serves for inspection, maintenance and assembly purposes
- is folded up for transport.
The access ladder (4)
- allows access to the uppercarriage for inspection, maintenance and assembly purposes,
- is dismounted for transport.
The hydraulic tank (5)
- is protected against possible contamination via a return filter and breather filter,
- features inspection glasses and an electrical filling level sensor for filling level inspection.
The fuel tank (2)
- supplies the diesel engine and the optional standstill heating with fuel,
- is fitted with a refuelling pump and a level monitor.
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2.5.1 Central power unit
27
Central power unit from the front left, LRB 255
1 Pump components 7 Diesel engine

2 Splitter box 8 Intercooler
3 Mounting position gear oil cooler 9 Exhaust
4 Dipstick splitter box 10 Compensator reservoir cooling system
5 Water seperator 11 Water cooler
6 Dry air filters
The water cooler (11)

- cools the cooling water of the diesel engine,
The hydraulically driven cooler motor is temperature regulated.
The intercooler (8)
- cools the charge air of the suction system and both exhaust turbochargers.
The hydraulically driven cooler motor is temperature regulated.
The compensator reservoir of the cooling system (11) features
LRB255_V001 (mf) LWN - TD4/2/2010
- an excess pressure valve for bleeding,

- a filling cap for filling coolant.
The gear oil cooler (3) serves cooling of the oil for the splitterbox.
The dry air filters (12) supply the diesel engine with filtered fresh air.
The exhaust (9) is comprised of stainless steel.
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2.5.2 Diesel engine
28
Diesel engine
1 Oil filler cap engine oil 6 Generator

2 Lubricating oil filters 7 Compressor, Air-condition *
3 Oil dip stick diesel engine 8 Starter
4 Fuel filters 9 Exhaust turbo charger
5 Power take offs 10 Oil separators
The engine oil can be filled into the diesel engine via oil filler caps (1). The oil level can be checked
via the oil dipstick (3).
The engine oil is filtered and cleaned via the lube oil filter (2).
Both fuel filters (4) clean the diesel fuel.
Two oil separators (10) aerate the engine housing and clean the exhaust air of oil residue.
The diesel engine is fitted with an electronic engine module, all necessary engine data of which is
transmitted by the Litronic-control, as well as controlling the diesel engine.
This CAN-Bus engine module
- contains the entire engine control,
- is connected with a transfer plug to the CAN-Bus of the Litronic-control.
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2.5.3 Pump components
29
upper row lower row
Pump components, LRB 255
1 Gear-type pump 8 Axial piston variable displacement double

pump
2 Gear-type pump 9 Splitterbox
3 Axial piston variable displacement pump 10 Axial piston variable displacement pump
4 Axial piston variable displacement pump 11 Axial piston pump
5 Gear-type pump 12 Axial piston variable displacement pump
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2.6 Undercarriage
30
Undercarriage from the front left
1 Track pad 10 Travel drive right-hand crawler track

2 Step (2 x) 11 Rotary transmission
3 Track adjustment cylinder (2 x) 12 Uppercarriage locking
4 Travel drive left-hand crawler track 13 Roller
5 Left crawler track carrier 14 Idler
6 Tumbler 15 Hydraulic connections, plug *
7 Centre section 16 Guide rails *
8 Operating lever track adjustment 17 Adapter casing oscillator *
9 Right crawler track carrier
* used with the optional casing oscillator
The undercarriage centre section (7)

- is designed as a torsion-free welded construction,
- supports the rotating uppercarriage and both crawler track carriers.
The rotary transmission (11) establishes the hydraulic and electrical (optional) connection from the
uppercarriage to the undercarriage.
The undercarriage has been prepared for operation with the casing oscillator *. Therefore the adapter
(17) and the guide rails (16) are mounted on the front side of the centre section. The required
hydraulic connections (15) and the auxiliary hydraulics are available as an option.
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Both crawler track carriers (5) and (9)

- can be adjusted between transport and operating track via the track adjustment cylinder (3).
The transport track (narrow track) has been provided exclusively for transport of the machine.
The left crawler track is shown in transport track, the right crawler track in working track.
The operating lever (8) serves actuation of the track adjustment cylinder.
The steps (2) allow access to the uppercarriage and the operator's cab. For transport they can be
folded up.
The maintenance-reduced and contamination-protected drive system of the crawler track carrier is
comprised of:
- Idler (14),
- Rollers (13),
- Travel drive (4 and 10) with axial piston motor, planetary gears and multi-disc holding brake,
- a pre-tensioned crawler track as well as track pads (1).
The uppercarriage locking (12) should be installed for transport, extended breaks in operation and for
maintenance and repair tasks. It prevents an undesired turning of the uppercarriage.
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2.7 Counterweight
2.7.1 Rear counterweight
The rear counterweight is prerequisite for stability of the machine.
31
Rear counterweight, LRB 255
1 Tensioning bolts (2x) 3 Butt straps

2 Eye bolts (2x) 4 Rope pulleys (2 x)
The rear counterweight

- comprises essentially of a counterweight weighing 12.3 t,
- is suspended from both eye bolts,
Assembly is resulted via the auxiliary crane or optional counterweight assembly device.
The rear counterweight is pinned to the uppercarriage via two butt straps (3) and leashed via two
tensioning bolts (1).
32
2.7.2 Additional ballast *
If required, an additional 1.4 ton ballast plate can be
bolted onto the bottom of the rear counterweight.
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2.8 Summary of the hydraulic cylinders
Hydraulic cylinders LRB 255 Figure 2-03
1 Auxiliary jib-adjusting cylinder (Z17) 7 Track adjustment cylinder

2 Tensioning cylinder 8 Lower leader rotary cylinder (Z3)
3 Upper pinning cylinder (Z11) 9 Basic arm-adjusting cylinder (Z4)
4 Lower pinning cylinder (Z12) 10 Support arm brace-support cylinder (Z2)
LRB255_V001 (mf) LWN - TD4/2/2010
5 Leader height adjusting cylinder (Z5) 11 Leader lateral inclination cylinder (Z6)
6 Leader foot cylinder ** 12 Upper leader rotary cylinder (Z3)
** Option, not represented
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2.9 Technical data

Transport complete
33
Leader length in m [ft] Overall weight in t [lbs]

21.2 [70'] 77.8 [171500 lbs]
24.2 [80'] 78.9 [173900 lbs]
27.2 [90'] 80.0 [176400 lbs]
30.2 [100'] 81.2 [179000 lbs]
Transport weight piling rig and drilling device (fully fuelled and ready for operation)
- with piling rig and drilling equipment,
- counterweight 12.3 t [27100 lbs],
- without piling rig and drilling equipment (e.g.: drilling drive, torque stay rod, etc.)
- without special equipment (options).
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Transport in sections
34
Leader length in m Weight of piling rig and

[ft] drilling device in t [lbs]
21.2 [70'] 26.7 [58900]
24.2 [80'] 27.8 [61300]
27.2 [90'] 28.9 [63700]
30.2 [100'] 30.1 [66400]
Transport weight piling rig and drilling device

- without piling rig or drilling equipment (e.g.: drilling drive, torque stay rod, etc.)
- without special equipment (options).
35
Basic machine Counterweight in t [lbs]

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LRB 255 in t [lbs]

38.5 [84900] 12.3 [27100 lbs]
Transport weight piling rig and drilling equipment (fully fuelled and ready for operation),
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LRB 255 in application
36
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2.9.1 Nominal data

Machine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LRB 255 M
Leader type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4460
Leader design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Box-type leader
Leader length variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 / 24.2 / 27.2 / 30.2 m

[70 / 80 / 90 / 100 ft]
Max. stepless leader inclination to the front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:6 (9,5°)
Max. stepless leader inclination to the rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:3 (19° )
Lateral leader inclination to the right / left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:20 (3°)
Max. payload on auxiliary jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 t [170600 lbs]
Max. payload second piling rig including cover and pile . . . . . . . . . . . . . . . . . . . . . . . . 30 t [66100 lbs]
Max. hammer weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 t [33100 lbs]
Max. pile weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 t [33100 lbs]
Max. pull force supported . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 t [88200 lbs]
Slewing range of leader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 x 45°

by changing to rotary cylinder, 90° to the left
90° to the right
Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3 t [27100 lbs]
Reach (middle of slewing axis - front edge of leader) . . . . . . . . . . . . . . . . . 4,0 m - 5,7 m [13.1 - 18.7']
Leader height adjustment (depending on leader length) . . . . . . . above ground level approx. 3 m [10'],
below ground level approx. 5 m [16']
max. torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 kNm
Permissible gradient angle (travelling on a slope) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10°
Permissible gradient angle (travelling across a slope) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3°

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Permissible max. windspeed when operating the machine . . . . . . . . 20 m/s [44.7 mph] (wind force 8)
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Operating weight and load bearing capacity

These details are valid for the following equipment of the LRB 255:
• Piling rig and drilling device with 21.2 m [70'] leader,
• Counterweight 12.3 t [27100 lbs]
• without piling rig or drilling device
Weights could deviate depending on the design of the machine.
Triple grouser pads Operating weight in t [lbs]

in mm [in]
800 [32''] 78.0 [172000 lbs]
900 [35''] 78.5 [173100 lbs]
2.9.2 Application requirements

Ambient temperatures
- for operation at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 20 °C [-4°F] to + 40 °C [104°F]
- with optional cold-weather kit down to . . . . . . . . . . . . . . . . . . . . . . - 25 °C [-13°F] or 40 °C [-40°F]
- for storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 40 °C [-40°F] to + 40 °C [104°F]
Application heights
The exhaust turbocharger of the diesel engine reduces influence of the drop in air pressure in the
engine output considerably.
A drop in output of the diesel engine should nevertheless be expected if the machine is operated in
high altitudes and in high ambient temperatures.
2.9.3 Emissions
Emission limit values of the engine exhaust . . . . . . . . . . . . . . in accordance with 88/77/EWG, EURO 0
Sound pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 dB(A)
Sound pressure in the operator's cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 dB(A)
2.9.4 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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2.9.5 Engine aggregates

Diesel engine with
- Exhaust turbocharging,
- Intercooling,
- Electronic engine speed sensing,
- Automatic power limit control of all main functions
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D 2842 LE
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAN
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1440 kg [2756 lbs]
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder in 90°-V-arrangement
Combustion process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-stroke cycle, electronic diesel injection
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Nominal output . . . . . . . . . . . . . . . . . . . . . . . . . 670 kW [898 HP] in accordance with ISO/DIN 3046 IFN
Nominal speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1900 rpm
Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 rpm
Maximum torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 Nm at 1300-1700 rpm
Fuel consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210-230 g/kWh at 2100 rpm
Engine oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 0.5% of fuel consumption
Electrical system
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V, 9 kW
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 V, 70/140 A
Fuels
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . commercially approved vehicle diesel fuel
Tank content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 l [211.3 gal]
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . authorised engine oil in accordance with the lubricant chart
Filling amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.5 l [11 gal]
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water with admixture of anticorrosive and anti-freeze
Filling amount (entire cooler system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 70 l [18.5 gal]
Detailed information concerning these fuels can be found in chapter 7, maintenance.
2.9.6 Hydraulic system

The hydraulic aggregate
- is powered by the diesel engine via a splitterbox,
- is comprised of an axial piston variable displacement double pump, 5 axial piston variable
displacement pumps, 3 axial piston pumps and 7 gear-type pumps,
- operates with open and closed hydraulic circuits,
- is fitted with an energy-saving and pump preserving variable power control.
The hydraulic system
- limits pressure peaks resulted from pressure cut-off,
- cleans electronically monitored filters of the hydraulic oil.
The LUDV-block (2-piece)
LRB255_V001 (mf) LWN - TD4/2/2010
- is the central distributor block in the hydraulic system,

- allows a through-flow distribution independent of the load.
The hydraulic system must be specially adapted for the connection of hydraulically powered options
(casing oscillator, etc.).
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . authorised hydraulic oil (see chapter 7, Maintenance)
Filling amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 l [264 gal]
Operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 350 bar [5076 psi]
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2.9.7 Winches
Feed winch
The feed winch is mounted on the head piece of the leader. It serves movement of the universal
carriage along the leader.
The following auxiliary equipment has been provided:
- Upper and lower limit switches
- Rope length measuring
The feed winch is fitted with
- an interior planetary gear,
- axial piston motors for the drive
- hydraulic, spring-loaded multi-disc brakes (holding brakes).
Line pull (nominal load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 kN [33100 lbs]
Crowd force (retracting/applying pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 kN [99200 lbs]
Rope diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 mm
Cable drum diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480 mm [19'']
Rope speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 87 m/min [285 ft/min.]
Auxiliary winch
The auxiliary winch is mounted on the head piece of the leader. It serves picking up of the sheet
pile, assembly of baskets, etc.
- Hoist limit switch on the leader head
- 3-coil-limit switch
The auxiliary winch is fitted with
- an interior planetary gear,
- axial piston motor (constant motor) for the drive
- hydraulic, spring-loaded multi-disc brakes (holding brakes).
Line pull (nominal load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 kN [17600 lbs]
Rope diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 mm
Cable drum diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 mm [13'']
Rope speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 60 m/min [200 ft/min.]
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Kelly winch
The optional Kelly winch is mounted on the uppercarriage. It can be used during drilling, vibrator or
hammer operation.
- Hoist limit switch on the Kelly jib
- 3-coil-limit switch

Rope speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 90 m/min. [295 ft/min.]
Rope diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 mm
Rope speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 70 m/min. [233 ft/min.]
Rope diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 mm
The Kelly winch is distinct due to its

- compact, reduced-maintenance design,
- load support via the hydraulic system,
- spring-loaded multi-disc brakes (holding brakes).
The drive of the Kelly winch
- is resulted via high-pressure regulated axial piston displacement motors,
- takes advantage of full engine output in partial load operation via speed adaptation to the
respective line pull,
With the free-fall device a large dimensioned multi-disc brake takes over the clutch function as well
as the braking function. This wet, interior multi-disc brake has been designed around reduced wear
and is maintenance-free.
The Kelly winch can be used optionally as a drilling free-fall. For automatic following of the Kelly
rope, a constant pull valve (handwheel) has been installed in the operator's cab.
For the application of the Kelly winch, guide pulleys must be mounted on the inclination device
(lateral adjustment) and the Kelly jib must be mounted.
2.9.8 Swing gear

The swing gear is comprised of a roller bearing slewing ring with interior toothing and a swing gear.
The swing gear is comprised of
- axial piston motor,
- planetary gear,
- hydraulic, spring-loaded multi-disc brake,
- swing gear pinion.
In swing gear free-swing the braking torque is controlled hydraulically.
Rotational speed of the uppercarriage
(3 speed ranges can be steplessly regulated) . . . . . . . . . . . . . . . . . . . approx. 0 - 1 / 0 - 2 / 0 - 4,5 rpm
LRB255_V001 (mf) LWN - TD4/2/2010
2.9.9 Travel gear

Both crawler track carriers of the travel gear operate independently of each other and can be
actuated oppositely.
Preferred travel and operating positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idler to the front
Travel speed (can be steplessly regulated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 1.5 km/h [0.9 mph]
Overall machine line pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630 kN [139000 lbs]
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2.9.10 Control
The Litronic control of the LRB 255
- is an electro-hydraulic proportional control,
- allows simultaneous carrying out of all main movements,
- has been designed for extreme temperatures and the toughest building site applications,
- is undergoing further development by Liebherr-Werk Nenzing GmbH and is manufactured solely
by them.
The electronic control is
- arranged in the operator's cab,
- connected via a CAN-Bus system with the engine control as well as with all sensors, triggers and
limit switches on the machine.
The LCD-display screen in the operator's cab displays
- all necessary information for the respective operation type,
- all error reports in clear text.
Operating elements in the operator's cab:

• Two joysticks for control of all main functions.
• Keys
- for pre-selection for the electronic control,
- for switching and regulation of heating, windshield wipers, etc.
- for service purposes.
- for operation of the piling rig and drilling system and of the auxiliary equipment.
• two foot pedals for travel drive control (can be adapted with two levers for hand lever control).
• a brake pedal for free-fall control in connection with the Kelly winch (optional).
• a handwheel for control of the drilling free-fall of the Kelly winch (optional)
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.
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2.9.11 Load chart for piling rig and drilling equipment

Lead resting on the ground
The driver can use full tensile force, irrespective of the outreach of the lead.
Lead not resting on the ground

Apply the permitted load capacities as shown in the load capacity table, depending on the outreach
of the lead.
WARNING !
If the maximum loads are exceeded, the machine could become damaged. There is a danger
of tipping!
The specified loads may not be exceeded as no moment shut-down is resulted!
Load chart for piling rigs in accordance with EN996:
Load chart for drilling device in accordance with EN791:
See volume "Load chart book".

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2.10 Equipment - Summary

Should any queries arise concerning the equipment, please contact the manufacturer. The equipment
is not included in the delivery scope as standard.
Double rotary drilling CFA drilling
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Kelly-drilling, casing oscillator

(The dimensions L, L1, R and Ø are dependent on the type of Kelly rod or casing oscillator.)
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Vibrator Hammer
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Push&Pull equipment
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Boom equipment
Hook / Slurry wall grab / Casing oscillator
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NOTES:
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3. SAFETY PRECAUTIONS
3.1 General
Your safety - as machine operator or maintenance technician - is of the utmost priority. Many
situations, problems or malfunctions occurring on the machine can pose a serious risk to safety if
you are not fully familiar with the actions to be taken to prevent and avert possible dangers.
This chapter
- establishes what is meant by appropriate use of the machine,
- contains generally applicable information on safety and safety precautions,
- explains the meaning of the symbols and pictograms used in this operating manual and in the
signs on the machine,
- gives information about the necessary protective equipment and which requirements apply to
operating and maintenance personnel,
- shows the location of the safety and monitoring devices on the machine,
- gives information concerning dangers and other risks which can also occur even when the
machine is being operated properly.
Special handling and situation-specific notes on safety are specified where relevant in the following
chapters of this operating manual and in further sections of the documentation included on delivery.
State-of-the-art technology
At the time of delivery, this machine represents state-of-the-art technology.
The applicable standards are cited
- for the design, in the Declaration of Conformity, (does not apply to the US market)
- for calculating the load capacities, on the cover of the load capacity chart.
Nevertheless, the machine can pose dangers if the Safety precautions in this operating manual are
not observed and implemented.
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3.1.1 Use as directed; Leader

The equipment included in delivery
- determines the utilisation possibilities,
- is precisely documented under point 1.3 "Machine pass".
The machine may only fundamentally be used for applications which are specified and described in
this operating manual. Special options for use as directed have been defined and determined in
chapter 9.
The machine should be used as directed
- when complying with the valid national safety regulations,
- when observing all notes on safety in this operating manual,
- if all necessary safety devices are available and functioning,
- if the determined limit values described in chapter 2 under point "Technical data" are not
exceeded.
All ramming and drilling devices (vibrators, hammers etc.) are permitted providing they have been
supplied or approved by LIEBHERR (written authorisation required in latter case).
Attaching other equipment is not classified as intended use.
For use as directed, all inspection and maintenance tasks are to be carried out punctually and
completely by authorised personnel.
Procedure:
- The piling rig element is operated into the ground vertically or inclined.
- The piling rig element is extracted out of the ground vertically or inclined.
- Drilling is carried out with the leader at different reaches.
Special operation
- is to be discussed first with the manufacturer,
- may only be carried out with written consent of the manufacturer.
Any other or excessive use of the machine without written approval from the manufacturer is
considered not use as directed.
The user is solely responsible for any occurring damage.
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3.1.2 Examples of use not as directed; Leader

Use of the machine not as directed can
- cause fatal injuries,
- lead to serious damage to the machine, as well as subsequent damage to property,
- almost certainly invalidate warranty claims.
Examples of use of the machine not as directed:

• Every constructional modification of the machine influencing operating safety and carried out
without written consent of the manufacturer.
• Start-up of the machine
- without a legally prescribed, national acceptance test,
- by personnel not authorised by the user,
- without the required training, experience and familiarity with the operating manual,
- should the operating manual be incomplete or has not been published in the respective language
of the user,
- if the machine operator does not understand the operating manual due to insufficient knowledge
of the language.
• Every working principle, which endangers operating safety.

• Operating the machine with
- faulty safety devices
- safety and protective equipment which is faulty or has not been mounted correctly
• Applications during assembly operation.
• Operation when the maximum permissible wind speeds have been exceeded.
• Operation when personnel remain on the machine, other than in the operator's cab.
• Transport of personnel using the hoisting winch.
• Lifting operation, application as an auxiliary crane.
• Lifting loads with the cylinder of the piling rig and drilling system.
Exception: with the counterweight mounting device.
• Earthmoving operation (levelling, etc.).
• Breaking loose snagged loads with the winches or with the swing gear.
• Scraping a load across the ground with swing gear or crawler.
• Mounting of spare parts and use of fuels not approved and authorised by the manufacturer.
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3.1.3 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.
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.
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3.1.4 Areas of responsibility

The manufacturer
- is responsible for the technically safe condition of the machine supplied, together with acces-
sories and documentation,
- is aware of his duty to monitor product performance and documents all maintenance and repair
work carried out by Liebherr personnel,
- ensures that the machine is kept operational by a global service and repair service,
- runs a training centre and provides training for the owner's operating and maintenance personnel
as a service.
The operator or a person authorized by him

- ensures that only adequately trained and qualified personnel who have read and understood the
operating manual, in particular Chapter 3 "Safety Precautions", operate and service the machine,
- delegates the duties and assigns clear responsibilities to specific machine operating and
maintenance personnel,
- places the necessary protective equipment and gear at the disposal of operating and main-
tenance personnel,
- regularly checks that personnel are aware of safety considerations when working,
- is responsible for the safe condition of the machine,
- shuts down the machine as soon as there is a safety risk involved in its operation,
- performs inspections on the machine based on national regulations in addition to the inspections
stipulated by Liebherr,
- checks that stipulated and necessary inspections are carried out properly,
- ensures that the machine is serviced and maintained at the prescribed intervals,
- reports to the manufacturer every accident on the machine leading to serious injury or substantial
property damage,
- grants Liebherr personnel unimpeded access to the machine in connection with their duty to
monitor product performance,
- carefully and conscientiously implements operational planning for the machine.
The machine operator

- must wear the necessary protective gear for his personal safety,
- makes a visual inspection of the machine for obvious defects every day before starting work,
- before starting up the diesel engine, makes sure that all the controls in the cab are set to zero or
neutral,
- checks during daily commissioning that the various holding brakes, emergency stop and emer-
gency shutdown devices are working properly,
- is responsible for the safe operation of the machine,
- operates the machine appropriately within the limits specified in the load capacity chart for the
given boom configuration,
- reports every irregularity that affects the safe operation of the machine to his superior or to the
owner of the machine,
- stops operation at once if safe operation is no longer possible,
- before leaving the cab, makes sure that all the controls are in the zero or neutral position and
that the diesel engine is switched off,
- after work, locks the cab and keeps the ignition key safe, as well as the keys for the cab and the
engine compartment doors, to prevent unauthorized startup.
- keeps the cab, the windscreens, the platforms and the steps clean.
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3.2 Personal attributes required of the machine operator

The machine operator must
- have the requisite physical and mental aptitude,
- be trained and qualified to operate the machine,
- demonstrate to the operator that he is able to operate the machine,
- have read and understood this operating manual,
- know how to administer first aid and know how to use a fire extinguisher,
- have reached the statutory minimum age, normally 18 years,
- have passed the legally required medical examinations.
Physical requirements:
• Adequate vision with unimpaired peripheral vision
• Satisfactory spatial perception
• No colour blindness
• Adequate hearing
• Adequate physical aptitude
• Quick reaction times
• Manual dexterity
Mental requirements and character:

• Adequate intellectual abilities
• Satisfactory spatial intelligence
• Attentiveness
• Stress tolerance
• Patience
• Reliability
Persons with the following physical conditions are not suitable to be employed as machine operators,
or if they are receiving special medical care they are of limited suitability:
• Epileptic fits or attacks of dizziness
• History of heart attack
• Have electronically-operated implants, such as a pacemaker
• Have physical disabilities, such as the loss of fingers, which limit the ability to operate the machine
• Are red/green colour blind
The following persons must not operate the machine

- Alcoholics or drug addicts
- Individuals taking reflex-inhibiting medication.
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3.3 Personal protective wear

Always wear tight-fitting protective clothing when operating, maintaining or starting up the machine,
as well as the correct personal protective gear for the task in question.
WARNING!
There is serious danger of injury from getting stuck in, caught up in or pulled into moving
machine parts.
Precautions:
• Do not wear loose clothing, scarves, open jackets or shirts with undone sleeves.
• Do not wear jewellery (rings, bracelets, earrings, etc.).
The personal protective gear may comprise:

• safety helmet, if head injuries can be expected due to
- collision,
- swinging, falling, toppling or flying objects,
- long, loose hair.
• safety goggles, if eye injuries are possible due to
- corrosive or pressurized liquids,
- loose flying parts.
• ear protection, if the sound level is liable to exceed 85 dB(A).
• breathing mask, in the event of health-threatening gases, steam, vapours or accumulations of
dust in the working environment.
• protective gloves, if hand injuries are possible due to
- burns,
- pointed or sharp objects,
- corrosive or pressurized liquids.
• safety boots, if foot injuries are possible due to

- collision or trapping,
- stepping on pointed or sharp objects,
- falling, toppling or rolling objects.
• reflective, boldly-coloured clothingif prompt recognition by other personnel is important.
• special protective clothing, where there is a risk of burns, hypothermia, chemical burns, stabbing
or cutting injuries to the body.
NOTE!
You are responsible for making sure that you
LRB255_V001 (mf) LWN - TD4/2/2010
- wear the required personal protective gear,

- clean and maintain it regularly,
- replace any part of the protective gear that has become damaged and useless.
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3.4 Work area

In accordance with the Machinery Directive, the following guidelines have been laid down for the
operation of the machine:
Required operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 machine operator
Prescribed work area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cabin on the upper carriage
Depending on the application assistants may be necessary.
While operating the machine

- no one apart from the machine operator may be on the machine,
- the machine operator may not vacate the cabin, even briefly.
The controls may only be operated from the driver's seat. Operating any controls through the open
cab doors is strictly prohibited.
Requirements for a safe working environment:
• Keep the cabin clean: clean dirty foot pedals, empty ashtrays regularly, only place drinks in the
holders provided.
• Do not place magazines or other objects on the control panels.
• Do not keep tools in the cabin.
• Discarded clothing or parts of the protective gear or personal effects must not be allowed to block
the doors to the cabin nor hinder operation of the machine.
• Keep the entrance to the cabin clean and free from snow and ice and any other obstructions.
• Keep all screens and rear-view mirrors of the machine clean and free of condensation and ice.
1
First aid kit (Figure 1, item 1)
The "First Aid" kit is fitted out according to ÖNORM V
5101.
IMPORTANT!
Familiarize yourself with the "First Aid" measures.
All sterile items and plasters are to be replaced accord-
ing to national guidelines or after use.
Emergency hammer (Figure 1, item 2)

If the cab door will not open, use the emergency ham-
mer to break one of the windows to create an
emergency exit.
IMPORTANT!
Hit the window around the edges only. Protect your eyes
and other parts of your body from flying glass.
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3.5 Safety and monitoring devices

3.5.1 Safety devices
Safety devices, LRB 255 Fig. 3-01

1 Hoist limit switch 9 Horn
2 Fall protection runner 10 Door lock
LRB255_V001 (mf) LWN - TD4/2/2010
3 Flashlight 11 Fire extinguishers (2x on the inside of the

doors left and right side)
4 Roof grid* or Falling rock protection* 12 Stop-valve for free-fall *
5 Working spotlight (6x on uppercarriage) 13 Battery-main switch
6 EMERGENCY-OFF-keys (3x) 14 Horn and acoustic signal transmitter
7 Ignition switch 15 Key for assembly- and free-fall operation *
8 Safety lever for control
Not represented
- Electronic load moment limitation (boom equipment)
- Stop valve on hydraulic tank (see monitoring devices)
- Second EMERGENCY-Shut-OFF-key on uppercarriage in the back right
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Functions of the signalling devices:

• The flashing light (3) show that
- the electronic load moment limitation has been bridged,
- the machine is in assembly operation upon actuation of the key (15) in left-hand control panel
(X12),
- the travel gear or swing gear has been actuated.
• The horn (9) can be actuated by the machine operator. The acoustic signal transmitter installed
alongside reports actuation, as well as bridging of the electronic load moment limitation.
• The acoustic signal transmitter (14) at the rear counterweight indicates travel movement of the
machine or swinging of the uppercarriage.
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3.5.2 Monitoring devices
Monitoring devices, LRB 255 Fig. 3-02
Description of the monitoring devices (fig. 3-02):
1 Anemometer 5 Dipstick for the diesel engine

2 Angle display 6 Sluice valve for the hydraulic tank
LRB255_V001 (mf) LWN - TD4/2/2010
3 LCD-display screen 7 Inspection glasses on the hydraulic tank

4 Dipstick at splitter box
Not displayed:
- Internal and external rear-view mirror
NOTE !
The boom equipment for the machine is optional.
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3.6 Safety signs on the machine

Negligence of important safety signs on the machine can cause death or serious injury.
WARNING !
Safety risks resulting from damaged or illegible safety signs.

Countermeasures:
• Continually check safety signs for completeness and legibility.
• Any safety signs that are missing or illegible must be replaced immediately with new ones.
• For application of the machine in another country, the safety signs are to be displayed in the
corresponding language.
The number and locations of the safety signs can be found in the following representation.
IMPORTANT!
These signs are not shown to scale.
The CE mark only appears on the driver's cab if delivery is made to a member country of the
European Union.
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3
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6
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3.6.1 Safety signs on the machine, USA
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9
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10
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3.6.2 Meaning of the safety signs

The symbols on the safety signs
- have a precise meaning,
- are divided into three groups with different shapes and colours.
Prohibition signs
These symbols
- are circular and of a bold red colour,
- are located wherever a potentially dangerous action is prohibited.
No fire, naked flames or smoking.
No access for unauthorized personnel.
No access for persons with pacemakers.
Lifting load vorbidden.
Access prohibited - keep off.
Warning signs
These symbols
- are triangular and of a bold yellow colour,
- are intended to draw attention to objects and situations that could pose
dangers to life and limb.
Warning of a suspended load.
Warning of dangerous driving machinery.

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Warning of hot surfaces.
Warning of slipping hazard.
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Warning of danger from batteries.
Warning of danger from ropes.
Warning of electromagnetic fields.
Warning indicating crushing hazard.
Warning indicating crushing hazard from above.
Warning against standing in the slewing range.
Warning of dangerous electrical voltage.
Warning of danger from rotating parts.

Do not open if motor is running.
Warning of risk of machine toppling over.

Mount ballast only with wide track.
Warning of risk of machine toppling over.

Remove ballast only with wide track.
Warning of operator error.

Read the operating manual.
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Fire protection signs

These symbols
- are rectangular and of a bold red colour,
- are intended to draw attention to objects and information and how to use them
in case of fire.
Fire extinguishers
Signs giving orders

These symbols
- are circular and blue in colour,
- stipulate the wearing of personal protective gear to protect against dangers.
Wear a safety helmet.
Wear ear protection.
Wear protective gloves.

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3.7 Machine-specific dangers

3.7.1 Injuries resulting from operating machinery
WARNING!
There are numerous hazards and situations involving the machine that can cause injuries.
Therefore please observe the following safety precautions:
Do not stand under a suspended load!
Make sure no one is standing in the danger zone of the machine.
Do not reach into moving drive units or parts of the machine.
Access to the top of the superstructure is only permitted

- to carry out assembly, maintenance or service work,
- with appropriate safety measures against falling, such as wearing non-slip
boots.
Do not walk on the cab roof.
Secure open sliding doors or the front windscreen of the cab, as well as open
engine compartment doors, to prevent them inadvertently sliding back or closing.
When driving bolts or pins in or out

- under no circumstances stand between or underneath equipment components
(for example intermediate pieces, etc.),
- never align bolt connections by hand,
- use appropriate special tools (mandrils, stud wrenches etc.),
- always wear safety goggles; there is a risk of injury due to splintering of
surface-hardened metal parts.
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Safety precautions and preventive measures to avoid mechanical hazards (continued):

• Only remove protecting bonnets and safety devices
- after the machine has been shut down and
- it has been secured against accidental restarting.
• Before starting operation, check that all
- protective covers and casings are fitted correctly,
- the engine compartment doors are locked,
- the safety devices are in good working order.
• Do not use wire ropes or chains that are damaged or with inadequate load-bearing capacity.
• Always wear protective gloves when handling wire ropes.
Do not allow limbs or objects to come into contact with the engine fans. Objects
falling or poked into the fan will be shredded and thrown out and can cause
serious injury.
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3.7.2 Injuries due to hydraulic energy
WARNING!
Escaping hydraulic oil under high pressure can cause serious

injury if it
- penetrates clothing and the surface of the skin,
- enters the flesh and causes tissue damage
- and/or gets into the bloodstream.
First aid in case of injuries:

Bandage the injured area(s) with an anti-bacterial dressing and seek medical attention.
These safety precautions and preventive measures protect against injuries:

• Repairs to hydraulic equipment may only be carried out by qualified technicians with specialized
knowledge and experience of hydraulics.
• Before starting repair work, depressurize all pressure hoses and the system sections that are to be
opened.
• When leaks are small, it is sometimes hardly possible to see the hydraulic oil seeping out. Never
try to locate the leak with your bare hand; always use a piece of cardboard or wood for this
purpose.
• Check all hoses, hose connections and screw fittings regularly, but at least annually, for leaks and
damage.
• Damaged hoses and hose connections should be
- replaced immediately with original Liebherr parts,
- never repaired.
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3.7.3 Risk of burns
WARNING!
Certain machine surfaces and operating media reach an operating tempera-

ture of over 65 °C [149 °F].
First aid in case of burns:

First
- immediately run cold water over the burn and cool it down,
- then cover the burn with an anti-bacterial dressing and seek medical attention.
The following safety precautions are intended to protect against burns:

• Always wear protective gloves when working on hot components.
• The engine cooling system is pressurized and escaping steam can cause scald injuries. Therefore
- only check the coolant level after the cover on the equalizing reservoir has cooled to the point
where it can be touched,
- then turn the cover on the equalizing reservoir carefully by 90° to release the excess pressure.
• Avoid touching
- the coolant or parts bearing hydraulic oil,
- the hot hydraulic or engine oil,
- the hot exhaust and the turbocharger.
• Carry out cleaning and maintenance work on the machine after it has cooled down.
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3.7.4 Risk of chemical burns
WARNING!
Both batteries of the machine

- are filled with acidic electrolyte,
- produce explosive detonating gas under high-rate charging or discharg-
ing.
Battery acid
- can lead to blindness if it comes into contact with the eyes,
- can lead to chemical skin burns and may destroy body tissue,
- ruins clothing.
First aid after contact with battery acid:

1. Acid sprayed into the eyes or on the skin must be rinsed away as quickly as possible with large
quantities of clean water. In the event of eye injuries, if possible use an eye-bath to rinse the eyes.
2. Then cover the injured area with an anti-bacterial dressing and seek medical attention.
3. Neutralize escaping battery acid with a soda solution:
Dissolve soda powder, available as detergent or baking powder, in water. Pour the solution carefully
on the acid until it no longer foams.
Observe the following Safety precautions:

• The following are strictly prohibited in the vicinity of battery acid
- smoking,
- fire and naked flames,
- ignition sources (for example, electrical devices).
• When working with or near batteries, always wear safety goggles and protective gloves.
• Never short circuit the battery. Never place any tools on the batteries.
• Lock the engine compartment doors before starting the machine.
• Discharged batteries
- may freeze and burst open,
- must always be charged and stored in frost proof rooms.
• Stored batteries must
- always be kept horizontal,
- never be stored near hot objects such as radiators,
- not be exposed to direct sunlight,
- be checked for sufficient charge at intervals of four weeks and trickle charged if necessary.
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3.7.5 Fire and explosion hazards
WARNING!
When refuelling the machine, an explosive gas mixture may be created.

Escaping diesel fuel or hydraulic oil may ignite if it comes into contact with
a hot surface.
During high-rate charging or discharging, both machine batteries produce

an explosive detonating gas.
Procedure in case of fire:

1. Switch off the engine.
2. If possible use the radio to call for help.
3. Turn the ignition key to the 0 position and leave the cab.
4. Evaluate the situation:
In a dangerous situation, leave the machine and call the fire brigade.
Only if there is no risk to your personal safety should you start to fight the fire.
5. To fight the fire, take one of the machine's fire extinguishers from its mounting and prepare it for
use.
6. Find the seat of the fire. Fight the fire with several short bursts from the fire extinguisher. Only
spray the seat of the fire from below.
7. While fighting the fire, ask your co-workers to
- alert the fire brigade,
- help with putting out the fire by bringing in more fire extinguishers filled with appropriate
extinguishing substances.
NOTE!
Hydraulic oil that has caught fire
- can only be successfully put out with the fire extinguisher at the very start of the fire,
- leads after a short time to a fully-fledged fire and to the total loss of the machine.
Observe the following safety precautions:

LRB255_V001 (mf) LWN - TD4/2/2010
• Get to know the number and location of the fire extinguishers, familiarize yourself with how to use
them.
NOTE!
The location of the fire extinguishers is described in Chapter 3 under Safety Devices
The fire extinguishers supplied are
- filled with extinguishing powder,
- suitable for use in the temperature range - 20°C to + 60°C [- 4 °F to + 140 °F],
- approved for fire classes A, B and C.
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Fire classes:
A = solid materials (incl. cable fires)

B = liquid and liquefied materials
C = burning gases and gaseous materials
NOTE!
Fire extinguishers are subject to national regulations and must therefore be replaced by the operator
if necessary.
11 Correct use of the fire extinguisher
• Attack the fire with the wind behind you (Figure 11,
item 1)
• Tackle surface fires from the front by attacking the
seat of the fire (Figure 11, item 2)
12
• Extinguish dropping and liquid fires from the top to the

bottom (Figure 12 item 1)
• Use a sufficient number of extinguishers at the same
time - not one after the other (Figure 12, item 2)
13
• Make sure the fire does not reignite (Figure 13 item 1)

• Do not put the fire extinguisher back in place after use
- have it refilled (Figure 13, item 2)
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• Only refuel the machine in a well ventilated area.

• Before filling the fuel tank or the hydraulic tank
- turn off the engine,
- turn off the cab heater,
- turn off the auxiliary heating*.
• While filling the fuel tank or the hydraulic tank
- smoking and the use of fire or naked flames is prohibited,
- no one may remain in the cab (in case the machine is started by accident).
• When filling the fuel tank through the filler neck, electrostatic discharges may occur between the
machine and the fuel rig. Therefore
- make sure there is good metallic contact between the pump nozzle and the filler neck
- or before refuelling, create a conductive connection between the machine and the fuel rig.
• If any fuel has spilled while refuelling, immediately
- wipe it off the machine,
- neutralize it on the ground with bonding agents.
• After refuelling, only start the diesel engine when
- the lockable tank cap has been replaced,
- the refuelling rig has been taken away or the suction hose of the refuelling system removed,
- no personnel are in the vicinity of the machine.
• Only start the diesel engine as described in this operating manual.
Do not use any starting aids containing ether - risk of explosion!
• Do not carry any combustible liquids on the machine other than in the tanks provided for this
purpose.
• Do not use any combustible liquids to clean the machine!
• In the area of the central power unit
- do not store cleaning cloths, rags etc.,
- regularly remove flammable residues and deposits (e.g. pools of oil, dry leaves, pine needles,
ash, waste paper, etc.).
• Regularly check that protective covers, cable and hose holders are complete and fit tightly. Attach
loose cables and hoses and secure them to stop them fraying.
• Check all the lines, hoses and screw fittings of the hydraulic and fuel systems regularly for leaks
and possible damage. Fix leaks immediately and replace any damaged components with new
original parts.
• The following are strictly prohibited in the vicinity of battery acid
- smoking,
- fire and naked flames,
- ignition sources (for example, electrical devices).
• Make regular checks on the electrical system and fix all faults immediately, such as loose clamping
connections, scorched or frayed cables, etc.
• At the site where the machine is being used, only the small amounts of fuel or highly flammable or
LRB255_V001 (mf) LWN - TD4/2/2010
self-igniting material absolutely essential for the work in hand may be stored.
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3.7.6 Risk of poisoning and asphyxiation
WARNING!
The engine exhaust gases of the machine contain carbon monoxide and
other substances hazardous to health.
When the machine is used in areas where there are hazardous materials,
such as toxic waste dumps, it is possible to come into contact with
materials and gases that are injurious to health.
NOTE!
Carbon monoxide
- blocks the intake of oxygen and leads to death by asphyxiation,
- is a colourless and odourless gas,
- is created by incomplete combustion,
- is heavier than air and collects on the ground.
Symptoms of carbon monoxide poisoning, with increasing intensity:

• Slight: headache, breathlessness with little exertion, heart palpitations.
• Medium: increased tiredness, dizziness and confusion.
• Severe: impaired judgement, nausea with vomiting, cramps and unconsciousness. Death results
from respiratory and circulatory failure.
First aid upon first signs of carbon monoxide poisoning

When the symptoms of poisoning appear
- turn off the engine of the machine and all fuel-driven machinery,
- leave the cab and the location of the machine immediately,
- breathe in plenty of fresh air and seek medical attention.
Self-preservation measures when rescuing unconscious persons:
ventilate closed rooms thoroughly before entering them.

• make sure there is adequate ventilation before operating the machine in an enclosed area.
• do not operate the auxiliary heating* in an enclosed area. check the setting on the timer in the cab
to prevent the heater starting up unexpectedly.
• In areas where there are hazardous materials, always wear suitable protective gear.
• If a breathing mask is necessary, wear it at all times and renew the filter elements in good time.
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3.7.7 Electromagnetic influences
WARNING!
Operating the machine near transmitters, relays or radar stations can

- cause a temporary or even a permanent break down of the Litronic control
system.
- induce dangerous electrical voltage in the metal parts of the machine or in
the lifted load, which can cause painful electric shocks.
Electronic devices subsequently fitted in the cab (radio telephones, mobile phones, etc.) may
also cause the control system to malfunction.
Sensitive electronic devices or electronic medical implants may be subject to interference in
the vicinity of the machine.
NOTE!
The Litronic-control system with internal VME bus complies with the ISO DIN 13766 standards. The
electrical and electronic components comply at least with EN 55022 or EN 55024.
On the site where the machine is operated
- the levels and frequency distribution of electromagnetic interference are, however, usually
unknown,
- the permitted limits stipulated in EMC standards may be greatly exceeded under certain
circumstances.
Unusual displays or control system responses when operating near transmitter, relay or radar
stations are an indication of electromagnetic disturbance. However, there are no clear, reproducible
indicators for electromagnetic disturbance.
Precautions:
• Take particular care when operating the machine near transmitters, relays or radar stations.
Under certain circumstances, control functions and safety functions, such as electronic load
moment limitation, may no longer be working without this being obvious to the machine operator.
• The machine must be stopped if electromagnetic interference occurs or is even suspected.
• The operator of the machine must instruct suitable specialist personnel to locate and eliminate the
interference source. If the disturbance cannot be eliminated, special screening measures must be
implemented on the machine before resuming operations.
NOTE!
The manufacturer
- has the required specialist knowledge to effectively eliminate the disturbances,
- will, on request, undertake the requisite screening measures for the machine.
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• Persons with pacemakers must not go near the machine if options and accessories that generate
strong electromagnetic fields have been installed.
• No additional devices may be installed in the switch cabinet of the control system without the
written consent of the manufacturer
• Radio devices that operate in the UHF or VHF range may only be installed in the cab if
- the device complies with EN 50082 part 2 and IEC 801-3,
- the maximum transmitting power does not exceed 2 watts,
- they are installed at a distance of more than one meter from the switch cabinet.
• Mobile phones with an output greater than 2 watts may only be used if they are at least 2 meters
away from the switch cabinet!
• In the cab, do not lay the cables for radio telephones, etc. parallel to the control cables!
• The switch cabinet behind the cab must remain closed during operation.
• Find out from the operator of a neighbouring transmitting station about the frequency, power and
airtime of the transmitter.
3.7.8 Endangering the environment
CAUTION!
Fuels, oils, cleaning agents and similar liquids damage and pollute the
environment if they get into the ground, into water or into the sewer
system.
Follow these Safety precautions and precautionary measures:
• Fix any leaks on the machine immediately.

• Neutralize escaped oil or fuel straight away with a binding agent.
• Comply with the environmental protection regulations relating to the disposal of fuels and lubricants
applicable in the particular country. If in doubt, discuss suitable methods of disposal for the various
fuels and lubricants with the competent collection point or recycling centre.
• When draining fuels and lubricants, use only containers that are big enough, do not leak and are
resistant to oil, fuel and chemicals.
• Use separate containers to collect and dispose of the different fuels and lubricants.
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3.7.9 Hazardous area
WARNING!
No personnel may remain in the danger area during operation.
The danger area is set out as follows:
• Danger area when drilling,
14
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• Danger area when pile driving (LRB)
15
Back half of the machine: Turning circle of the superstructure + 0.5 m
Front half of the machine: Length of the piledriving element (pile) + 1.0 m
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• Danger area when moving the machine
16
- Always take care, that when moving and setting up the machinery, all assistants are outside the
danger area (swivel area, path of movement). They should also be in clear view.
- Only after the machine has reached its designated point of operation, and is safely
aligned (i.e. the machine is no longer swiveling or traveling), can it then be brought back into
operation.
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3.8 Additional dangers

3.8.1 Effects from wind and storm
WARNING!
There is great danger of injury if the maximum permissible wind speeds are neglected during
operation of the machine !
Effects of the wind can cause the pile or the drilling equipment to start swinging and cause
- personal injury,
- machine damage.
Countermeasures:
Check the valid load charts for operation of the machine.
In the introduction, there is a chart featuring the authorized wind speeds for the actual set-up stage.
Optionally mounted catwalks on the boom-intermediate pieces reinforce the wind load on the
main boom.
Wind load on the piling rig and drilling system

- reduces stability,
- has the effect of an additional load on the leader,
- increases risk of tipping.
The maximum permissible wind speed is dependent upon the length of the leader:
Leader length in m [ft] maximum permissible wind speed

for operation as well as assembly and disassembly
in m/s [mph]
LRB 255 21 - 30 [70'-100'] 20 [45]
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Wind load on the rear side of the main boom

- reduces machine stability,
- has the effect of an additional load on the
cable hook,
- increases the danger of tipping at the front.
Effects of the wind at the rear side of the load

- increase the tail radius,
- possibly lead to oscillation of the load,
- can tip the machine due to overload or destroy the
main boom.
Effects of the wind from behind Fig. 3-07
Wind load on the front side of the main boom

- reduces stability of the machine,
- is especially dangerous with maximum main boom
angle without load,
- can overload the overtopping guard struts and
destroy the main boom.
Effects of the wind on the front side of the load can

lead to oscillation of the load. If the load comes into
contact with the main boom, the main boom could be
damaged or destroyed.
Effects of the wind from the front Fig. 3-08

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Wind load on one side of the main boom and load

- has the effect of an additional inclined hoist,
- can buckle the main boom,
- can cause the machine to tip.
Effects of the wind from the side Fig. 3-09
The maximum permissible wind speed is dependent upon the setting-up stage of the machine:
Main boom lengths maximum permissible wind speed

m/s mph
11 - 17 m [36 - 56'] 14,0 46
20 - 53 m [66' - 174'] 12,0 39
Wind speeds
The optional anemometer on the boom head records the actual wind speed and displays the value in
m/s on the display screen in the operator's cab.
It is possible to estimate wind forces and wind speeds without an anemometer using the chart on the
next page.
IMPORTANT!
When estimating the wind speed, take into consideration that higher wind speeds can occur on the
boom than on the ground.
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Wind force Wind speed Effects of the wind

inland
Beaufort description m/s km/h mph
0 Calm 0 - 0,2 1 under 1 Smoke rises straight upwards
1 Slight draw 0,3 - 1,5 1-5 1-3 Wind direction is indicated by the
draw of smoke, but not yet by the
weathervane.
2 Light breeze 1,6 - 3,3 6 - 11 4-7 Wind is noticeable in the face, leaves
rustle, the weathervane is moving.
3 Weak 3,4 - 5,4 12 - 19 8 - 12 Leaves and thin twigs are moving.
breeze Wind stretches out a pennant.
4 Modest 5,5 - 7,9 20 - 28 13 - 18 Wind lifts dust and loose paper,
breeze moves twigs and thin branches.
5 Fresh breeze 8 - 10,7 29 - 38 19 - 24 Small deciduous trees begin to sway.
White crests start to form on lakes.
6 Strong wind 10,8 - 13,8 39 - 49 25 -31 Thick branches are moving, overhead
electrical lines are humming, umbrel-
las are blown inside out.
7 Stiff wind 13,9 - 17,1 50 - 61 32 - 38 Whole trees are moving.
8 Stormy wind 17,2 - 20,7 62 - 74 39 - 46 Wind snaps branches off trees.
Walking outside is made considerably
more difficult.
9 Storm 20,8 - 24,4 75 - 88 47 - 54 Minor damage to houses (lost roof-
tiles, chimney covers, etc.)
10 Heavy storm 24,5 - 28,4 89 - 102 55 - 63 Storm uproots trees.
Major damage to houses.
11 Gale-force 28,5 - 32,6 103 - 117 64 - 73 Widespread storm damage.
storm
12 Hurricane 32,7 - 36,9 118 - 133 74 and Serious devastation.
over
Wind force Chart 3-01
IMPORTANT!
Please note in particular all wind-related safety guidelines and protective measures in the initial
pages of the valid load chart, as well as the following additional points:
• Even before the application planning, the wind conditions for the job site and the weather
predictions for the period of operation planned must be known and taken into consideration.
• The machine operator must be aware of the weather report and the actual wind speed at the
machine's job site before beginning work. If impermissibly high wind speeds are expected in the
LRB255_V001 (mf) LWN - TD4/2/2010
next few hours, operation should be aborted and protective measures against storm damage
should be taken.
• During operation of the machine with permissible wind speeds
- respect dangerously high gusts of wind,
- do not lift any large flat-surfaced loads, like for example prefabricated elements,
- reduce loads and main boom angles as a precaution,
- move the loads carefully and slowly and avoid every oscillation.
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• If the maximum permissible wind speed is exceeded, shut down operation immediately: Lower the
load, secure and block the machine in the parking position.
Parking position
The parking position
- protects the machine against storm damage,
- is suitable for wind speeds in conditions above the maximum permissible wind speed for the
operation up to a wind speed of 20 m/s [45 mph] (wind force 8).
DANGER !
It is hazardous to remain in the immediate vicinity of the machine during wind speeds of over
20 m/s [45 mph]!
The occurring wind loads could lead to partial or complete destruction of the boom and could
tip the machine.
Countermeasures:
If expecting wind speeds above 20 m/s [45 mph] or wind force 8, the complete boom must be laid
flat on the ground.
The safest measure that can be taken is always to completely lay down the boom.
IMPORTANT!
Please refer to the notes in chapter 5 unter "Parking position".
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DANGER!
The wind loading increases in line with the square law as the wind velocity increases. In other words,
an increase from 7 m/s [16 mph] to 10 m/s [22 mph] means that the wind force practically doubles.
This is illustrated in the following table.
Wind in m/s (calculation) Wind in mph (calculation) Wind force factor (ap-
proximation)
7 m/s (7 x 7 = 49) 16 mph (16 x 16 = 256) 1
10 m/s (10 x 10 = 100) 22 mph (22 x 22 = 484) 2
16 m/s (16 x 16 = 256) 36 mph (36 x 36 = 1296) 5,2
22 m/s (22 x 22 = 484) 49 mph (49 x 49 = 2401) 10

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3.8.2 Ground composition at the site

The ground upon which the machine has to travel must be
- firm and level,
- able to bear the dead weight of the machine with the additional hoisting load.
Danger!
Danger due to soft foundation! Insufficient load-bearing capability of foundations will result in
the machine tipping over.
Countermeasures:
• Ascertainment of the permissible foundation pressure values by approved experts.

• When planning the load lift, calculate the foundation pressure exerted by the machine during
operation.
- Request the data required for this calculation from the manufacturer.
- With machine types HS and LR, there is an option to check the foundation pressure display to
obtain the actual foundation pressure exerted by the machine during operation.
- With machine types LRB and LB, the foundation pressure values are shown in the load capacity
table.
Adhere to the following safety precautions and protective measures:

• Before operating the machine
- level the area over which the crane will move,
- if possible, remove all obstacles in that area, such as rocks, tree trunks,
- temporarily cover drainage ditches or fill them in.
• Before operating the machine in depressions or along river banks, etc., check if there is a danger
of flooding after heavy rainfall.
• Maintain a safe distance between the machine and
- slopes or overhangs,
- excavations, ducts, ditches,
- edges of crevices, pits, dumps and embankments,
- subsiding or undermined embankments.
NOTE!
Erect barriers, place thresholds or wedges to maintain a safe distance in obscured spots or if
operating in tight spaces.
Are there opportunities to compact subsiding ground and prepare it for the machine?
To increase the stability of the machine, you can use
- special mattresses that are at least 1 meter [3 3"] wider than the travel gear,
- appropriate running rails or steel plates under the tracks,
- a sufficient stable wooden platform with closely spaced slatting.
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3.8.3 Snow and ice loads
DANGER!
Danger of accidents due to chunks of ice breaking off and falling down.
Increased risk of damage due to frozen limit switches.
Precautions:
• Lay down the piling and drilling equipment and carefully knock off the ice that has collected.
• Carefully remove the ice from all sensitive parts, such as limit switches, guides, etc.
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3.8.4 Lightning strikes
WARNING!
When lightning strikes the machine, there is danger of injury to all persons
in the immediate vicinity from flashovers or dangerous voltage levels.
Preventive measures:
• Lay down the lead in good time, before the storm begins.
• During the storm do not go near the machine or any large metallic objects.
NOTE!
Inside the enclosed cabin, the machine operator is well protected against the direct effects of
lightning strikes. The cabin acts like a Faraday cage and deflects the lightning strike over the unit.
When to lay down the lead is a matter of opinion and is the responsibility of the machine operator,
especially on sites that experience frequent storms or are cramped.
The manufacturer explicitly recommends that the main boom is laid down promptly when a storm is
brewing
- at exposed sites,
- near river banks, etc.
CAUTION!
A lightning strike can cause extensive damage to the machine, including:

• Total failure of the Litronic control system.
• Damage to local welding spots or bearings on the rotary connection between the upper and lower
carriages.
Measures to take after observing or suspecting a lightning strike on the machine:

• Thoroughly check the machine. Pay special attention to damaged cables or lines and check for
leaks.
• Run a function check on the entire control system.
• Slowly move the swing gear and listen for unusual noises in the rotary connection, especially in
the swing ring.
• Lay down the lead and examine for damage. Repair damage to the paintwork at the point where
the lightning struck.
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3.8.5 Overhead power lines
DANGER!
If the machine touches a high voltage power line it could cause a fatal
electric shock
- for the machine operator,
- to anyone who touches the machine, the hoisting rope or the load,
- for everyone in the vicinity of the machine.
Preventive measures:
Keep a safe distance from the overhead power lines as specified in national
guidelines or by the authority responsible for the power lines.
• Should it not be possible to keep a safe distance from the overhead power lines, then the
technicians of the local power company must either
- switch off the power lines and earth them,
- divert the power lines around the site where the machine will be erected,
- run power cables underground through the site.
• If it is not possible to keep a safe distance from the overhead power line and none of above
actions is possible:
barriers must be used to restrict the working area of the machine and to maintain a safe distance
from the power line.
Safe distances from overhead power lines
The safe distance mainly depends on the nominal voltage of the power line.
In Europe, the safe distances to power lines are specified in EN 50110, part 1 "Operation of
Electrical Installations". In part 2 of EN 50110, the nationally applicable safe distances in the
individual member states of the EU are listed.
17
LRB255_V001 (mf) LWN - TD4/2/2010
Safety distance (x) to overhead power lines
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For example, in Germany the following safe distances from overhead power lines are to be
maintained when operating the machine:
Nominal supply voltage (effective value) Minimum distance

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 in Germany Table 3-03
In the United States of America the following safe distances from overhead power lines are to be
maintained when operating the machine:
Nominal supply voltage (phase to phase) Minimum distance

ft m
up to 50 kV (50000 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 when operating the machine in the USA Table 3-04
In the United States of America the following safe distances from overhead power lines are to be
maintained when transporting the machine or when it is moving under its own power:
Nominal supply voltage (phase to phase) Minimum distance

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 when transporting the machine in the USA Table 3-05
Prerequisite: The lead is laid down or dismantled.
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How do you find out the nominal supply voltage of an overhead power line?
Certain characteristics can be used to make preliminary estimates:
Network level and Low voltage supply Medium voltage sup- High voltage supply
nominal voltage up to 1000 V ply from 1000 V up to over 30 kV
30 kV
Mast form Wooden mostly wooden masts, mostly steel lattice
occasionally concrete towers or concrete
or steel lattice towers masts
Mast distances 40 - 60 m 50 - 100 m 200 - 400 m
[131' - 197'] [164 - 328'] [656 - 1312']
Number of overhead 4 or 5 3 or 6 2 or 4, or a multiple of 2
conductors
Insulators small (approx. fist-siz- large (approx. head- Insulator chains or
ed) sized) stabilizers
Conductor routing to houses and buildings to transformer stations to power stations,
and electricity generat- transformer substations
ing stations or railway systems
Characteristics of overhead power lines Table 3-06
NOTE!
Only the relevant power station can provide definitive figures regarding the nominal voltage of an
overhead power line.
Measures to take during work planning:

• Always inform the relevant authorities and the power station.
• With the competent person from the power station, discuss:
- the planned application,
- the safe distance to be maintained,
- the required safety devices.
• All workers on the site are to be informed of the danger.
• Set the exact procedure of how the lead will be raised and lowered without infringing the safe
distance from the overhead power lines.
Safety precautions and protective measures when operating the machine near overhead
power lines
• Only start work once the work area has been checked and approved by the authorized person
from the power station.
• Even after it has been shut down, the power line has to be regarded as under voltage, as long as
it has not been explicitly declared (e.g. in writing) to be free of voltage by the competent power
station authorities.
LRB255_V001 (mf) LWN - TD4/2/2010
• As the machine operator

- work with particular alertness and concentration,
- move the machine and the pile or drilling equipment slowly,
- take reaction times and possible errors into account when estimating distances.
• No one should remain in the vicinity of the machine.
• Be aware of the effects of the wind:
The hoisting load (drill pipe, etc.) may start to sway. The conducting cables of the overhead power
lines could swing out horizontally and vertically.
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• Be aware of uneven ground:

If the machine is on a slant, it could come too close to the overhead power line.
• If the use of a signalman is the only safety measure that can be adopted when working in the
vicinity of power lines, this is only acceptable for very short periods of operation. The signalman
observes the machine from a position from which he has a clear all-round view and must be able
to contact the operator each time the machine comes dangerously close to the power line.
• Never remove, shift or cross any barriers, markers, etc., that are delimiting the working area of the
machine.
What happens if you get too close to an overhead power line?
With low voltage power lines (up to 1000 V), an overspill to the machine will only occur if it touches
the power line.
With high voltage power lines, a flashover with the formation of an electric arc will occur as soon as
the machine encroaches within a certain distance.
When a flashover occurs, flammable material, the hoisting load, for example, could spontaneously
combust; the machine might catch fire.
Short circuit
When a short circuit occurs, the machine comes into contact with at least two different conductor
cables of a power line. This can apply a hazardous voltage to the machine.
Earth fault
If the machine only touches one conducting cable or if a flashover occurs from a single conducting
cable
- an earth fault results,
- current flows over the machine into the earth and returns to the source of voltage,
- a hazardous voltage is applied to the machine,
- with high voltage, a hazardous resistance area also forms around the machine.
NOTE!
Even if a conductor cable from an overhead high voltage power line has been torn down and is lying
on the ground, the earth fault with the formation of a resistance area still occurs.
On the other hand, an earth fault on a low voltage power line does not create a hazardous
resistance area around the machine.
WARNING!
The safety devices of the various national electricity networks react differently in the event of
a fault. It cannot be assumed that there will be an automatic and lasting shut-down of the
power lines after a short-circuit or earth fault.
The machine or a torn down conductor cable can therefore still be under hazardous voltage
levels and form a resistance area even if there is no flashover, smoke formation or crackling
noises.
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Resistance area
18
Distance from the

location of the earth fault in m [ft]
Voltage [kV]
Resistance area during an earth fault
During an earth fault the current is distributed from the point it enters the ground. The high voltage
decreases along a funnel-shaped curve - a resistance area is formed.
The extent of the resistance area depends on the voltage, the current intensity and the ground
resistance.
If someone is within the resistance area, a voltage difference, known as the step voltage, forms
between his feet.
The step voltage is higher
- the closer the person is to the earth fault,
- the greater the step.
Depending on the insulating properties of his shoes, an electrical shock is created above a certain
step voltage. If the person falls to the ground, a potential difference is formed immediately along his
body, surpassing the level of the step voltage - a life threatening current flows through his body.
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What must a machine operator do in the event of a flashover or if a conductor cable is

touched?
1. First, remain calm - do not panic!

2. Do not vacate the cabin!
The cabin is relatively safe, unless there is an electrical discharge into the cabin or the machine
catches fire.
3. If the controls are still functioning:
Initiate travel in the opposite direction immediately and move the machine out of the danger area:
Swing the upper carriage away or move the leader and activate the travel gear.
Only stop the machine when
- the prescribed safe distance from the overhead power line has been reached,
- there is a distance of at least 10 m [33 ft] between it and any torn conductor cable lying on the
ground.
Inform the relevant power station of the accident. Secure the area around any torn down conductor
cable to prevent anyone going near it: Cordon off an area with a radius of 10 m [33 ft].
Thoroughly inspect the machine before resuming operation.
NOTE!
A flashover from the power line creates an electric arc that can expand considerably when the
machine is removed.
Even in such cases, continue moving the machine away from the danger zone until the electric arc is
extinguished and the prescribed safe distance away from the power line has been re-established.
4. If the control no longer functions, use the radio or call

- to everyone in the vicinity not to come any closer or touch the machine or any torn down conductor
cables; tell them to keep at least 10 m [33 ft] away,
- the relevant power station to cut the power to the power lines.
DANGER!
Even power lines that appear to be switched off can be switched on again manually, or by
automatic safety devices, for fault detection purposes.
Do not vacate the cabin until you have reliable confirmation that the power line really has
been switched off.
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Leaving the machine in case of an emergency
DANGER!
When you leave the machine in an emergency, you are putting your life at risk:
• Touching the machine and the ground at the same time will be fatal!
• Remaining in the resistance area is life-threatening!
So only leave the machine if there is imminent danger to your life through flashover or fire.
When in doubt, leave the machine as if there had been an accident involving a high voltage power
line.
The procedure for leaving the machine varies depending on whether the accident occurred with a
low-voltage or a high-voltage power line.
In the case of low voltage the danger lies in touching live parts of the machine (including the
hoisting rope, hoisting load etc.) or a torn-down cable at the same time as touching the ground.
In the case of high voltage lines in addition to the danger of touching parts of the machine that are
under voltage or a torn down conductor cable, there is also the risk posed by the resistance area
that forms around the machine.
Procedure for low voltage incidents:

• Jump to a safe distance from the machine and land on both feet at the same time.
• Jump in a direction that avoids any contact with metallic parts that are touching the machine or a
power line.
• When leaving the danger zone, avoid any contact with metal objects.
Procedure for high voltage incidents:

• Jump to a safe distance from the machine and land on both feet at the same time.
• Jump in a direction that avoids any contact with metallic parts that are touching the machine or a
power line.
• Land with both feet close together to avoid exposing yourself to a dangerous step voltage.
• Leaving the resistance area: With the legs pressed together, hop along on both legs until you
reach the minimum safe distance of 10 m [33 ft] from the machine.
• While jumping away, keep well clear of any metal objects within the danger zone.
NOTE!
Instead of hopping, you can also leave the danger zone by pressing your knees together and taking
small steps.
Your shoes must
LRB255_V001 (mf) LWN - TD4/2/2010
- always rub against each other to remain in contact with each other,
- never leave the ground completely.
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What should be remembered when rescuing casualties?
WARNING!
Before any rescue attempt, find out what supply voltage the power line involved in the
accident is carrying.
The measures taken during the rescue differ significantly depending on whether it is a low
voltage (up to 1000 V) or high voltage incident!
First aid measures following an accident involving low voltage power lines.
1. Notify rescue service or fire brigade.

Report
- an electrical accident involving a low voltage overhead power line,
- the location of the accident,
- the circumstances of the accident,
- the number of injured persons,
- your name and telephone number.
2. Notify the relevant power station if this has not already been done by the rescue service or fire brigade:
Inform them of the exact location of the accident.
Arrange for the power lines to be switched off.
Request the assistance of trained personnel from the power station.
Ensure that they at least phone you back to confirm that the power lines have been switched off.
3. Secure the scene of the accident. Do not allow access to any unauthorized persons.
4. When rescuing injured person(s), obey the self-protection measures described below.
WARNING!
A person injured by electricity may be still charged with a dangerous voltage.

They are touching either a part of the machine or the load, or a torn down power line.
Precaution: Do not touch an injured person directly during rescue.
NOTE!
No dangerous resistance area forms when low voltages are involved. Therefore it is possible to
approach the scene of the accident and rescue injured persons before the overhead power line has
been switched off.
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Procedure
• Find a piece of insulating material for self-protection:
dry clothing, rubber gloves, plastic bag, dry wood, etc.
• Approach the injured person cautiously. Keep well clear of all metal objects at the scene of the
accident.
• Use the insulated material to pull the injured person away from the live object, avoiding any direct
contact with it.
• Only after the contact with the live object has been broken is it safe to touch the injured person
and to move him from the scene of the accident.
• Administer first aid until the rescue service or the emergency doctor arrives.
CAUTION!
Always seek medical attention after every powerful electric shock, even if there are no
noticeable injuries or after-effects.
The doctor can carry out an ECG to check for an irregular heartbeat.
First aid measures following an accident involving high-voltage power lines
1. Notify rescue service or fire brigade.

Report
- an electrical accident involving a high voltage overhead power line,
- the location of the accident,
- the number of injured persons,
- your name and telephone number.
2. Notify the relevant power station if this has not already been done by the rescue service or fire
brigade:
Inform them of the exact location of the accident.
Arrange for the power lines to be switched off.
Request the assistance of trained personnel from the power station.
Clarify how you are to receive confirmation from the power station that the power lines have been
switched off: personally, by trained personnel from the power station at the scene of the accident, or
by a return phone call.
3. Secure the scene of accident within a radius of 10 m [33 ft] with barriers, cordons, etc. Do not allow
access to any unauthorized person.
DANGER!
Your life is at risk from electric shock when you enter the scene of the accident!
LRB255_V001 (mf) LWN - TD4/2/2010
If an earth fault occurs, a dangerous resistance area forms around the scene of the accident.
Following a short circuit, a power line that appears to be switched off could be switched back
on again briefly for fault detection purposes.
Precaution: Do not act hastily when attempting a rescue!
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4. Rescue injured persons

- only after the shut-down and earthing of the overhead power line have been reliably confirmed,
- if possible under supervision of trained personnel from the relevant power station.
5. Administer first aid until the rescue service or the emergency doctor arrives.
DANGER!
In the case of accidents involving high voltages, the lives of injured persons are often acutely
at risk from respiratory and circulation failure.
Therefore begin first-aid measures such as artificial respiration and heart massage imme-
diately following the rescue. These resuscitation methods must be taught and practised often,
so they can be used effectively when an emergency occurs.
3.8.6 Underground pipes and cables

With underground working, it is possible to damage
- underground electric cables,
- gas pipes,
- telephone, TV and data cables,
- sewage pipes, district heating pipes etc.
WARNING!
If a live underground cable is damaged, lives are at risk from electric shock.
There is an extreme danger of explosion and fire in the vicinity of a damaged gas pipe.
Operational planning measures
The construction company carrying out the work is responsible for gathering accurate information
about possible underground cables within the working area of the machine so that work in the vicinity
of underground cables can be carried out safely:
• Obtaining information from the relevant utility companies.
• Examining the as-built plans of
- utility companies (electricity, gas or water),
- cable operators (telephone companies, factories, transport companies),
- housing authorities.
• Only use the latest, up-to-date plans.
• If the construction plans are modified or extended, make new enquiries.
• If in doubt, locate the underground cables around the site using a locating device via search slots
or test digs.
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• The relevant utility companies, cable users and public authorities

- must be informed in good time about the start of the work,
- must be asked for written approval for the civil engineering work to be carried out.
• When several construction companies are involved, their activities must be coordinated. All
companies must have the same up-to-date information on underground pipes, etc. on the construc-
tion site.
Safety precautions and protective measures for operating the machine in the vicinity of
underground pipes and cables
• Do not start work until you have obtained all the approvals from the utility companies and the
cable operators.
• The machine operator must obtain all relevant information about the exact location of all under-
ground cables before starting work. These plans must be available for inspection on the construc-
tion site.
• Operate the machine with particular care near underground pipes and cables: All applicable
national Safety Precautions as well as the special guidelines and safety measures of the utility
companies should be noted and obeyed.
• In the event of any unexpected encounters with underground cables or associated warning tapes
and protective coverings: Cease operation of the machine immediately and inform the appropriate
superiors.
• Underground pipes and cables must not be uncovered with the machine. Underground pipes and
cables may only be uncovered manually, using blunt tools.
• Secure, support or prop up all exposed underground cables so that they cannot sway, slide or
become deformed.
• Stabilize the cable ducts and trenches and secure the edges to prevent them caving in.
What needs to be considered regarding gas pipes?
• Report any change in position or damage to the pipe casing to the appropriate gas company. The
gas pipe may only be backfilled after inspection, repair and approval by specialist personnel from
the gas company.
• All devices of the gas supply network around the site must remain accessible (valves, surface
boxes, manhole covers etc.). Existing markings and warning signs must not be covered, relocated
or removed.
What happens when a gas pipe is damaged?
The escaping gas

- forms an inflammable gas-air mixture around the affected area,
- can strike personnel or machines if escaping from gas supply pipes under high pressure, as well
as ejecting lumps of earth or stones,
- endangers not only personnel and equipment on the site, but also passers-by and neighbouring
residents.
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A gas fire can develop in seconds and spread explosively. In a conventional supply pipe with a leak
of 50 mm [2''], for example, the flames can be up to
10 m [33 ft] high if the gas is escaping at a pressure of 1 bar [14.5 psi]. The machine and
surrounding construction machinery will quickly be burnt out.
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Even a minor change in the position of the gas pipe can result in damage to other sensitive points of
the gas network, for example connection points or house feeder pipes. Leaks and small leaks that
are not immediately detectable are very dangerous if gas is allowed to escape over a lengthy period
of time and penetrate along the gas pipe network into the surrounding buildings. An explosive gas-air
mixture is formed considerably more quickly in enclosed spaces than in the open air. Any ignition
source, such as on/off switches on electrical equipment or the turning on of a light, can trigger an
explosion.
Corrosion can cause leaks to form within 5 - 10 years of minor damage to the casings of metal gas
pipes.
What must the machine operator do if a gas pipeline is damaged and gas escapes, or a leak
is suspected?
1. Stop work immediately.

2. Leave the machine after shutting down the engine and all additional fuel powered units.
3. Alert all site personnel: Avoid producing any sparks and maintain a strict no-smoking policy.
4. Shut down all construction machinery and vehicle engines in the immediate vicinity.
5. Clear the danger area and secure a wide area with barriers or cordons. Do not allow access by
unauthorized personnel.
6. Inform the relevant gas company and agree further measures.
Inform them of
- the extent of the damage,
- the exact location of the site,
- how long ago the accident occurred,
- a name and telephone number for a return call.
7. Should there be the slightest suspicion that gas may be leaking into a building, alert the occupants by
knocking or calling. Do not ring the door bell or call them by telephone, as this may trigger an
explosion.
If gas can already be smelt in the building, especially around the area where the gas pipe is known to
enter the house: do not operate any electrical systems or equipment! Open all doors and windows
wide for ventilation purposes and leave the building immediately.
8. In the event of major damage, evacuate the occupiers of all the surrounding buildings with the
cooperation of the police or fire brigade.
9. Building site personnel
- must assist all specialist personnel from the gas company during the repair work,
- may therefore only leave the building site with the consent of the specialist personnel.
10. Work on the building site may only begin again if authorisation has been given by the relevant gas
company.
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What do you do in the event of a gas fire?
CAUTION!
Extinguishing a gas fire requires specialist knowledge!

A gas fire that has already been extinguished can flare up again should more gas escape and
break out again in an unexpected spot!
Precautions:
• Alert the local fire brigade to fight the fire.
• Do not attempt to put out the fire before the fire brigade arrives unless lives are in danger or there
is risk of major damage to property.
• If the gas fire is not causing any immediate danger, it is sometimes better, in certain cir-
cumstances, to let the gas burn. As soon as the gas company shuts off the gas pipe, the fire will
go out of its own accord.
Things to remember concerning underground electric cables:
• For excavation work, observe the nationally prescribed minimum distance from the underground
cable (at least 1 m [3'4"]).
• Even minor damage to the outer casing of an underground cable should be reported to the
relevant power station. If moisture is allowed to penetrate, the cable could fail in the future. The
location of such a fault is to be precisely measured to establish who or what caused the damage.
What happens if the machine damages an underground cable?
After it has penetrated the insulation, the machine can become charged with a dangerously high
voltage.
If an underground cable is sheared, burn-out at the fault location with strong electrical arcing may
occur.
If a high-voltage power cable becomes damaged, a hazardous resistance area may form around the
fault location.
WARNING!
The safety systems of the different national electricity grids react differently in the event of a
fault. Therefore it cannot be assumed that there will be an automatic and lasting shut-down
following damage to an underground cable.
The machine and the damaged underground cable can therefore still be under hazardous
voltage levels and form a resistance area, even if there is no flashover, smoke formation or
crackling noises.
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What must the operator do if the machine damages an underground cable?
The same procedures apply as described in section 3.8.5 "Overhead power lines":
1. First, remain calm - do not panic!

2. Do not leave the cab!
3. If the controls are still functioning:
Initiate travel in the opposite direction immediately and break contact with the underground cable.
Then drive the machine out of the danger area.
Do not stop the machine until you are well away from the fault location.
- at least 5 m [17 ft] in the case of a low-voltage cable (up to 1000 V),
- at least 10 m [33 ft] in the case of a high-voltage cable, or if uncertain about the voltage of the
underground cable.
Inform the relevant power station of the accident. Prevent access to the area around the fault
location: Fence off an area with a radius of 10 m [33 ft].
Thoroughly inspect the machine before resuming operation.
4. If the control system is no longer working, use the radio or shout

- to everyone in the vicinity not to come any closer or touch the machine, the hoisting rope or load;
tell them to keep at least 10 m [33 ft] away,
- have the relevant power station shut down the underground cable.
DANGER!
Even an underground cable that appear to be switched off may be switched on again
manually or by automatic safety devices for fault detection purposes.
Precaution:
Do not vacate the cab until you have reliable confirmation that the underground cable has been
switched off.
NOTE!
Leaving the machine in an emergency and rescuing casualties is described in section 3.8.5
"Overhead power lines".
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3.9 Safety precautions for the machine operator

In view of the numerous options of the machine, this operating manual can not describe all situations
and dangers that may occur during operation.
It is therefore especially important that the machine operator
- knows precisely what the capabilities and operating limitations of the machine are (see Chapter 2
"Applications of the machine", "Technical data" and Chapter 3 "Appropriate use" and section 3.1.2
"Examples of improper use"),
- knows about all the safety devices of the machine (see section 3.5 "Safety and monitoring
devices"),
- requests information from the manufacturer immediately if an undocumented, dangerous situation
occurs in connection with the machine.
As machine operator, you should conscientiously perform all the tasks that come within your area of
responsibility (see section 3.1.4 "Areas of responsibility").
Familiarize yourself with the local Safety Precautions applicable on the site where the machine is
used.
Please note the special Safety Precaution in subsequent chapters of this operating manual:
Chapter 5 - for start-up and operation of the machine
Chapter 6 - for erection, dismantling and transportation of the machine
Chapter 7 - for maintenance work on the machine that you can carry out yourself
3.10 Safety precautions for maintenance and repair personnel

The operational safety, readiness for use and service life of the machine depend on you doing your
work conscientiously.
Familiarize yourself with the dangers specific to the machine listed in section 3.7, to which you may
be exposed when carrying out maintenance and repairs. Adhere to the special safety precautions in
the appropriate chapters.
NOTE!
Specialist knowledge is required to work on the hydraulic and control system and on the various
brakes of the machine.
The manufacturer provides this specialist knowledge through training courses which are tailored
specifically to the customer's requirements.
If several people carry out maintenance and repair of the machine, their duties and areas of
responsibility must be clearly defined by the operator or by a person authorized by the operator. This
includes upkeep of the inspection book.
The inspection book for earth moving equipment
- will be handed over to you when you take possession of the machine
- specifies the necessary inspections of the machine by the manufacturer's Customer Service
department.
The person responsible for the inspection book
- periodically takes a reading from the service hour meter of the machine,
- informs Customer Service in good time when an inspection of the machine is due.
LRB255_V001 (mf) LWN - TD4/2/2010
NOTE!
The last page of the inspection log contains stickers showing the number of services hours until the
next inspection. After the inspection affix a sticker beside the service hour meter or in a clearly
visible place in the cab.
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3.11 Safety precautions for construction site personnel

No personnel may remain in the danger area of the machine during operation.
The danger area is the area surrounding the machine, in which people can be injured by
- working movements of the machine,
- a swaying or falling load,
- optional accessories of the machine.
All barriers around the machine, which confine the danger area, may not be climbed over, reposi-
tioned or removed.
The instructions of the machine operator must be followed and the acoustic warning signals of the
machine must be observed.
Standing near the machine is particularly dangerous
- during assembly and dismantling
- during a storm or thunderstorm.
3.11.1 Signalman
The national guidelines relating to the use of a signalman and the signals to be used must be
adhered to.
A signalman should normally be available to the machine operator
- whenever the working or travel area is no longer completely visible from the cab,
- when manoeuvring the machine and load in confined areas,
- in the vicinity of overhead electrical power lines,
- during excavation work in the vicinity of underground cables.
Only one signalman may work with the machine operator at a time. Should several signalmen be in
the vicinity of the machine, there must be no doubt as to which signalman is actually giving the
instructions (for example, he should wear a fluorescent vest).
The signalman must not stand in the danger area or in the immediate path of the machine.
The danger area around the machine and its path of travel must be monitored by the signalman. The
load must never be directed above the heads of persons below. Persons should therefore be
requested to leave the danger area immediately.
The signalman must not carry out any other tasks that may distract him during his direction duties.
Safety precautions for signalling by radio

• Before operation
- check the battery capacity of the radio equipment and, if necessary, have replacement batteries
available,
- test the radio link with the machine operator and, in the event of a problem, arrange a different
transmission frequency.
• Handle the radio equipment with care and protect it against humidity.
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Safety precautions for signalling with hand signals
WARNING!
Misunderstood hand signals between the signalman, the rigger and machine operator can
lead to serious accidents!
Precautions:
• When signalling, always remain in visual contact with the machine operator and always stand in a
clearly visible position. Arrange sufficient lighting for night work.
• When signalling, wear clearly visible gloves such as white ones.
• The hand signals
- should be given slowly and clearly,
- are to be arranged with the machine operator and rigger beforehand, particularly if the application
is out of the ordinary.
• When working together with a rigger, the signalman relays the rigger's hand signals to the machine
operator.
• The machine operator, signalman and rigger must always keep an overview of all the hand signals
used close to hand.
NOTE!
A compilation of the most widely-used hand signals can be found in the following pages.
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3.11.2 Rigger
During operation of the machine, the rigger is responsible for ensuring that the load is slung or
released safely and carefully.
The rigger must therefore only use appropriate, undamaged lifting and slinging equipment, so that
the load will not slip or fall.
The rigger must always wear protective gloves when carrying out his tasks. He may only approach
the load with the permission of the signalman or the machine operator. Standing under a raised load
is prohibited.
The rigger
- remains in visual or radio contact with the signalman and follows his instructions,
- reports his entry to or exit from the danger area around the machine when starting or finishing
his tasks.
If no signalman is available, the rigger works directly with the machine operator.
When using hand signals, the same Safety precautions as for the signalman apply.
3.11.3 Hand signals

The hand signals
- are used for communication where there is visual contact between the machine operator and site
personnel such as the signalman and rigger,
- are clearly defined under certain national standards.
It must therefore be agreed between all persons involved which hand signals are to be used.
The following summary is limited to the widely-used hand signals
- for use in lifting operations,
- in Germany in accordance with BGV A8 (formerly VBG 125),
- in the United States of America in accordance with ASME/ANSI B30.5.
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General hand signals in accordance with BGV A8 (formerly VBG 125)
19
Hand signals, general
Caution, start, attention Stop, interruption, halt move- Stop - danger

Hold the right arm stretched ment First stretch out both arms hori-
vertically upwards. Stretch both arms out to the zontally to the sides.
The palm faces forwards. side, horizontally. The palms face forward.
The palms face forward. Now bend and stretch the arms
alternately.
20
Hand signals, vertical movements
Lift, up Lower, down Slowly

Hold the right arm up. Hold the right arm down. Stretch out the right arm hori-
The palm faces forward making The palm faces inwards mak- zontally.
a slow circling motion. ing a slow circling motion. The palm faces down and is
LRB255_V001 (mf) LWN - TD4/2/2010
moved slowly up and down.
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General hand signals in accordance with BGV A8, continued
21
Hand signals, horizontal motions
Depart Approach Move away

Hold the right arm up. Bend both arms. Bend both arms.
The palm faces forwards. The palms face inwards. The palms face outwards.
Move the arm sideways to and Wave in with the forearms. Wave away with the forearms.
fro.
22
Hand signals, horizontal motions
Travel right (from the signal- Travel left (from the signal- Indicate reduction of dis-
man's viewpoint) man's viewpoint) tance
Lightly bend the right arm while Lightly bend in the left arm Hold both palms parallel and
holding it out horizontally and while holding it out horizontally move them toward each other
move to and fro to the side. and move to and fro to the to indicate the distance.
side.
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Hand signals for lifting operations in accordance with ASME/ANSI B30.5
23
Hand signals in accordance with ASME/ANSI B30.5
Lift load Lower load Use main winch (winch 1)

Bend the right arm and hold it Hold the right arm down. Tap the safety helmet with the
upwards. The extended index finger fist.
The extended index finger points downwards. Then give further hand signals.
points upwards. The hand makes small, circular
The hand makes small, circular movements.
movements.
24
Use auxiliary winch (winch 2) Raise main boom Lower main boom
Bend the right arm and hold it Stretch out the right arm hori- Stretch out the right arm hori-
upwards. zontally. zontally.
Tap the underside of the elbow Make a fist, but with the thumb Make a fist, but with the thumb
with the left hand. pointing upwards. pointing downwards.
Then give further hand signals.
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Hand signals for lifting operations in accordance with ASME/ANSI B30.5, continued
25
Move slowly Raise main boom and lower Lower main boom and lift
Give the hand signal for the load load
desired movement with one Stretch out the right arm hori- Stretch out the right arm hori-
hand. zontally. zontally.
Hold the other hand above it or The thumb points upwards. The thumb points downwards.
below it. Stretch and bend the remaining Stretch and bend the remaining
Example: Raise load slowly. fingers alternately for as long fingers alternately for as long
the load has to be lowered. the load has to be lifted
26
Rotate Stop Emergency stop

Stretch out the right or left arm Stretch out one arm horizon- Stretch out both arms
horizontally. tally. horizontally.
The palm faces down. The palm faces down. The palms face down.
The extended fingers point in Swing the arm to and fro hori- Swing both arms to and fro
the direction of rotation. zontally. horizontally.
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27
Travel Shut down and lock machine Travel with both crawler
Stretch one arm out in front of Cross your hands in front of chains
you. your body. Hold both fists in front of the
The palm faces forwards and is body.
slightly raised. Indicate travel direction with cir-
Make a movement in the travel cular motions (forwards or
direction with the open hand. backwards).
28
Travel with one Extend boom Retract boom

crawler chain (telescopic arm) (telescopic arm)
Bend the arm with the fist Hold both fists in front of the Hold both fists in front of the
LRB255_V001 (mf) LWN - TD4/2/2010
raised on the side of the crawl- body. body.

er chain that has stopped. The thumbs point outwards. The thumbs point toward each
Bend the other arm in front of other.
the body.
Indicate the travel direction via
circular movements with the fist
(forwards or backwards).
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29
Extend boom Retract boom

(telescopic arm) (telescopic arm)
One-handed signal: One-handed signal:
Hold one fist in front of your Hold one fist in front of your
chest. chest.
Your thumb points to your Your thumb points outwards.
chest.
Special hand signals for lifting operations

These hand signals are not assigned to any specific standard and supplement the hand signals
described.
30
Special hand signals
Lift load slowly Lower load slowly Lift main boom slowly
Bend the right arm and hold it Hold the right arm down. Bend the right arm.
upwards. The extended index finger The thumb points upwards.
The extended index finger points downwards. Hold the left hand above it.
points upwards. The hand makes small, circular
The right hand makes small, movements.
circular movements. Hold the left hand below it. The
Stretch out the left hand and palm faces upwards.
hold it over the right hand.
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Special hand signals for lifting operations, continued
31
Lower main boom slowly Lift main boom and hold load Lower main boom and hold
Bend the right arm. Bend the right arm. load
The thumb points downwards. The thumb points upwards. Bend the right arm.
Hold the left hand below it. The The left hand makes a fist un- The thumb points downwards.
back of the hand faces upward. der the right hand. The left hand makes a fist un-
der the right hand.
32
Raise main boom and lower Lower main boom and lift Swing superstructure to the
load load right
Bend the right arm. Bend the right arm. Bend the left arm and hold it
The thumb points upwards. The thumb points downwards. up.
LRB255_V001 (mf) LWN - TD4/2/2010
Bend the left arm. Bend the left arm. The thumb points outwards in
The index finger points down- The index finger points up- the direction of rotation.
wards. wards. Stretch out the right arm down-
Hold the left hand under the Hold the left hand under the wards.
right hand and rotate. right hand and rotate. The index finger points down-
wards.
The hand makes small, circular
movements.
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Special hand signals for lifting operations, continued
33
Swing superstructure to the Open grapple Close grapple

left Stretch out the right arm hori- Stretch out the right arm hori-
Bend right arm and it hold up. zontally. zontally.
The thumb points outwards in Hold the hand downwards with Close the hand into a fist.
the direction of rotation. fingers half-open.
Stretch out the left arm down-
wards.
The index finger points down-
wards.
The hand makes small, circular
movements.
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NOTES:
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4. CONTROL AND OPERATING ELEMENTS
4. CONTROL AND OPERATING ELE-

MENTS
4.1 General
The control and operating elements are described in this chapter. They are arranged on the
uppercarriage, undercarriage and operator's cab according to their respective functions.
All further information concerning important devices for safe operation are described in chapter 3,
Safety and safety and monitoring devices.
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4.2 Operating elements on the undercarriage

1
Undercarriage from the front, LRB 255
1 Control lever track adjustment cylinder
The operating elements on the undercarriage are required exclusively for assembly and disassembly
of the machine. See chapter 6 "Assembly and disassembly".
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4.3 Operating elements on the uppercarriage

2
Uppercarriage from the front, LRB 255
1 Ball valve for free-fall authorisation * Chapter 5 "Free-fall operation"

2 Control panel fuel-filling pump * Kapitel 9 "Fuel-filling pump"
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4.4 Cab
4.4.1 Cab overview
Overview of cab Figure 4-01
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Names of 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 grille on the cab
Details:
Cab platform:
The cab platforms (Figure 4-01, item 9, 12) can be removed for transporting the machine.
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!
A door catch is available as an option. The door is automatically secured in the fully open position.
Pushing the lever (top left) forwards releases the locking device, allowing the door to be closed.
Cab window:
The front window in the cab can be tilted.
Push the two knobs (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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4.4.2 Overview of the control stand
Overview of control stand Figure 4-02
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Names of components in Figure 4-02:

1 Left control panel (X12) 16 Hooter
2 Mode selector switch * 17 Handwheel for constant tension winch 1
and 2 / drill free-fall *
3 Left control panel (X11) 18 LCD screen
4 Left joystick for slewing gear, 19 Right control panel (X23)
and drilling drive 2 (Double rotary 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 (Double rotary drilling) *
Feed winch and auxiliary winch *
7 Holding strap 22 -
8 Recirculated air/fresh air switch 23 Radio
9 Air vents 24 Additional desk (X26) *
10 Hand lever for left and 25 Additional desk (X25)
right travel gear
11 Brake pedal for free-fall brake* of the Kelly 26 PDE monitor *
winch
12 Spirit level for inclinometer * 27 PDE control system *
13 Pedal for left travel gear 28 Printer *
14 Pedal for right travel gear 29 Washer fluid container
15 Brake pedal for free-fall brake * of winch 1
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4.4.3 Overhead view of control stand
Overhead view of control stand Figure 4-03
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Names of the components (Figure 4-03)
1 Spirit level for inclinometer 14 -

2 Brake pedal for free-fall brake* of the Kelly 15 Radio
winch
3 Pedal for left travel gear 16 Windshield wash container, front wind-
shield
4 Air vent 17 Storage compartment
5 Hand lever for left and right travel gear 18 Drink holder
6 Pedal for right travel gear 19 Windshield wash container, roof window
7 LCD screen 20 Left control panel (X12)
8 Right control panel (X23) 21 Mode selector switch *
9 Right joystick 22 Left control panel (X11)
10 Ignition starter switch 23 Safety lever for Litronic control system
11 Emergency shut-down switch 24 Left joystick
12 Cigarette lighter 25 Holding strap
13 Ashtray
not shown: Hooter

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• All important operational controls are mounted in the control stand. Space is available for extra
equipment with additional operational controls or control desks.
• All the necessary settings on the LCD display (Figure 4-02, item 18) are made using function keys
F1 - F8.
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 desk (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 desk (X25) (Figure 4-02, item. 24).
• The additional desk (X26) * is used to control accessory units.
• The left control panel (X12) is used for selecting particular operating modes.
• The optional selector switches (Figure 4-02, item 2) are provided for additional functions.
• The EMERGENCY SHUT-DOWN button (Figure 4-03, item 11) 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.
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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3
4.5 Switch levers, pedals, handwheel
Left switch lever (Fig. 3)
The left switch lever is used to adjust:
- the swing gear,
- the Kelly winch * and
- drilling drive 2 (double rotary drilling) *
The key buttons on the left switch lever have the follow-
ing functions:
1-
2 Automatic parallel displacement
forward/back or
turning the leader left/right
3 Inclining the leader forward/back or left/right
4 Swing gear free swing
5 Lead height adjustment or leader foot cylinder *
6 Auger cleaner */relative displacement cylinder */
Sheet pile feeder *
Reset cable length kelly winch
7 Vibrator button
8 Drill free-fall *, chisel control *,
Mooring (assembly/dismantling) *
9 Automatic vertical device
4
Right switch lever (Fig. 4)
The right switch lever is used to adjust:
- the drilling drive (Kelly and CFA drilling) *,
- drilling drive 1 (double rotary drilling) * and
- the feed winch and auxiliary winch *
The key buttons on the right switch lever have the
following functions:
1 Diesel engine speed adjustment /
eccentric adjustment
2 Storing movements:
feed and drilling drive(s)
3 Torque change-over (drilling drive 1) */
retract upper pin/
closing the clamping tongs *
4 Drilling drive - auxiliary winch change-over * /
LRB255_V001 (mf) LWN - TD4/2/2010
diesel engine speed -

eccentric adjustment change-over
5 Torque change-over (drilling drive 2) /
retract lower pin/
starting the vibrator or the hammer *
Rock gear (Kellydrilling)
6 Fast feed speed/vibrating drilling drive *
7 Vibrator button
8 double rotary drilling: drilling drive 2 (pipe) opposed
when operating drilling drive 1 *
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5
Pedal arrangement, handwheel *
The pedals in the driver's cab have the following func-
tions:
1 Brake pedal for the Kelly winch free-fall brake *
2 Left travelling gear
3 Right travelling gear
4 Accelerator *
5 Brake pedal for the winch 1 free-fall brake *
6 Handwheel for drill free-fall * / Constant tension *
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4.6 Left control panel (X11)
Front windshield wiper
Upper windshield wiper
Control panel left Figure 4-04

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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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4.7 Left-hand control panel (X12)
Left-hand control panel (X12) fig. 4-05
NOTE !
The keys of control panel (X12) remain active as long as the indicator lamp below the key is lit.
Pre-selection key "Assembly operation"

Assembly operation is designated exclusively for assembly, disassembly and
conversion of the machine. Assembly operation is activated via actuation of this
pre-selection key.
Pre-selection key "Free-fall unsecured" *

Unsecured free-fall is activated for winch 2.
LRB255_V001 (mf) LWN - TD4/2/2010
Pre-selection key "Authorization of LMB-bridging" *

Authorization of LMB-bridging is resulted via pressing of this pre-selection switch.
Bridging of the LMB" itself is then resulted on the right-hand control panel (X23).
Only with optional boom operation.
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Key "Line pull limitation winch 2" *

For limitation of the line pull of winch 2 down to 10 t.
See chapter 5 under "Notes on operation".
Key "Extending overtopping guard strut cylinders "

Not used with this machine.
Key " Retracting overtopping guard strut cylinders "

Not used with this machine.
Key "Preselect operating mode"

Preselects the operating mode.
NOTE !
As an option, further keys can be installed.
DANGER !
With all operation types which are activated via a pre-selection key,
- the safety function is inactive or only available limited,
- risk of fatal accident or dangerous situations and serious damage to the machine possible.
The respective safety guidelines apply to the operation type!
Countermeasures:
The machine operator must familiarize himself with the utilization possibilities, special features and
dangers of these operation types.
The cover for the control panel can be locked. Misuse can thus be prevented.
As soon as a special operation type is no longer needed, the corresponding pre-selection key should
be switched off immediately.
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4.8 Right-hand control panel (X23)
2
LRB255_V001 (mf) LWN - TD4/2/2010
Right-hand control panel (X23) fig. 4-06
Description of keys
All pre-selection and function keys on the right-hand control panel are equipped
with a light emitting diode (LED), ensuring ideal optical display of the activated
function or respective pre-selection.
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Pre-selection key "Free-fall * On / Off"

For pre-selection of free-fall operation * for winch 1 and 2.
(Winches 1 and 2 must be free-fall winches.)
Pre-selection key "Unlimited swing On / Off"

With these pre-selection keys the swing gear free-swing is pre-selected. The
display is resulted on the LCD display screen.
(see chapter 5 under "Swing gear free-swing")
Pre-selection key "Swing speed "

For pre-selection of three different speeds for the swing. The pre-selected level is
displayed with the affiliated symbol on the LCD-display screen.
Pre-selection key "Cylinder adjustment functions On / Off"

For authorisation of the cylinder adjustment functions. The cylinder required can
be subsequently controlled via the affiliated key or lever.
Pre-select key "shunt LMB" *

For short term shunting of the load moment limiter (LMB) * during lifting opera-
tion. Shunting may only be used to move the machine out of the danger zone
and place the load on the ground.
Shunting is possible during the following two operating conditions:

Possibility "1"
- Switch on the pre-select key "release LMB-shunting"
to the left on the control desk (X12).
- Press key "shunt LMB" to the right on the control desk (X23);
the LMB is permanently shunted.
Possibility "2"
- The pre-select key "release LMB-shunting"
to the left on the control desk (X12) is not switched on .
- Press key "shunt LMB" to the right on the control desk (X23);
The main boom adjusting hoist is shunted in lifting (or lowering) direction
as long as the key is pressed.
Only the stop in the selected direction is overridden.
Only when working with the optional boom application.
Pre-selection key "Bridging limit switch"

Assembly operation:
certain limit switches for assembling or disassembling of the machine are
bridged permanently
Leader operation:
the limit switches are bridged as long as the pre-selection key is pressed
Key "Casing oscillator On / Off " *

This key allows to switch-on the casing oscillator *. The indications on the LCD-
screen are modified correspondingly.
(see chapter 5 under "Casing oscillator")
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Key "Auxiliary winch on / off" *

For switching the auxiliary winch on and off.
Key "Tugger winch on / off" *

For switching the tugger winch on and off.
Key "Constant tension winch on / off" *

For switching the constant tension winch on and off.
Key "Reinforcing vibrator on / off" *

For switching the reinforcing vibrator on and off.
Key "Vibrator or Hammer On / Off"

For switching the vibrator or hammer on and off.
Key "Close clamping tongs"

For closing of the clamping tongs or for activation of the clamping tongs auto-
matic.
Key "Open clamping tongs"

For opening of the clamping tongs.
Key "Winch synchronization"

For switching the winch synchronization on and off.
Key "Extend eccentric / hoist cylinder"

For extending the eccentric or hoist cylinder.
Key "Retract eccentric / hoist cylinder "

For retracting the eccentric or hoist cylinder.
Pre-selection key "Speed level boom adjustment "

To enter three different speed levels for boom adjustment. The pre- selected
speed level always applies for the luffing of all booms and is displayed in the
LRB255_V001 (mf) LWN - TD4/2/2010
"Display field-hoist" of the LCD-display screen (1, 2 or 3).

Only when working with the optional boom application
Pre-selection key "Constant gas programming"

This key button is used to store or delete the current speed of the diesel engine.
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Potentiometer
Both potentiometers on the right hand control panel can be used for different adjustments, depending
on the options installed in the machine. Each of the two potentiometers have been allocated two
different functions. Allocation of the function is indicated via the respective LED in the pre-selection
display.
The potentiometer is adjusted in a clockwise direction from minimum to maximum value. Two turns
are possible. It can be fixed in the desired position via the small lever.
Potentiometer 1
Pre-selection display "Flow rate auxiliary hydraulics" *

For adjustment of the flow rate for the casing oscillator, vibrator and hammer.
Pre-selection display ""Grab slow-down height"

For adjusting of the grab slow-down height.
Potentiometer 2
Pre-selection display "Output regulation casing oscillator"

For output regulation of the casing oscillator and for adjusting the eccentric of the
vibrator *.
Pre-selection display "Slack rope cut out"

For adjustment of the threshold switch of the slack rope cut out.
NOTE !
Adjustment of the potentiometer always applies to the activated pre-selection.
(LED in the pre-selection display lights up.)
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4.9 Auxiliary panel (X25)

6
Auxiliary panel (X25), LRB 255
All keys and pre-selection keys on the auxiliary panel feature a light emitting
diode (LED) which
- optically displays the pre-selection or activated function,
- flashes in the direction keys if a cylinder is selected via a switch lever
(directional display).
Potentiometer
The four potentiometers on the auxiliary panel can be used for different adjustments, depending on
the options installed in the machine. Each of the four potentiometers can thus be allocated two
different functions. The actual function allocation is displayed via the LED of the pre-selection
LRB255_V001 (mf) LWN - TD4/2/2010
display.
The potentiometer is set from minimum to maximum value in a clockwise direction.
Principle of the cylinder adjustment

The cylinder adjustment functions are pre-selected on the auxiliary panel and then actuated via the
respective direction key (T1, T9, T19 and T27).
The LEDs in the respective direction keys only light up if a cylinder adjustment function has been
pre-selected and authorised.
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Potentiometer 1
Pre-selection display "Contact pressure control feed" *

For adjustment of contact pressure for pressure control of the feed.
See chapter 5 under "Actuate feed".
Pre-selection display "Function 2"

This function is currently not allocated.
Potentiometer 2
Pre-selection display "Feed speed"

For adjustment of the feed speed.
See chapter 5 under "Actuate feed".

Potentiometer 3
Pre-selection display "Automatic control" *

The automatic control is an option and customized.

Potentiometer 4
Pre-selection display "Speed drilling drive"

For adjustment of the drilling drive speed.
See chapter 5 under "Drilling operation".

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Description of keys
Key "lift/right"
The pre-selected cylinder can be actuated in the "lift" or "right" directions (if the
LED is lit).
Key "lower/left"
The pre-selected cylinder can be actuated in the "lower" or "left" directions (if the
LED is lit).
Key "lift/open"
The pre-selected cylinder can be actuated in the "lift" or "open" directions (if the
LED is lit).
Key "lower/close"
The pre-selected cylinder can be actuated in the "lower" or "close" directions (if
the LED is lit).
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Pre-selection key "Leader height adjustment"

For pre-selection of the leader height adjustment cylinder (Z5).
Pre-selection key "Leader lateral inclination"

For pre-selection of the leader lateral inclination cylinder (Z6).
Pre-selection key "Basic arm adjustment"

For pre-selection of the basic arm-adjusting cylinder (Z4).
Key T5 "Retract upper pin"

The upper pinning cylinder (Z11) is retracted and the pin of the leader height
adjustment carriage is retracted.
Pre-selection key "Leader support" *

For pre-selection of the optional leader foot cylinder.
Pre-selection key "Support arm brace adjustment"

For pre-selection of the support arm brace-support cylinder (Z2).
Pre-selection key "Proportional shifting/Pile threading device" *

For pre-selection of the proportional shifting cylinders or the pile threading device
(see chapter 5 "Double rotary drilling").
Pre-selection key "Auxiliary jib adjustment" *

For pre-selection of the auxiliary jib-adjusting cylinder (Z17).
Pre-selection key "Rotate leader"

For pre-selection of the leader-rotary cylinder (Z3).
Key T14 "Retract lower pin"

The lower pinning cylinder (Z12) is retracted and the pin of the leader locking
carriage is retracted.
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Pre-selection key "Pile guide" *

For pre-selection of the pile guide (see chapter 9 under "Pile/pipe guide").
Pre-selection key "Lifting frame" *

For pre-selection of the lifting frame.
"Superstructure support" preselect key *

For selecting the superstructure support cylinders.
Pre-selection key "Auxiliary winch" *

For pre-selection of the optional auxiliary winch (see chapter 5 "Auxiliary winch").
Pre-selection key "Drilling feed" *

For switching the drilling feed on and off (see chapter 5 "Drilling operation)".
Pre-selection key "Pressure control/Mooring"

For switching the pressure control on and off (see chapter 5 "Feed system").
Pre-selection key "Parallel operation winch 2" *

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

For preselection of the automatic control. The automatic control is customized
(eg.: Pull automatic).
"Drilling free-wheel on / off" * button

LRB255_V001 (mf) LWN - TD4/2/2010
For switching the drilling free-wheel on and off (kelly drilling).
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4.10 Auxiliary panel (X26) *

7
Auxiliary panel (X26) *
The auxiliary panel(X26) * is used for controlling the 4-time press (Push&Pull variant X26).
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All keys and pre-selection keys on the auxiliary panel feature a light emitting
diode (LED) which
- optically displays the pre-selection or activated function,
- flashes in the direction keys if a cylinder is selected via a switch lever
(directional display).
Potentiometer
The four potentiometers on the auxiliary panel can be used for different adjustments, depending on
the options installed in the machine. Each of the four potentiometers can thus be allocated two
different functions. The actual function allocation is displayed via the LED of the pre-selection
display.
The potentiometer is set from minimum to maximum value in a clockwise direction.
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Potentiometer 1
Pre-selection display "Speed cylinder rams"

For adjustment of the speed of the cylinder rams.
See chapter 5 under "Push&Pull, Variant X26".

Potentiometer 2
Pre-selection display "Funktion 1"


Potentiometer 3


Potentiometer 4


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Description of keys
Key "Retract cylinder ram 4"

For retracting of cylinder ram 4.



Key "Retract all cylinder rams"

For retracting of all cylinder rams.
Key "Open clamping tong 4"

For opening of the clamping tong 4.


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Key "Extend cylinder ram 4"

For extending of cylinder ram 4.



Key "Extend all cylinder rams"

For extending of all cylinder rams.
Key "Close clamping tong 4"

For closing of the clamping tong 4 or for activation of the clamping tong
automatic.

automatic.

automatic.

automatic.
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Pre-selection key "Push&Pull automatic"

For switching the Push&Pull automatic on and off.
Pre-selection key "Program 1"

For preselection of the first program.
The cylinder rams are activated as follows: 4_1_3_2

For preselection of the second program.
The cylinder rams are activated as follows: 1_4_2_3

For preselection of the third program.
The cylinder rams are activated as follows: 4+3_2+1

For preselection of the fourth program.

For preselection of the fifth program.
Key "Close clamping tongs"

For closing of all clamping tongs or for activation of the clamping tong automatic.
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4.11 Overview LCD-display screen

NOTE !
The values on the following pages are not binding for the machine and are only included for
explanatory purposes!
4.11.1 Display screen-prime data area

The LCD-display screen of the Litronic-control is subdivided into four prime data areas. These prime
data areas are generally valid, if not specially noted, for all display screen pages.
Overview LCD-display screen
1 Status displays 2 Check displays

3 Function key symbols 4 Function keys F1 - F8 *, light diodes
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4.11.2 Description of display screen prime data areas

Status displays (fig. 8, no. 1)
The different status displays appear in the upper part of the LCD-display screen as symbols. A
maximum 8 symbols can be displayed on the screen simultaneously.
The status displays show
- actual pre-selections,
- type of operation,
- speed level,
- triggered limit switch.
The status displays

- will not be shown on the start-up screen, in the set-up screens or on the "Error display" page,
- are represented on all other display screen pages with the same symbols.
Example of a status display:
Display "Swing speed"

Displays pre-selected speed level 1 for the swing.
Check displays (fig. 8, no. 2)
All actual check displays required are portrayed in the middle area of the LCD-display screen (e.g.
operation screen, engine and filter monitoring, set-up stage, error text, etc.).
Example of a check display:
Display "Cable length winch 1" *

Displays the actual cable length of winch 1 in m [ft] ,the reeving of the load hook
and rotation direction of the winch.
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Function key symbols (fig. 8, no. 3)
The affiliated symbols for the function keys are portrayed in the lower area of the LCD-display screen
F1 - F8 .
The function key symbols
- can change depending on the display screen page,
- have been allocated several certain function keys.
Example of a function key symbol:
Symbol "Components page"

Pressing function key F2 will switch over to the page for "Component monitoring".
There are two variants of the LCD screen possible. The function is the same on both variants,
operation slightly varies.
Variant 1: Screen with function keys * (item 1)

The function keys F1 - F8
- are located on underneath the LCD display,
- are defined by the associated function key symbols,
- can have different functions assigned depending on the
screen page.
Variant 2: Screen with integrated control panel * (item 1)

Alternativ is a screen without function keys (F1 - F8) installed
(see machine license). Operation is done by touching the
function key symbols positioned directly at the lower margin of
the LCD display.
Changing values on the LCD screen

To maintain the surface don't use sharp pointed items like
pens or pencils. The surface is treated most carefully when
using the finger to touch the function symbols to change
values or pages.
The two LEDs (Figure 8, item 5) next to function key F8 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 Order of display screen pages

The Litronic-control provides the machine operator with various display screen pages for operation of
the machine:
Start-up screen
The start-up screen
- appears on the LCD-display screen upon switching on the
ignition,
- disappears, as soon as the Litronic-control is ready for
operation,
- is replaced by the actual set-up stage screen.
Set-up stage screen *

The set-up stage screen
- is displayed following the set-up screen, if no error reports
have been submitted,
- displays the valid set-up stage of the machine,
- serves programming of the set-up stage.
After programming or confirmation of the set-up stage, page
"Operation screen " can be displayed.
If the optional load moment limitation is not available the
set-up screen is not displayed. The operation screen will show
up.
Page "Operation screen" Boom *

The operation screen
- is the standard display during lifting operation,
- provides the machine operator with all essential information.
Aside from the operation screen, further display screen pages
can be called up by pressing the corresponding function key.
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Page "Operation screen" Leader

The operation screen
- is the standard display during piling and drilling application,
- 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,
- Double rotary drilling field,
- Vibrator field,
- Push&Pull field,
- Hammer field,
- Soil mixing field.
Other displays can be called from within the mode screen by

pressing the corresponding function key.
Page "Preselect operating mode"

This display screen page is for preselecting the operating
mode.
Page "Component monitoring"

This display screen page contains all important data of the
main components.
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Page "Error displays"

This display screen page
- shows error reports as error text in the respective language,
- can consist of several error pages.
Page "Adjustments"
This display screen page serves for entering the necessary
values depending on the operating mode.
Page "Load chart" *

This display screen page shows the valid load chart for the
programmed set -up stage.
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4.12 Page "Operation diagram" Leader

9
Page "Operation diagram" Leader
The operation diagram contains important displays and information for the pre-selected operation
type. It is displayed only when the auxiliary panel (X25) is plugged in.
Description of status displays
Symbol " Freefall-winch 1" *

Shows that the winch 1 is currently in free-fall.
Symbol "Freefall-winch 2" *

Shows that the kelly winch (winch 2) is currently in free-fall (drilling free-fall) (see
chapter 5 "Actuating kelly winch").
Symbol "Kelly winch mooring" *

Indicates that mooring has been selected (see Chapter 5 "Mooring for assembly
and dismantling").
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Symbol "Unsecured free-fall operation" *

Indicates that unsecured free-fall operation * has been pre-selected.
Symbol " Secured free-fall operation" *

Indicates that secured free-fall operation * has been pre- selected.
Symbol "Assembly operation"

Displays the assembly operation has been switched on.
"Movement stored" symbol

The movement of the feed and/or the drilling drive(s) is stored.
Symbol "Fuel level"

This display flashes if the fuel level drops below approx. 15% (reserve display).
Symbol "Hydraulic oil temperature too low" *

See chapter 9 "Cold weather kit".
Symbol "Eccentric" *
The eccentric is preselected and can be adjusted via the rocker switch on the
right-hand switch lever. See chapter 5 "Vibrator".
Display "Swing speed"

Displays the adjusted speed level for the swing (1, 2 or 3).
The speed level desired for the swing is adjusted via a pre-selection switch on
the right-hand control panel.
Symbol "Display "Free swing"

Indicates that free swing has been activated. The number in the limit switch
symbol displays the adjusted speed level.
The speed level desired for the swing is adjusted via a pre-selection switch on
the right-hand control panel.
Symbol "Drive limited"

This symbol flashes in the status display if several limit switches respond
simultaneously and at the same time a directional movement is actuated which
has been blocked by a triggered limit switch.
LRB255_V001 (mf) LWN - TD4/2/2010
If only one limit switch responds and is blocked directional movement is actuated, the corresponding
limit switch symbol flashes in the status display in place of the previous symbol, "Drive limited".
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The following limit switch symbols can be displayed:
Symbol "Upper limit switch auxiliary winch"

The hoist limit switch for the auxiliary winch has been activated.
The lifting direction of the auxiliary winch and adjustment of the auxiliary jib is
blocked.
Symbol "Lower limit switch auxiliary winch"

The 3-coil-limit switch on the auxiliary winch has been activated.
The lowering direction of the auxiliary winch is blocked.
Symbol "Upper limit switch kelly winch"

The hoist limit switch for the kelly winch has been activated.
The lifting direction of the kelly winch, forward inclination of the leader and
extending the leader height adjusting cylinders (lift leader) are blocked.
Symbol "Lower limit switch kelly winch"

The 3-coil-limit switch on the kelly winch has been activated.
The lowering direction of the kelly winch is blocked.
Symbol "Lower limit switch leader height adjustment"

The lower limit switch for the leader height adjustment has been activated.
Retracting of the leader height adjusting cylinder is blocked.
Symbol "Upper limit switch feed" *

The upper limit switch for the universal carriage has been activated.
The lifting direction of the feed winch is blocked.
Symbol "Lower limit switch feed"

The lower limit switch for the universal carriage has been activated.
The lowering direction of the feed winch is blocked.
Symbol "Limit switch leader zero position"

The leader is not positioned vertically in its zero position (+/- 1°).
The leader rotary cylinder is blocked.
Symbol "Parallel operation"

The parallel operation is pre-selected on the auxiliary panel (X25) .
The universal carriage (hoisting/lowering) and the leader adjustment are blocked.
"Bolts withdrawn" symbol *

Double rotary drilling drive: the auger and the pipe are not bolted together.
The drilling drive is stopped in CFA drilling.
"Leader outreach limit switch" symbol

The limit switch for maximum outreach has been activated.
Extending of the basic arm-adjusting cylinder has been blocked.
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Description of check displays
Display field-kelly drilling
The display field-kelly drilling is overlayed on the LCD-display screen if kelly drilling has been
pre-selected.
Elements in the display field-kelly drilling
Inclination display (as seen from the top of the leader)

-0.3° . . . . . . . . . . . . . . . . . . . . . Inclination in X-direction (to the left)
0.1° . . . . . . . . . . . . . . . . . . . . Inclination in Y-direction (to the front)
+ . . . . . . . . . . . . . . . . . . Actual value, actual position of the leader
. . . . . . . . . . . . . . . . . . . . . . Reference value, set reference value
for the leader inclination
Operating pressure leader pump

For analogous display of the operating pressures for the leader
pump (cylinder, feed winch, etc.)
11.5 m Cable length measurement kelly winch

The cable length measurement
- shows position and directional movement (+/-) of the kelly rod
(e.g.: 11.5 m),
- serves the determination of differences in height,
- shows the depth with a " - " before the number,
- can be reset to zero via the corresponding function key,
- should be set to zero immediately beforehand, enabling a precise
measurement.
LRB255_V001 (mf) LWN - TD4/2/2010
9.85 m/min Rope speed Kelly winch

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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Operating pressure drilling drive

Shows the operating pressure of the drilling drive in analogous
form.
Torque drilling drive*

Shows the torque of the drilling drive in analogous form.
24.5 Speed drilling drive

Shows the speed of the drilling drive (e.g.:24.5) in rpm.
Small torque
The small torque (high-speed) of the drilling drive is pre-selected via
the corresponding key on the switch lever.
Pins retracted
The upper or lower pin has been retracted. The corresponding key
has been actuated. The condition of the pinning is determined via
limit switches.
Pins inserted
The upper or lower pin is inserted. The condition of the pinning is
determined via limit switches.
NOTE !
If the symbol (the pin) starts flashing, condition of the pinning has not been defined. The pin is
neither retracted nor correctly inserted.
CAUTION !
Secure locking of the upper and lower pins should always be checked by the machine
operator (visual inspection!).
The displays on the LCD-display screen are not sufficient.
Drilling flight auger

Shows the groove spacing of the drilling flight auger as analogue,
provided that the rope length measurement has been set to zero at
the beginning of the pile.
When the drilling flight auger is full, the symbol flashes.
Kelly winch load capacity display *

Shows the current load on the Kelly winch in both analog and digital
form (e.g. 72) in kN [lbs.].
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Feed display
Shows the crowd force as analogue.
- Pulling:
the bar "in the leader symbol" rises from the bottom up.
- Pressurizing:
the bar "in the leader symbol" rises from the top down.
Shows the crowd force digitally (e.g.: 127) in kN [lbs].
Feed slow gear

Slow gear for the feed has been pre-selected.
Feed fast gear

Fast gear of the feed is pre-selected via the corresponding key on
the right-hand switch lever.
15.3 m Cable length measurement feed

The cable length measurement
- shows the position and directional movement (+/-) of the
universal carriage (e.g.: 15.3 m),
- serves to determine differences in height,
- can be reset to zero at any time via the corresponding function
key,
- should be set to zero immediately beforehand, enabling a precise
measurement.
Speed diesel engine

Shows the actual speed of the diesel engine in rpm .
With too high a speed, the bar in the display starts flashing.
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Display field-kelly drilling with casing oscillator
The display field-kelly drilling is overlayed on the LCD-display screen if,

- kelly drilling and
- the casing oscillator
are pre-selected on the right-hand control panel (X23).
Operating pressure casing oscillator

Shows the operating pressure of the casing oscillator as analogue.
Drilling free-wheel
Drilling free-wheel has been switched on.
Rock gear
Rock gear has been switched on.
NOTE !
The other elements have already been described in the display field-kelly drilling.
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Display field CFA drilling
The display field CFA drilling is overlayed on the LCD-display screen if CFA drilling has been
pre-selected.
Elements in the display field CFA drilling
Display Concrete pressure *

Shows the concrete pressure as analogue if the optional concrete
pressure sensor is connected.
The display can be scaled as 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 crowd winch was being used
(e.g.: auger was extended)
Over quantity concrete measuring *

Shows the calculated over quantity during concrete operation in
percent.
NOTE !
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The other elements have already been described in the display field-kelly drilling.
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Display field double rotary drilling
The display field double rotary drilling is overlayed on the LCD-display screen if double rotary drilling
has been pre-selected.
Elements in the display field double rotary drilling
Operating pressure drilling drive 1

Shows the operating pressure of drilling drive 1 as analogue.
24.5 Speed drilling drive 1

Shows the speed of the drilling drives (e.g.: 24.5) in rpm if the
optional speed sensor is connected.
Operating pressure drilling drive 2

Shows the operating pressure of drilling drive 2 as analogue.
17.3 Speed drilling drive 2

Shows the speed of the drilling drives (e.g.: 17.3) in rpm if the
optional speed sensor is connected.
NOTE !
The other elements have already been described in the display field-kelly drilling or CFA drilling.
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Soil Mixing display field
The soil mixing field appears on the LCD screen if soil mixing operation is selected.
The display field depends on the number of drilling drives.
Elements of the soil mixing display field
Flow quantity suspension

Shows the flow quantity of the suspension in l/m [gpm].
Suspension quantity
Shows the total suspension quantity in m³ [yd³].
Drilling drives working pressure

Shows the working pressures of the three drilling drives.
NOTE!
The other elements are already described in the CFA drilling field.
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Display field-vibrator
The display field-vibrator is overlayed on the LCD-display screen if vibrator operation has been
pre-selected.
Elements in the display field-vibrator
Operating pressure vibrator

Shows the operating pressure of the vibrators as analogue.
Vibrator frequency and amplitude

Shows the frequency of the vibrator (e.g.: 33.5) in Hz.
Shows the amplitude of the vibrator (e.g.: 10.6) in mm [in].
If the optional sensor is connected.
Clamping tongs
This symbol flashes upon closing of the clamping tongs (manually
or via the clamping tongs automatic) until the clamping tongs are
completely closed.
Operating pressure clamping tongs

Shows the operating pressure of the clamping tongs or the actual
pressure as analogue.
NOTE !
The other elements have already been described in the display field-kelly drilling or CFA drilling
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Display field-Push&Pull
The display field Push&Pull is overlayed on the LCD-display screen if Push&Pull operation is
pre-selected.
Elements in the display field-Push&Pull
Cylinder ram 1
Cylinder ram 2
Cylinder ram 3
Cylinder ram 4
The following applies for all cylinder rams:
Cylinder ram selected

The border of the symbol appears in bold.
Cylinder ram retracted

The arrow in the symbol flashes during retraction..
Cylinder ram extended

The arrow in the symbol flashes during extension.
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Clamping tongs open
Clamping tongs closed
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Cylinder ram working pressure

Shows the working pressure of the relevant cylinder ram in analog
form.
Symbol "Attention"
Advance warning "torque getting too high"
Symbol "Stop"
The maximum allowed torque is reached.
NOTE !
Further elements have already been described in the display field Kelly drilling or vibrator.
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Display field-hammer
The display field-hammer is overlayed on the LCD-display screen if hammer operation has been
pre-selected.
Elements in the display field-hammer
Operating pressure hammer

Shows the operating pressure of the hammers as analogue.
Number and force of impacts

Indicates the number of impacts for the hammer (e.g.: 20) in 1/min.
Indicates the force of impact (e.g.: 25) in kNm [ft.lbs].
Hammer impact force

Indicates the force of hammer impact analogous.
NOTE !
The other elements have already been described in the display field-kelly drilling or CFA drilling
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Description of function key symbols
Some function keys have several function key symbols allocated to them and display is dependent
on operation. The following function key symbols appear initially as standard when calling up the
operation diagram.
Symbol "Preselect operating mode"

Upon actuation of function key F1 , page "Preselect operating mode" is switched
over to.
Symbol "Aggregate monitoring"

Upon actuation of function key F2 , page "Aggregate monitoring" is switched over
to.
Should an error report occur on the aggregate page, this symbol flashes and a
warning buzzer sounds.
Symbol "Error displays"

Upon actuation of function key F3 , page "Error displays" is switched over to.
Should an error report occur, this symbol flashes and a warning buzzer sounds.
Symbol "Adjustments"
Upon actuation of function key F6 , page "Adjustments" is switched over to.
This symbol is displayed only in assembling operation.
Symbol "Switch-over function keys"

Some function keys have several function key symbols allocated to them and are
displayed dependent on operation. Upon actuation of function key F7 these
function key symbols are overlayed. The function keys apply respectively for the
overlayed function key symbols.
Symbol "Acknowledging warning buzzer"

Upon actuation of function key F8 , the warning buzzer is switched off.
The warning buzzer sounds with every error report.
NOTE !
Upon actuation of this function key, no error acknowledgement or error remedying is resulted!
Symbol "Reset feed"

Upon actuation of function key F6 , the display "Cable length feed" is reset to "0".
Symbol "Reset kelly winch"

Upon actuation of function key F4 , the display "Cable length kelly winch" is reset
to "0".
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The following function key symbols only appear upon actuation of function key F7.
Symbol "Reference value leader inclination"

Upon actuation of function key F4 , this symbol "Reference value Leader inclina-
tion" begins flashing, the actual inclination (digital and analogous) fade and the
current reference value overlayed in its place. The new reference value can be
entered via the Litronic-service panel and confirmed via "ENTER".
Symbol "Zeroing inclination display "

Following actuation of function key F3 , the digital inclination displays in the
display field start flashing. The inclination display can now be set to zero via
actuation of function key F4 "Confirm entry".
Symbol "Confirm entry".

Upon actuation of function key F4 , the digital and analogous leader inclination
display is reset to 0.
The following function key symbols only appear upon re-actuation of function key F7 .
Symbol "Layer-change kelly winch"

Upon actuation of function key F5 , the kelly winch is pre-selected for the
programming of the layer-change. The display (e.g.: 11.5) starts flashing for 3
secs..
Symbol "Set Layer-change 1 - 2"

Upon actuation of function key F1 , the layer-change of the selected winch is
programmed from the 1st to the 2nd layer (while display of the cable length
flashes).
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4.13 Page "Preselect operating mode"

10
Page "Preselect operating mode"
This page serves for preselecting the operating mode.
The status displays are described in chapter 4 under "Operation diagram".
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Description of monitoring displays
Display "Boom mode"

Tap the current display to select the "Boom mode" operating mode on the
screen.
Display "Ramming control"

Tap the current display to select the "Ramming operation" operating mode on the
screen.
Display "Vibrator operation"

Tap the current display to select the "Vibrator operation" operating mode on the
screen.
Display "Hammer operation"

Tap the current display to select the "Hammer operation" operating mode on the
screen.
Display "Grab operation"

Tap the current display to select the "Grab operation" operating mode on the
screen.
Display "CFA drilling"

Tap the current display to select the "CFA drilling" operating mode on the screen.
Display "Double rotary drilling"

Tap the current display to select the "Double rotary drilling" operating mode on
the screen.
Display "Soil mixing"

Tap the current display to select the "Soil mixing" operating mode on the screen.
Display "Kelly drilling"

Tap the current display to select the "Kelly drilling" operating mode on the screen.
Display "Push&Pull operation"

Tap the current display to select the "Push&Pull operation" operating mode on
the screen.
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NOTE!
The currently selected operating mode is surrounded by a darker frame on the display.
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Symbol "Operation diagram"

Upon actuation of function key F1 the screen switches to the page "Operation
diagram".
Symbol "Confirm entry"

Upon actuation of function key F8 the entry is accepted.
Symbol "Turn off ignition"

Upon actuation of function key F8 the current symbol is displayed on the screen.
See description of "Selecting operating modes" in Chapter 5.
NOTE !
The further function key symbols are described in chapter 4 under "Operation diagram".
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4.14 Page "Monitoring of components"

11
Page "Monitoring of components"
This display screen page gives information concerning the operating condition of all main compo-
nents.
Description of monitoring displays
Symbol "Caution"
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Symbol "Stop"
Symbol "Danger of tipping"
Symbol "Assembly operation"
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The represented four symbols of the monitoring displays

- also appear in the Display field-hoist *,
- are described in chapter 4 under "Operation diagram" boom *.
WARNING !
Ignoring an error report can lead to serious damage to the machine. The diesel engine does
not stop automatically when an error report occurs.
The machine should be switched off immediately upon the occurrence of an error report in
order that the error can be remedied.
Symbol "Splitter box temperature too high"

This symbol flashes if the gear oil temperature in the splitter box 105 °C totals.
Symbol "Coolant level too low"

This symbol flashes if the coolant level in the cooling system's equalising reser-
voir has fallen below the minimum. No precautionary shutdown occurs - the
machine operator is responsible for ensuring that the coolant is refilled.
CAUTION!
Danger of burns!
Let the engine cool down before refilling the coolant as explained in chapter 7
Symbol "Hydraulic oil level too low" 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!
Danger of burns!
Top up the hydraulic oil as explained in chapter 7.
Charge control display

Displays the actual charging stage of the batteries.
No charging of the batteries is resulted with "charging OFF", and with "charging
ON" the batteries are charged via the generator.
The actual battery voltage is displayed under the battery symbol in V .
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Symbol "Charge pressure too low"

If the charge pressure falls below 5.5 bar in more than one closed hydraulic
circuit, the depicted display flashes.
Symbol "Charge pressure winch 1 too low"

If the charge pressure falls below 5.5 bar in the hydraulic circuit of winch 1, the
depicted display flashes.
Symbol "Charge pressure winch 2 too low"

We If the charge pressure falls below 5.5 bar in the hydraulic circuit of winch 2,
the depicted display flashes.
Display field-Component
All important data of the main components are repre-

sented in the display field with symbols and bar
displays.
Symbols in the Display field-Component
Symbol "Intercooler pressure"

Displays the actual intercooler pressure of the diesel engine as
girders in bar .
Symbol "Lubricating oil pressure"

Displays the actual lubricating oil pressure of the diesel engine in
bar .
Symbol "RPM diesel engine"

Displays the actual RPM of the diesel engine in U/min [rpm] .
Symbol "Cooling water temperature"

Displays the actual cooling water temperature of the cooling system
in °C .
Symbol "Tank level"

Displays the actual level of the fuel tank in % of the maximum
filling level.
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Symbol "Hydraulic oil temperature"

Displays the actual hydraulic oil temperature in the hydraulic tank in
°C .
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NOTE !
All further monitoring displays are already described in chapter 4 under "Operation diagram".

diagram".
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.

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• 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 Page "Error displays"

12
Page " Error displays "
This page displays error reports as text in the respective language.
Example of an error report
"1/1 M0033: Dynamometer axis 1 boom signal too low or not available".
A warning buzzer sounds if an error occurs.
The first number of the error report (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 eases searching for the error.
Description of symbols in the display area
Symbol "Error report cancelled"

This symbol appears alongside the error text upon cancellation of the error
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report.
NOTE !
Before carrying out any further operation with the machine, all error reports should be cancelled and
the cause of the error(s) remedied if possible.
Cancellation of the error report alone will not remedy the cause of the error!
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Symbol "Arrow pointing up"

This symbol appears on the upper right-hand side of the LCD-display screen if
further error reports or error pages are available beforehand.
Symbol "Arrow pointing down"

This symbol appears on the lower right-hand side of the LCD-display screen if
further error reports or error pages are available afterwards.

Upon actuation of function key F1 the page "Operation diagram" is switched over
to.
Symbol "Component monitoring "

Upon actuation of function key F2 the page "Component monitoring" is switched
over to.
This symbol flashes following an error report on the aggregate page.
Symbol "An error report upwards"

Upon actuation of function key F4 , the next error report will be skipped up to.
Symbol "An error report downwards"

Upon actuation of function key F5 an error report will be skipped down to.
Symbol "One page upwards"

Upon actuation of function key F6 , one page will be browsed through upwards .
This symbol only appears if at least two error pages are available. The Litronic-
control generates a new error page, as soon as more than 5 Error reports have
occurred.
Symbol "One page downwards"

Upon actuation of function key F7 , one page will be browsed through down-
wards.
This symbol only appears if at least two error pages are available.
Symbol "Cancellation of an error report"

Upon actuation of function key F8 all error reports on the error page displayed
are cancelled.
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4.17 Page "Adjustments"

13
Page "Adjustments"
This display screen page serves

- for entering the necessary values depending on the operating mode,
- is displayed only in assembling operation.
Description of adjustment area
The values listed in this area

- can be adjusted by the operator,
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- depend on the selected operating mode,

- have a command in the the respective language of the user *,
- have to be entered according to the adjusted units (SI or US).
NOTE!
The permitted limits may not be exceeded. Take note of the information provided by the manufac-
turer for the attachments.
The further elements are described in chapter 4 under "Operation diagram".
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diagram".
NOTE !
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14
4.18 Litronic service panel on the LCD

screen
4.18.1 Menu bar
The menu bar (Figure 14, 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,
15
- switch to the keyboard menu (Figure 15, 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 15, item 2).
Increase volume
Adjusts the volume of the warning buzzer.
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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
16
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.
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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 familiarises you with operation of the LRB 255.
The fundamental notes on operation at the beginning of the chapter have a decisive influence on
working safety and life-expectancy of the machine.
The chapter runs through the working procedure and describes the operating stages
- for a safe start-up,
- for actuation of main components, such as boom or swing gear, crawler or leader,
- for drilling, vibrator and hammer operation with detailed information,
- for a safe shutting down of the machine.
5.2 Notes on operation

The switch lever and foot pedals in the operator's cab are actuated steplessly. Precise working with
exact speed regulation is thus possible in all directions.
This includes:
• Minimum modulation of switch lever = minimum speed
• Maximum modulation of switch lever = maximum speed
Speed of the respective drive can be additionally modified when working with small loads via rpm
adjustment of the diesel engine.
The machine's winch drive and gears are equipped with multi-disc holding brakes. The multi-disc
holding brakes close automatically, as soon as the respective switch lever is put into zero position
and the drive is at a standstill.
5.2.1 Working safely with the LRB 255

The machine operator is responsible for safe operation of the piling rig and drilling machine.
When working with the LRB 255, it is especially important:
- to note and implement precisely the safety guidelines in chapter 3,
- to familiarise yourself once more with arrangement of the operating elements before start-up (see
chapter 4),
- to be able to recall information provided in this chapter and instructions from the manufacturer.
WARNING !
Operating errors can endanger peoples lives as well as seriously damage or even destroy the
machine!
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The LRB 255 features different safety devices, preventing dangerous operating conditions. These
safety devices however cannot prevent damage resulted from operating errors or grossly negligent
working procedure.
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5. OPERATION
Precautionary measures:
• Under no circumstances should the stability of the machine be compromised, note ground
pressure and ground bearing pressure.
• Begin every movement from the start position slowly and sensitively.
• Do not permit any dynamic effects, such as oscillation of the load.
• Always work with foresight and overall view: Allow plenty of time space for braking a movement.
• No loads may be lifted with the cylinders of the piling rig and drilling system.
Exception: With the optional counterweight-assembly device.
Notes on safety:
• Inspection work on the mounted leader must be carried out with sufficient safety (with catch belt
and fall protection runner).
• When working on the Pile or on the leader, set down the pile on the ground or on the pile lock.
5.2.2 Emergency-Off-switches
The Emergency-Off-switches
- are components of a safety switching,
- allow quick shutting down of the machine in a dangerous situation.
Installation positions of both standard Emergency-Off keys are represented in chapter 3 under
"Safety devices".
As soon as an Emergency-Off switch is actuated,

- the diesel engine is shut down,
- all movements are stopped immediately.
ATTENTION!
Do not use the Emergency-Off key for emergency shut-down and under no circumstances for
switching off diesel engine as part of operation!
With an emergency shut-down, the machine becomes extremely loaded in certain cases.
IMPORTANT !
Should a moved load trigger an emergency stop, the multi-disc holding brakes must then be
inspected by Liebherr service personnel.
An actuated Emergency-Off switch should be unlocked following reestablishment of operating safety

via turning.
IMPORTANT !
All Emergency-Off-switches must be unlocked, in order to restart the diesel engine.
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5. OPERATION
1
5.2.3 Actuating the safety lever
The safety lever (fig. 1, no. 1) on the left-hand control
stand
- takes all switch levers and foot pedals out of operation
(swing gear and crawler, leader functions, etc.) when in
the highest raised position,
- thus preventing undesired actuation of this operating
element.
The safety lever is
- to be lowered for operation and raised during breaks in
operation,
- arranged so that it must be raised by the operator
before he can leave the operator's cab.
CAUTION !
Raising the safety lever

- blocks functioning of the switch lever immediately,
- stops the drive only after a set integration period.
The uppercarriage can continue swinging danger-
ously until the swing gear is braked!
5.3 Inspections before start-up
CAUTION !
Never operate a damaged machine!

Report all determined deficiencies and faults to the superior responsible and have faults remedied by
specialists.
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5. OPERATION
5.3.1 Tour of inspection

A tour of inspection should be carried out before start-up of the machine, and in particular, the
following visual checks:
• Check entire machine and equipment for
- possible leaks (hydraulic, engine and gear oil, coolant, diesel fuel),
- (wilful) damage,
- missing safety elements,
- loose bolt or screw connections,
- signs of wear (ropes).
• Are there any hindrances to be found in the working area? Can the uppercarriage swing without
limitation?
• Are the safety signs legible and complete?
(See point 3.6 "Safety signs on the machine".)
5.3.2 Inspection duties

• Ensure a good, clear view from the operator's cab:
Remove snow and ice from operator's cab and uppercarriage.
Clean exterior mirrors and adjust as necessary.
• Check as to whether the operating instructions are on hand in the operator's cab.
• Check as to whether the fire extinguishers are readily retrievable and are functioning properly (lead
sealing, next inspection date).
HINWEIS!
It is to be noted with the following inspection duties:
Refilling of operating agents is described in chapter 7 "Maintenance", and any necessary safety
precautions are described in chapter 3, "Safety guidelines".
The following inspection duties have to be executed:

• Check engine oil level
• Check gear oil level
• Check the coolant level
• Check cooler, fan blade and drive engine for possible damage.
• Drain water separator and fuel filter
• Checking the hydraulic oil level
• Check the shut-off slide valve on the hydraulic tank
CAUTION !
The hydraulic system will be damaged if the diesel engine is started with the shut-off slide
valve closed (position at a right-angle to the suction pipe).
• Check the battery main switch
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5. OPERATION
5.4 Start-up 2
DANGER!
Only put the machine into operation if you have

authorisation and if you have read and understand
this operating manual!
Prerequisites:
• Sufficient battery capacity for starting the machine.
• All checks before start-up have been carried out.
• All Emergency-Off switches are unlocked.
5.4.1 Switch on ignition

Ignition is switched on via the ignition start switch (fig. 2) on the right-hand control stand.
Possible switch positions:

P Park position
0 Ignition Off
1 Ignition On
2 Start position
To switch on ignition, turn ignition start switch to position 1, "Ignition On".

The start-up screen first appears on the LCD-display screen.
The Litronic-control then carries out an automatic self-test. The procedure lasts approx. 15 - 30
seconds. Then the actual set-up stage diagram is overlayed in place of the start-up screen (with the
pre-selected operation type).
NOTE !
With a malfunction
- the operation diagram is not displayed,
- an error report of the Litronic-test system appears instead on the LCD-display screen.
NOTE !
After switching off ignition, wait for at least 5 seconds before switching back on again, otherwise
error reports may occur.
If after several attempts to switch on the ignition, the operation diagram is still not being displayed:
Inform the LIEBHERR after-sales-service responsible and notify them of the error report displayed.
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5. OPERATION
3
5.4.2 Checking the fuel level
The fuel level is displayed on the LCD-display screen
(fig. 3, no. 1) in the
- " Operation diagram "
- "Display field-aggregate" of the display screen page
"Aggregate monitoring".
As soon as the bars in the tank display (fig. 3, no. 2) or
the "Fuel level" display (1) start flashing on the operation
diagram, the tank is only filled with approx. 15 % diesel
fuel (reserve display).
In this case, the machine should be refuelled at the next
opportunity.
4
5.4.3 Refuelling the machine
IMPORTANT !
Observe the notes on safety and special instructions
under
- point 3.7.5 "Danger of fire and explosion",
- chapter 7 under "Diesel fuels".
Procedure when refuelling with fuel-filling pump
Operation of electric fuel-filling pump * is described in

chapter 9.
Procedure when refuelling from tanker
• Remove tank cover (fig. 4, no. 1).

• Inspect filling sieve (2) underneath and clean if necessary.
NOTE !
Do not remove filling sieve for refuelling.
• Refuel tank with diesel fuel of acceptable quality.
NOTE !
Refuel regularly in order to keep fuel level in the tank as high as possible. Corrosion in the tank is
thus avoided.
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5. OPERATION
5.4.4 Selecting operating mode
DANGER !
Fatally dangerous situations and severe damage to the machine can occur when operating
the machine, depending on the operating mode.
Countermeasure:
The machine operator must be familiar with the possibilities of use, special features and dangers of
the operation types.
5
Notes on operation
• Tap symbol "Preselect operating mode" (fig. 5, no.1)
The page "Preselect operating mode" (fig. 6) is dis-
played.
6
• Tap requested display e.g.: "Double rotary drilling"
(fig. 6, no.1)
The currently selected operating mode is surrounded
by a darker frame on the display.
The symbols are described in chapter 4 under "Preselect
operating mode".
7
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• Press key "Preselect operating mode" (fig. 7, no.1) on

the left-hand control panel (X12) and at the same
time tap the symbol "Confirm entry" (fig. 6, no.2) on
the screen.
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5. OPERATION
8
The symbol "Turn off ignition" (fig. 8, no.1) flashes on
the screen. All functions of the machine are locked now.
9
• Turn the ignition off, wait for a short period of time and
turn the ignition on again.
The requested operating mode is selected.
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5. OPERATION
5.4.5 Starting the diesel engine
DANGER !
Do not use any starting aids containing ether with low external temperatures - Danger of
explosion!
Suitable measures for improvement of starting with low external temperatures are described in
chapter 7 under "Diesel fuels".
Prerequisites for starting the diesel engine

• All checks before start-up have been carried out.
• Ignition is switched on.
• The Litronic-control is standing by.
• The operation diagram is shown on the LCD-display screen.
• The display "Fuel level" is not flashing, there is sufficient fuel available.
• No errors have been reported; all Emergency-Off switches are unlocked.
NOTE !
Liebherr diesel engines are equipped with a flame-start system.
Mercedes diesel engines do not have a flame-start system and can be started when the prerequi-
sites stated before are fulfilled.
After switching on ignition, the diesel engine is automatically pre-heated by the flame-start system
and made ready for operation when external temperatures are low.
The symbol "Flame-start cycle activated" appears in the status display of the
operation diagram during the pre-heating time.
Pre-heating time
- lasts correspondingly longer when external temperatures are low,
- is cancelled if the diesel engine is sufficiently heated following a break in
operation.
As soon as the diesel engine is ready to start, the symbol "Stand-by established"
appears in place of the previous symbol.
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5. OPERATION
10
The diesel engine can now be started (fig. 10):
• Turn ignition start switch to position 2 and release as
soon as diesel engine is running.
• The ignition start switch returns independently to posi-
tion 1 (ignition on).
The symbol " Stand-by established " will fade out,
when the diesel engine is running.
IMPORTANT !
Keep ignition start switch held in position 2 for a maxi-
mum 10 seconds. Then interrupt start-up and only try
anew after a break of no less than 20 seconds.
Only fully accelerate diesel engine after a short warm-up
period!
11
5.4.6 Setting the engine speed
Diesel engine speed can be adjusted steplessly from idle
up to maximum speed via the rocker switch (fig. 11 no.
1) on the right-hand switch lever:
• Actuate rocker switch to left = increase speed

• Actuate rocker switch to right = decrease speed
Automatic idle
Without actuation of a switch lever, the adjusted speed
of the diesel engine with rocker switch only remains valid
for approx. 7 seconds . Speed is then reduced to idle
speed. When a switch lever is actuated, the diesel en-
gine runs up to the previously set speed.
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5. OPERATION
Electronic load sensing

The electronic load sensing protects the diesel engine against possible overload and sudden
standstill.
If the speed of the diesel engine is reduced to below the speed currently set due to overload, the
hydraulic flow rate of the LPV pumps is adjusted back until the optimum speed of the diesel engine
is once again attained.
Constant speed
Procedure:
• Set the required speed with the rocker switch.
Use the "Constant gas programming" key button on the right control panel (X23)
to store the current speed of the diesel engine.
The LED in the key button lights up.
Press the key button again to delete the constant speed; the diesel engine then runs at idling speed.
NOTE !
The entered constant speed should be at least 1400 rpm in order that the diesel engine can work
effectively and be exerted.
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5. OPERATION
12 5.4.7 Lower safety lever (access lever)
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
5.5 Operating the machine - Main functions

13
Operating functions, Leader
The adhesive foil illustrated above

- is arranged on the underside of the front windshield,
- gives information concerning switch lever reference and function of the foot pedals.
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5. OPERATION
5.5.1 Checks before commencing operation
CAUTION
Do not operate the machine if errors and malfunctions can impair working safety.
Report all determined deficiencies and errors to the superior responsible and have them remedied by
specialists.
Carry out these checks before beginning work with the machine:
• Check display screen displays for unusual deviations.
• Check all further control elements and displays for main functions of the machine for flawless
functioning.
• Test all operating elements for main functions of the machine, which means
- actuate winches and activate hoist limit switches,
- adjust piling rig and drilling system,
- check inclinometer,
- actuate swing gear and crawler.
• Test lighting and all signal devices.
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5. OPERATION
5.5.2 Actuating the crawler
WARNING !
The machine may tip in crawler operation

- as a result of operating errors,
- if the permissible application limits are exceeded.
The following points are therefore to be noted:

• Travel operation is only permitted over firm, high load bearing capacity ground (see chapter 3
under "Ground composition at the job-site").
• The ground composition is to be checked for the entire travel area!
• Note wind speed ! Do not initiate travel if the wind speed exceeds 20 m/s [44.7 mph].
• Before commencing travel, lower the piling rig element and the piling rig or drilling device as low
as possible.
• Avoid all jerky movements !
• Do not allow the load to swing during travel !
• Adapt travel speed to the situation. When travelling inclinations, crests and when travelling with
load, reduce speed.
• Drive conscientiously !
• Always mount the travel drive of the crawler track carrier on the side of the counterweight in order
that an operational error is avoided in crawler operation. The uppercarriage is positioned parallel to
the undercarriage.
IMPORTANT !
With every travel movement the warning light flashes on the cab roof and as an option, a warning
signal sounds.
Travelling with leader laid down

When travelling with the leader laid down, particular care should be taken
- to continuously check stability,
- to observe tail swing of the leader when turning with the crawler.
Travelling with leader (level underground)

The leader
- must be positioned vertically (actuate manual or automatic vertical alignment),
- is to be adjusted so that it is just above the ground.
Travelling with load

LRB255_V001 (mf) LWN - TD4/2/2010
Travelling with load is only permitted

- over a firm, level surface
- if the permissible values in the load charts are not exceeded (see volume 2),
- if the reach is correspondingly reduced.
max. travel speed with load: 0.5 km/h [0.3 mph]
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5. OPERATION
14
Travelling on a slope with mounted leader
(fig. 14)
When travelling on a slope (lateral to inclination)
- the track adjustment on the operating track (wide track)
must be extended,
- do not turn the machine with the crawler,
- do not rotate the uppercarriage,
- check as to whether the swing gear brake is applied,
- do not travel any inclination greater than 3° lateral to
the slope (vertical positioning of the leader would be
impossible),
- keep the leader positioned horizontally at all times.
Travelling inclinations with mounted leader

(fig. 15)
When travelling inclinations
- always position the leader on the slope side,
- do not rotate the uppercarriage,
- check as to whether the swing gear brake is applied,
- do not travel any inclinations greater than 10°,
- always reposition the leader in the vertical position.
15
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5. OPERATION
16
Foot pedal control
The crawler is actuated proportionally via both foot ped-
als in the operator's cab:
• Press left-hand foot pedal (fig. 16, no. 1) forwards

= left-hand crawler track carrier moves forwards
• Push left-hand foot pedal down (front section of foot
pedal swings up) = the left-hand crawler track carrier
moves backwards
• Press right-hand foot pedal (fig. 16, no. 2) forwards =
right-hand crawler track carrier moves forwards
• Push right-hand foot pedal down = the right-hand
crawler track carrier moves backwards
17
Hand lever control
Special hand levers can be screwed onto the foot pedals
(fig. 17).
The travel movements can be controlled particularly sen-
sitively with this hand lever control.
Operation is identical for foot pedals and hand levers.
IMPORTANT !
All directional movements are only valid if the travel
drive of the crawler track carrier is mounted on the side
of the counterweight.
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5. OPERATION
Travelling straight ahead
CAUTION !
Before initiating reverse travel, check the travel area for any danger.
Only travel in reverse with the aid of an assistant!
The assistant
- monitors the areas not visible to the machine operator,
- directs the machine operator via radio or with hand signals.
Travelling forwards
• Push both foot pedals forward simultaneously.
Travelling in reverse
• Push both foot pedals down simultaneously.
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5. OPERATION
18
Turning on one crawler
Travelling to the left (fig. 18, position A)

• Press right-hand foot pedal forwards.
Travelling to the right (fig. 18, position B)

• Press left-hand foot pedal forwards.
IMPORTANT !
Always turn with the greatest radii possible.
Preserve the crawler: Turning at acute radii, as well as
turning while reversing should be avoided as far as
possible.
19
Turning on the spot
Turning to the right (fig. 19, position A)

• Push left-hand foot pedal forwards.
• At the same time press right-hand foot pedal down.
Turning to the left (fig. 19, position B)

• Push right-hand foot pedal forward.
• At the same time press left-hand foot pedal down.
IMPORTANT !
Preserve the crawler: Avoid turning on the spot as far as
LRB255_V001 (mf) LWN - TD4/2/2010
possible.
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5. OPERATION
5.5.3 Activating the swing gear

The swing gear turns the uppercarriage with the piling rig and drilling machine from 0 - 360°;
repetitive rotation is possible without limitation.
The speed stage should be adapted or checked before initiating every rotational movement.
Setting the speed stage
WARNING !
The machine is not equipped with any safety devices for limitation of the rotational speed. To
high a rotational speed could cause damage to the machine, the attachment and could lead to
the machine tipping over.
Countermeasure:
Before beginning each rotational movement the machine operator must
- check as to whether the pre-set speed stage is suitable,
- reduce the swing gear speed in gusty conditions.
For the rotational speed of the uppercarriage, one of the following three speed stages must be
determined:
• Stage 1 = 0 - 1 rpm
• Stage 2 = 0 - 2 rpm
• Stage 3 = 0 - 4.6 rpm
The speed stages can be selected via the pre-selection key "Speed stage swing
gear" on the right-hand control panel.
The display "Swing gear speed" shows the set speed stage on the LCD-display
screen in the status display of the operation diagram.
Checking the swing area
WARNING !
Danger of collision! Rotation of the uppercarriage can lead to the machine being damaged.
Adjust the mounted leader so that the leader foot can not collide with the crawler track carrier
when the uppercarriage is rotated.
Note the auxiliary cable, the hoses and any additional equipment!
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5. OPERATION
Open / close swing brake

The swing brake
- fixes position of uppercarriage,
- is always closed for start-up of the machine.
The swing brake is automatically blocked or unblocked
Actuation of the swing gear is blocked while

- the leader lateral inclination is being actuated,
- the leader is being rotated,
- parallel shifting is active,
- the leader support * is extended,
- the support of the uppercarriage * is extracted.
CAUTION !
When rotating the uppercarriage on slopes, always keep the leader in a vertical position
(manually or via automatic vertical alignment).
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5. OPERATION
20
Rotate uppercarriage
WARNING !
Before every turning movement of the uppercarriage,

the machine operator must personally ensure that no
persons or hindrances remain in the danger area!
WARNING !
Drastic acceleration and braking when rotating the uppercarriage can cause damage to the
machine.
Countermeasure:
Begin and brake every rotational movement sensitively.
Max. rotational speed with load: 1 rpm
The uppercarriage can be swung steplessly to left and right via joystick lever (fig. 20, no. 1):
• Move joystick to the left = uppercarriage swings to the left (anti-clockwise)
• Joystick in zero position = uppercarriage maintains its position, swing brake is/will be blocked.
• Move joystick to the right = Uppercarriage swings to right (clockwise)
NOTE !
A warning signal sounds with every swing movement of uppercarriage (optional).
Swing speed of uppercarriage

- is dependent upon the set speed levels,
- is proportional to switch lever adjustment:
• Move joystick further in swing direction = uppercarriage swings quicker (the swing accelerates)
• Move joystick back into zero position = uppercarriage is decelerated and swing brake is blocked.
• Move joystick beyond zero position in the opposite direction = uppercarriage is decelerated and
accelerated in opposite direction
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5. OPERATION
5.5.4 Swing gear free-swing

General
Pre-selection possible at all times. Utilisation with limited available space is not recommended.
The swing gear free-swing protects the swing gear from overdemanding operation which may occur
with oscillation of the load or diagonal pull.
The uppercarriage aligns itself into the load's respective direction of force automatically with swing
gear free-swing (also on uneven ground).
Setting the speed stage

See chapter 5 under "Actuating swing gear".
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5. OPERATION
Actuating swing gear free-swing
CAUTION !
The uppercarriage may continue to rotate involuntarily with swing gear free-swing!
- when working on slopes or when adjusting the piling rig element,
- when drilling.
In swing gear free-swing the swing gear brake remains released, even with the switch lever in
neutral position!
Countermeasures:
The rotational direction may be stopped by countering via the joystick.
The swing gear free-swing is switched off during breaks in operation
Prerequisites:
• Swing gear is at a standstill

• no switch lever functions activated
• Switch on swing gear free-swing on the right-hand control panel (X23)
Swing gear free-swing is pre-selected via the pre-selection key "Swing gear
free-swing On / Off" in the right-hand control panel.
With pre-selected swing gear free-swing, the "Swing gear free-swing" symbol
appears on the LCD display screen in the status display in the operating diagram.
21
• Button-operated swing gear free-swing (joystick)
The swing gear free-swing can also be activated via the
button on the joystick (fig. 21, no. 1).
Swing gear free-swing remains active as long as the
button remains pressed. The "Swing gear free-swing"
symbol appears on the LCD display screen in the status
display in the operating diagram.
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5. OPERATION
22
Rotating uppercarriage in swing gear free-
swing
WARNING !
Before every rotational movement of the uppercar-

riage, the operator must be absolutely sure that no
persons or obstacles are within the danger area!
Drastic acceleration and braking when rotating the
uppercarriage can cause damage to the machine. All
rotational movements, therefore, must be initiated
and braked sensitively.
The uppercarriage can be rotated steplessly to the left or right via the joystick (fig. 22, no. 1):
• Deflect joystick to the left = Uppercarriage rotates to the left (anti-clockwise)
• Joystick in neutral position = Swing gear free-swing
• Deflect joystick to the right = Uppercarriage rotates to the right (clockwise)
Should the joystick be deflected back into the neutral position after a rotational movement has been
initiated, the uppercarriage will continue to rotate at approximately the same speed and is only
braked via frictional loss in the swing gear.
NOTE !
With every rotational movement of the uppercarriage, a warning signal can be sounded as an option.
Rotational speed of the uppercarriage

- is dependent on the set speed stage,
- is maintained proportional to the switch lever position:
• Deflect joystick further in the rotational direction = Uppercarriage rotates quicker (the swing gear
accelerates)
• Deflect joystick beyond the neutral position in the opposite direction to the rotational direction =
Uppercarriage rotates slower (the swing gear brakes)
NOTE !
When braking, deflect joystick back into the neutral position as soon as the uppercarriage has come
to a standstill. Otherwise the uppercarriage begins to rotate in the opposite direction immediately
after coming to a standstill.
Switching off swing gear free-swing

The swing gear free-swing is switched off by re-actuating the pre-selection key, "Swing gear
LRB255_V001 (mf) LWN - TD4/2/2010
free-swing" in the right-hand control panel.

• Upon actuation of the pre-selection key during a rotational movement, the swing gear is braked
automatically via the pre-set integration time of the Litronic control!
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5. OPERATION
5.5.5 Swing gear limitation *
23
Swing gear limitation
The optional swing gear limitation limits the swing range of the upper carriage.
CAUTION!
Danger of accident or damage!

If there are dangerous obstacles within the operating area (electrical power lines, etc.) using
only the boom swing limiter is not adequate! In such cases additional safety measures must
be taken (refer to chapter 3 "Safety precautions").
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5. OPERATION
Description of the check displays
"Set swing gear to zero" display.

Pressing function key F5 or F6 sets the swing gear display to the current value.
A value can be entered from the Litronic service panel.
"Swing gear" display.

The center display shows the current position of the swing gear in degrees. The
bottom two displays show the maximum rotation to left and right.
24
Setting swing gear limitation

The machine operator specifies a limit stop on both right
and left for the machine's swing range. Swing gear
limitation blocks the range of angles between the two
limit stops.
Pressing function keys F5 and F6 displays an additional
display (Figure 24), which enables the limit angles for
the right-hand and left-hand stop to be entered.
CAUTION!
Risk of damage to the machine.

Depending on the speed setting of the swing gear, or if the machine is set up on a slant, the
values may stray slightly outside the limit angle range for the stops.
Precaution:
Safety clearances must be observed when defining the limit angles.
The two limit stops can be

- defined using a teach-in procedure
- or entered directly via the keyboard as an angle value.
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5. OPERATION
Teach-in procedure
• Carefully (with the help of a signalman) turn the upper carriage in a clockwise direction as far as
the obstacle, then stop.
• Press function key F6 to define the limit angle for the right limit stop.
• Carefully (with the help of a signalman) turn the upper carriage in an anticlockwise direction as far
as the obstacle, then stop.
• Press function key F5 to define the limit angle for the left limit stop.
25
Keyboard entry
Notes on determining the angle:
An upper carriage which is moving clockwise from the
direction of travel describes a full circle from 0° to 360°,
where 0° and 360° are exactly in the direction of travel.
An upper carriage which is moving anticlockwise from
the direction of travel describes a full circle from
360° to 0°.
Entry of a negative angle or of a value greater than 360°
is not permitted. If this does occur, then the earlier limit
angle remains unchanged.
• Starting from the direction of travel of the machine (0°) on the site, determine the two limit angles
with the aid of a measuring instrument.
• Press the right arrow key on the Litronic service panel (Figure 25) until the desired limit angle is
highlighted in black in the additional display.
• Enter the limit angle in degrees using the numeric keys on the Litronic service panel.
Use the left arrow key to correct input errors: each time the left arrow key is pressed the cursor
jumps back one position.
• Confirm entries by pressing the Enter key.
• Select the second angle value in the additional display, enter a limit angle and confirm it using the
Enter key.
NOTE!
The limit angles are saved when the machine is shut down regardless of whether they are entered
by means of the teach-in procedure or via the keyboard.
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5. OPERATION
Check swing gear limitation

The swing gear limitation should be checked
- in particular after the limit angle has been entered via the keyboard,
- whenever the machine is moved.
• Slowly move the upper carriage first to the right and then to the left limit stop.
As soon as it reaches a limit stop the upper carriage will stop and the associated limit angle will flash
in the swing gear limitation display field.
Cancel swing gear limitation

When entering values via the keyboard, enter an identical limit angle for both limit stops.
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5. OPERATION
5.6 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.).
5.6.1 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
5.6.2 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. OPERATION
5.6.3 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 26) appears on the LCD screen.
26
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 !
LRB255_V001 (mf) LWN - TD4/2/2010
While the Litronic® test system is in operation, fault messages from the Litronic® control do
not display!
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5. OPERATION
5.6.4 The menus

The description of the menu bars below always covers all the function symbols concerned.
5.6.5 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. OPERATION
5.6.6 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.
5.6.7 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. OPERATION
5.6.8 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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5. OPERATION
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. OPERATION
5.6.9 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. OPERATION
5.6.10 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
5.6.11 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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5. OPERATION
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.
LRB255_V001 (mf) LWN - TD4/2/2010
• 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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5. OPERATION
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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5. OPERATION
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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5. OPERATION
5.7 Operating the machine - Auxiliary functions

5.7.1 Adjusting operating elements
In order to ensure safe operation of machine, correct adjustment of operating elements in the
operator's cab is decisive. Operating elements for operator's seat and LCD-display screen are
described in chapter 4. It must also be ensured that the machine operator can easily reach the
operating elements in the manner intended, and then operate them. The displays on the LCD-display
screen must be clearly visible. Operation of machine may not lead to excessive fatigue of the
machine operator resulting in errors in concentration and operating errors (see chapter 3 "Safety
guidelines").
NOTE !
If adjustment of operating elements not be sufficiently possible for the machine operator, a solution
should be found with the manufacturer !
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5. OPERATION
27
5.7.2 Operator's seat
• By pulling up the adjusting lever (fig. 27, no. 8) on the
front side of the operator's seat, inclination of the
backrest (no. 2) can be adjusted.
Height and inclination adjustment
• Height and inclination of seat front edge (no. 4) is

modified via the lever (fig. 27, no. 5 + 6).
• Both arm rests can be adjusted in inclination via ad-

justing button (fig. 27, no. 3).
Weight adjustment
• The springs in the operator's seat can be adapted to

the bodyweight of the machine operator via the hand-
wheel (fig. 27, no. 7). Weight adjustment is displayed
on the handwheel.
28
Horizontal adjustment whole seat
• In order to find the correct distances to the pedals,

operator's seat including control stand can be moved
left and right via lever (fig. 28, no. 2) and also back
and forward. Only the operator's seat can be shifted
with this lever (no. 1).
• The operator's seat must always be adjusted so that

all operating elements are easily accessible to ma-
chine operator and that he remains fatigue- free.
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5. OPERATION
5.7.3 LCD-display screen adjustments

With brightness regulation, and inverse display screen representation, the display screen is adjusted
to the actual light conditions on the job-site.
Key "Brightness adjustment"

By pressing this key in the Litronic-service panel the following adjustments can
be switched through repetitively :
• normal representation - subdued

• normal representation - medium brightness
• normal representation - bright
• inverse representation - subdued

• inverse representation - medium brightness
• inverse representation - bright
5.7.4 Windshield wiper

Pre-selection key " Windshield wiper On / Off"
The windshield wipers for windshield and roof window in operator's cab are
switched on and off via the key in the left-hand control panel. Function is also
possible in the "Parking position" of ignition start switch.
Interval time
Pre-selection key "Interval control On / Off"
By pressing this key in the left-hand control panel, an interval time of 4 - 16
seconds.
Adjustment: Press key, windshield wiper runs once. Keep key pressed down for
the required interval between strokes . The duration that the button was pressed
is the interval time stored.
NOTE !
The set interval time is erased when the diesel engine is switched off and reset after 8 seconds.
When the diesel engine is restarted, the time interval must be reset.
Windshield washing system

Pre-selection key " Windshield washing system On / Off"
The windshield washing system is activated via corresponding key in the left-
hand control panel. The windshield washing system is active for as long as the
respective key is held pressed.
The windshield washing system also functions in the "Parking position" of ignition
start switch.
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5. OPERATION
29
Window cleaning agent
The container for window cleaning agent (fig. 29) is lo-
cated behind operator's seat.
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 (fig. 29, no 1) before

the windshield cleaning liquid can be topped up.
IMPORTANT !
Commercially available windshield cleaning liquid can
also be used.
For safety reasons, however, it should not be flammable!
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5. OPERATION
5.7.5 Inside lighting in uppercarriage

Key " Inside lighting On / Off"
(Prerequisite for activation of inside lighting: Ignition start switch to switch adjust-
ment P Parking position or 1 ignition On)
5.7.6 Cab lighting

A reading lamp is located on the right above the operator's cab. She can be switched on and off via
the switch at the lamp directly.
Switch cabinet lighting

For activation of switch cabinet lighting, the ignition start switch must be in the switch position P
parking position. The switch and lighting elements are located above in the switch cabinet.
5.7.7 Radio
The radio is installed on the right in the control stand. The radio also functions in "Parking position"
of ignition start switch.
NOTE!
If the radio is too loud, it can distract the machine operator, increases fatigue and therefore
increases risk of accident.
5.7.8 Horn
The horn is located below right hand near the brake pedals and also functions in "Parking position"
of ignition start switch.
5.7.9 Cigarette lighter / socket in the cab

The cigarette lighter is located in the right-hand control stand. The socket (24 V) is located in the
right-hand control stand behind the radio. Both functions also possible in "Parking position of ignition
start switch".
• Push in cigarette lighter, if the coil is glowing it will automatically switch off. Pull out lighter.
Ashtray
Only use for ash. Do not put in any burning rubbish!
Danger of fire!
Empty ashtray
Snap back ashtray. Squeeze inserts at both sides and pull out.
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5. OPERATION
5.8 Adjusting piling rig and drilling system 30
5.8.1 Adjusting the leader via auxiliary panel (X25)

General
The leader can fundamentally
- be adjusted via auxiliary panel X25 or
- via the left-hand and right-hand switch levers.
The cylinder adjustment functions are pre-selected on
auxiliary panel X25 via the pre-selection key and then
actuated via the corresponding direction keys. The LEDs
in the respective direction keys only light up if a cylinder
adjustment function has been pre-selected and direction
has been authorised.
When adjusting via the direction key, as opposed to
adjusting via the switch lever, the speed is reduced
automatically by up to 50 %.
The following allocation of the direction keys thus applies:

Auxiliary panel X25 is hypothetically divided into two halves. The cylinders, whose pre-selection keys
are arranged on the left-hand side, are adjusted via the left-hand direction key (key T1 or key T17),
and the cylinders that have pre-selection key arranged on the right-hand side, are adjusted via the
right-hand direction keys (key T8 or key T24).
Actuate cylinder adjustment functions simultaneously:

Due to the hypothetical division of the auxiliary panel into two halves, a function of the left half can
be operated together with a function of the right half. Keys T5 and T14 are arranged on the right
half.
Die Pre-selection of the cylinder functions for adjustment of the leader is always possible, as long
as the tower device and the automatic parallel adjustment are not pre-selected.
Adjustment of the leader (with the exception of the leader height adjustment) is blocked if the
optional leader foot cylinder is extended.
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5. OPERATION
31
Inclining the leader (forward/backward)
WARNING !
Note movement limitations depending on leader

length, reach and operation type!
The leader locking carriage must be secured against
rotating when inclining the leader (forward/back-
ward).
The leader is inclined via actuation of the support arm brace-support cylinder (Z2) in the Y-direction
(forward/backward).

For pre-selection of the support arm brace-support cylinder (Z2).
Key "lift/open"
Extend support arm brace-support cylinder. The leader is inclined forward.
This direction is only authorised if the following limit switches are not activated:
- Upper limit switch kelly winch *
Key "lower/close"
Retract support arm brace-support cylinder. The Leader is inclined backward.
This direction is always authorised.
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5. OPERATION
32
Adjusting leader reach
Various leader reaches can be operated in the vertical
leader position. The reach of the leader is adjusted via
actuation of the basic arm-adjusting cylinder (Z4).

Key "lift/right"
Extend basic arm-adjusting cylinder. Reach is extended.
Key "lower/left"
Retract basic arm-adjusting cylinder. Reach is reduced.
- Upper limit switch kelly winch *, winch 1 * and auxiliary winch in
the uppercarriage *
NOTE !
- Inclination of the leader can be changed manually via the support arm brace-adjusting cylinder.
- With "Parallel shifting", an automatic compensation of the inclination is resulted.
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5. OPERATION
33
Adjusting the leader height (repositioning
the leader)
The leader can be adjusted up and down via actuation
of the upper or lower pinning cylinder (fig. 34, no. 3) and
the leader height adjusting cylinder Z5 (2).
34
Connecting pins in the leader rear wall (fig. 34, no. 1)
Before retracting the upper connecting pin, the leader
height adjusting cylinder must be retracted by the depth
of the groove.
Before retracting the upper connecting pin, the leader
height adjusting cylinder must be extracted by the depth
of the groove.
DANGER !
The machine operator is solely responsible for cor-

rect securing of the connecting pins!
A visual inspection must be carried out indepen-
dently of the display on the LCD-display screen.
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5. OPERATION

For pre-selection of the leader height adjusting cylinders (Z5).

The lower pinning cylinder (Z12) is actuated. If the pin has been completely
retracted
- the directional keys are authorised for adjustment of the leader height adjusting
cylinder (LED lights up),
- the display is resulted in the display field of the operation diagram.
Hold key pressed down.
Key "lift/right"
Extend leader height adjusting cylinders. The leader or the leader height adjust-
ment carriage are adjusted upwards.
- Upper limit switch kelly winch *, winch 1 and auxiliary winch in the
uppercarriage *
Key "lower/left"
Retract leader height adjusting cylinders. The leader or the leader height adjust-
ment carriage are adjusted downwards.
This direction is only authorised if the following limit switches are not actuated:
- Lower limit switch leader height adjustment
- winch 1 and auxiliary winch in the uppercarriage *

The upper pinning cylinder (Z11) is actuated. If the pin has been completely
retracted (monitoring via limit switch)
- the directional keys for adjustment of the leader height adjusting cylinder is
authorised (LED lights up),
- the display is resulted in the display field of the operation diagram.
Hold key pressed down.
NOTE !
Procedure: Lowering the leader
• Retract the leader height adjusting cylinder (Z5) approx. 25 mm [1''].
• Retract upper connecting pin (actuate pinning cylinder Z11), hold key T5 on the auxiliary panel
pressed down.
• Extend leader height adjusting cylinder.
• Release key for the pinning cylinder at the desired insertion point. The upper connecting pin is
inserted (spring-loaded).
• Lift leader via leader height adjusting cylinder (Z5) approx. 25 mm [1''].
LRB255_V001 (mf) LWN - TD4/2/2010
• Retract lower connecting pin (actuate pinning cylinder Z12), hold key T14 on the auxiliary panel
pressed down.
• Retract leader height adjusting cylinder.
• Release key for the pinning cylinder at the desired insertion point. The lower connecting pin is
inserted.
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5. OPERATION
NOTE !
Procedure: Lifting the leader
WARNING !
Lifting the leader with maximum load can cause damage to the leader and lead to the
machine tipping over!
Countermeasures:
- Refer to the load charts for piling rig or drilling machine (see chapter 2).
- With maximum reach, the leader may only be lifted off the ground with maximum load, if it has
been determined that the pile does not exceed the maximum permissible centre of gravity height.
- With minimum reach, it is not permissible to lift the leader off the ground with maximum load. It
could cause overload of the leader.
Should it be necessary to lift the leader off the ground, please consult the manufacturer in
reference to the load.
- Do not secure any loose winch cables to the leader or to the machine. This could lead to major
damage when adjusting the piling rig and drilling system.
• Lifting of the leader is resulted accordingly in reverse order as was previously described for
lowering of the leader.
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5. OPERATION
35
Inclining the leader laterally
The leader can be adjusted laterally (X-direction) in the
vertical and inclined positions.
WARNING !
Actuation of the lateral inclination can cause damage to the piling rig and drilling system!
Countermeasures:
- Check functioning of the inclination display before beginning operation.
- The lateral inclination serves the alignment of the leader without the sheet pile being plumb!
- Maximum lateral inclination of the leader totals 3° to the left and right respectively.
- For pile driving operation with leader turned 90°, the lateral inclination may not be actuated under
load!
- When turning the leader in the direction of the ladder, the leader-lateral inclination cylinder on the
side of the ladder must be retracted completely!
- With leader turned around 90°, a correction of lateral inclination is only possible if the directional
movement is resulted from the support arm brace out !
Pre-selection key "Leader lateral inclination"

For pre-selection of the leader lateral inclination cylinder (Z6).
Key "lift/right"
The leader is adjusted to the right.
Key "lower/left"
The leader is adjusted to the left.
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5. OPERATION
36
Turning the leader
The leader can be turned vertically relative to the upper-
carriage.
WARNING !
Turning of the leader can cause damage to the piling rig and drilling system!
Countermeasures:
- Check functioning of the inclination display before beginning operation.
- Turning the leader is only possible if the leader is positioned vertically (+/- 1.0°), if the optional
second rotary cylinder has not been installed.
- For pile driving operation with leader turned 90°, the lateral inclination may not be actuated under
load ! The lateral inclination only serves the alignment of the leader without the sheet pile being
plumb!
- When turning the leader in the direction of the ladder, the lateral inclination kit should be
retracted completely on the side of the ladder! (Incline the leader completely to the right and then
position the leader to "0" again.)
- With leader turned 90° a correction in lateral inclination is only possible if the directional
movement is resulted from the support arm brace out!
- Before unplugging the leader rotary cylinder, the leader locking carriage should always be
secured to the support arm brace via the connecting pins
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5. OPERATION
• Leader is positioned vertically
Pre-selection key "Turning the leader"

For pre-selection of the leader rotary cylinder (Z3).
Key "lift/right"
The leader is turned to the right.
Key "lower/left"
The leader is turned to the left.
Both directional keys are only authorised if the leader is positioned vertically in its "Zero position" (+/-
1.0°).
• Leader is inclined or has been set down

If the leader is not positioned in its zero position (+/- 1.0°), the assembly
operation must be actuated in order that the leader can turn.
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5. OPERATION
37
Unplugging the pins of the leader rotary cylinder
IMPORTANT !
Unplugging of the leader rotary cylinder is only neces-
sary if the leader must be turned for the application.
• Mount the upper torque stay rods (Figure 37, No. 1).
They serve to stabilize the leader.
See chapter 6 under "Assembly stages with piling and
drilling device laid down"
38
DANGER !
Danger of accident !
Before unplugging the leader rotary cylinder, the
leader must be stabilized via the upper torque stay
rods.
• Dismantling pins of the leader rotary cylinder (fig. 38,

nos. 1 and 4)
• Adjust leader rotary cylinders ( 2 and 3) accordingly
• Insert pins and secure via safety springs
IMPORTANT !
The upper and the lower leader rotary cylinder are to be
inserted in the same positions respectively.
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5. OPERATION
39
Adjusting auxiliary jib *
The auxiliary jib can be adjusted off-set via actuation of
the auxiliary jib-adjusting cylinder.
NOTE !
The auxiliary jib should never be adjusted under load.
Pre-selection key "Auxiliary jib adjustment"

For pre-selection of the auxiliary jib adjusting-cylinder (Z17).
Key "lift/right"
The auxiliary jib is adjusted to the right/up.
This direction is only authorised if the following limit switches are not actuated:
- Upper limit switch auxiliary winch
Key "lower/left"
The auxiliary jib is adjusted to the left/down.
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5. OPERATION
40
Adjusting the leader foot *
The lead foot plate can be adjusted by operating the
lead foot cylinder.
Pre-selection key "Leader support"

For pre-selection of the leader foot cylinder.
Key "lift/open"
Retracting the leader foot cylinder. This direction is always authorised.
Key "lower/close"
Extending the leader foot cylinder.
NOTE!
If the leader foot cylinder is extended, the following functions are blocked:
- Swing gear,
- Crawler,
- Adjustment of the leaders with the exception of the leader height adjusting cylinder (Z5)
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5. OPERATION
5.8.2 Adjusting the leader via the switch levers

General
The leader can be fundamentally adjusted via auxiliary panel X25 or via the left-hand and right-hand
switch levers.
The cylinder adjustment functions are pre-selected via the corresponding keys (on the switch lever)
and actuated via selection of the switch lever.
Pre-selection of a cylinder is displayed automatically on the auxiliary panel (LED lights up). Actuation
of the cylinder (selection of the switch lever) is signalled via flashing of the LED for the correspond-
ing directional key.
Releasing the key or resetting of the switch lever into its zero position invalidates pre-selection of the
cylinder.
NOTE !
The same notes on safety apply as for adjustment via auxiliary panel (X25).
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5. OPERATION
41
Inclining the leader (forwards/backwards
and laterally)
Upon actuation of the key (fig. 41, no. 1) on the left-hand
switch lever and actuation of the left-hand switch levers
forwards/backwards or left/right, the leader is inclined in
die corresponding direction.
Procedure:
Hold key (fig. 41, no. 1) on the left-hand switch lever pressed down and:
• Switch lever in zero position = Leader remains in position
• Move switch lever to the left = Leader is inclined to the left
• Move switch lever to the right = Leader is inclined to the right
• Move switch lever forwards = Leader is inclined forwards
• Move switch lever backwards = Leader is inclined backwards
Prerequisites:
- no other cylinder adjustment via the switch lever active.
- no shut-down of the support arm brace support cylinder and the leader inclination cylinder.
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5. OPERATION
42
Adjusting leader height (repositioning the
leader)
switch lever and actuation of the left-hand switch levers
forwards/backwards, the leader height adjusting cylinder
is extended or retracted.
Actuating the leader height adjusting cylinder:

Hold key (fig. 42, no. 1) on the left-hand switch lever pressed down and:
• Move switch lever forwards = Retract leader height adjusting cylinder (lower leader)
• Move switch lever backwards = Extend leader height adjusting cylinder (lift leader)
Prerequisites:
- no other cylinder adjustment via the switch lever active,
- no shut-down of the leader height adjusting cylinder.
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5. OPERATION
43
Retract upper pin
Upon actuation of the key (fig. 43, no. 1) on the right-
hand switch lever, the upper pin on the leader height
adjustment carriage is retracted.
Prerequisite:
The leader height adjustment is pre-selected via the key
(fig. 42, no. 1) on the left-hand switch lever
Retract lower pin

Upon actuation of the key (fig. 43, no. 1) on the right-
hand switch lever, the lower pin on the leader locking
carriage is retracted.
Prerequisite:
The leader height adjustment is pre-selected via the key
(fig. 41, no. 1) on the left-hand switch lever .
CAUTION !
If the key on the left-hand switch lever is not pressed, an operational error is resulted. Either
the clamping tongs are closed, or the vibrator or the hammer are activated.
NOTE !
The procedure for repositioning the leader is determined each time in accordance with operation via
the auxiliary panel.
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5. OPERATION
44
Turning the leader
switch lever and actuation of the left-hand switch lever
left/right, the leader is turned.
Procedure:
Key (fig. 44, no. 1) on the left-hand switch lever pressed down and:
• Move switch lever to the left = Leader turns to the left
• Move switch lever to the right = Leader turns to the right
Prerequisites:
- No other cylinder adjustment via switch lever active,
- Leader positioned in its "Zero position" (inclination +/- 1.0°).
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5. OPERATION
45
Adjusting the leader foot (leader support) *
switch lever and actuation of the left-hand switch lever
left/right, the leader foot cylinder is extended or retract-
ed.
Actuating the leader foot cylinder:

Key (fig. 45, no. 1) on the left-hand switch lever pressed down and:
• Switch lever in zero position = Leader foot cylinder remains in position
• Move switch lever to the left = Retract leader foot cylinder
• Move switch lever to the right = Extend leader foot cylinder
Prerequisites:
- no shut-down of the leader foot cylinder.
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5. OPERATION
46
5.8.3 Leader inclination display
An inclination transmitter has been installed on the lead-
er which measures the longitudinal and lateral
inclination.
The following are shown in the display field on the
LCD-display screen
longitudinal (Y-direction): analogous a range of +10 and
-20° and digital a range of +/- 45°
as well as
lateral (X-direction): analogous a range of +/- 5° and
digital a range of +/- 9.9°.
Should a value be exceeded or fallen short of, "?.?"
appears in the corresponding number field.
Set leader inclination display to 0°

The inclination display can be set to "ZERO" via the control. The leader must be positioned as
vertically as possible (X and Y direction).

Actuate function key F7 .
Symbol "Zeroing inclination display"

Upon actuation of function key F3 , the digital inclination displays in the display
field start flashing.
Symbol "Confirm entry".

Upon actuation of function key F4 , the digital and analogous leader inclination
display is set to zero.
NOTE !
Upon actuation of function key F7 , the adjustment mode is abandoned.
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5. OPERATION
47
5.8.4 Automatic vertical alignment
The automatic vertical alignment positions the leader to
the set inclination (a programmed reference value).
Enter reference value leader inclination

The reference value is represented as analogue in the
display field of the display screen via the symbol " "
+
(fig. 47, no. 1) and the actual value via the " " symbol
( 2).
The digital representation of the actual value is over-
layed in the right-hand number fields and below the
display field (3)
Procedure:
Symbol "Reference value leader inclination"

Upon actuation of function key F4, the "Reference value Leader inclination"
symbol starts flashing, the actual inclination (digital and analogue) fade and the
current reference value is overlayed in its place.
Key "Cursor forward"

Pre-select the reference value to be modified (the pre-selected number field
appears inverse) via actuation of the "Cursor further" key on the Litronic-service
panel
Key "Cursor back"

Upon actuation of the "Cursor back" key on the Litronic-service panel, an entered
value can be corrected.
Enter reference value via the keyboard of the Litronic-service panel.

Limit values
left/right: maximum 5°/5°
forwards/backwards: maximum 10°/20°
Key "Enter"
The entered values are only accepted by the control following actuation of the
"Enter" key.
NOTE !
With incorrect entry, the old values are maintained.
Upon actuation of function key F7, the adjustment mode is abandoned and the actual value of the
leader inclination is once again overlayed.
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5. OPERATION
48
Actuating automatic vertical alignment
Upon actuation of the key (fig. 48, no. 1) the leader is
aligned via the support arm brace-support cylinder and
the leader inclination cylinder is automatically aligned to
the set inclination.
The X and Y directions are adjusted simultaneously.
IMPORTANT !
The automatic vertical alignment can also be actuated
during the travel and swing operation.
Prerequisites:
- no shut-down of the support arm brace-support cylinder and leader inclination cylinder,
- no sensor error of the inclination transmitter.
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5. OPERATION
49
5.8.5 Automatic parallel shifting
The parallel shifting function of the leader assures par-
allel operation (forwards/backwards) via the support arm
brace-support cylinder and the basic arm-adjusting cyl-
inder. The actual inclination of the leader is maintained.
Actuating automatic parallel shifting

• Upon actuation of the key (fig. 49, no. 1), the actual inclination of the leader is stored to memory.
Hold key pressed down and:
• Left-hand switch lever in zero position = Leader remains in position
• Move left-hand switch lever forwards = Leader is adjusted parallel forwards
• Move left-hand switch lever backwards = Leader is adjusted parallel backwards
• Left-hand switch lever once again back into zero position = Basic arm-adjusting cylinder remains
in position, the support arm brace-adjusting cylinder aligns the leader, if necessary further into the
stored inclination (only if the key remains pressed).
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5. OPERATION
50
5.8.6 Actuating the auxiliary winch *
Pre-selecting the auxiliary winch
Pre-selection of the auxiliary winch is only necessary in
drilling operation as the same switch lever is used here
for the drilling drive.
Pre-selection can be resulted via actuation of
• the pre-selection key (fig. 50, no. 2) on the auxiliary
panel ,
• the key (fig. 50, no. 1) on the right-hand switch lever
Pre-selection is only possible when the drilling gear has
come to a standstill.
Display: The LED lights up in the pre-selection key.
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 there are always at least three so-called safety windings
remaining on the winch.
The length of rope required for this purpose depends on the leader configuration and the type of
application.
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5. OPERATION
51
WARNING !
Danger of accident and possible damage to the ma-

chine !
The 3-coil-limit switch and the optional rope length
measurement can adjust themselves impermissibly
of their own accord via
- empty running of the auxiliary winch, if the hoist
cable has not been reeved,
- the hoist cable running out further, although the
load hook is already laying on the ground (loose,
irregular winding of the cable onto the winch).
Actuating the auxiliary winch

The auxiliary winch is adjusted from a standstill up to maximum speed directly proportional with the
right-hand switch lever (fig. 51, no. 1).
• Move switch lever to the left = Lift auxiliary winch
• Switch lever in zero position = Auxiliary winch remains in position
• Move switch lever to the right = Lower auxiliary winch
The adjustment range of the auxiliary is fixed by the hoist limit switch and 3-coil-limit switch.
Movement limitations of the auxiliary winch
As soon as the load hook triggers the hoist limit switch when raising with the
auxiliary winch, the "Upper limit switch Auxiliary winch" symbol flashes in the
status display of the operation diagram.
The lifting direction of the load hook is blocked.
As soon as the hoist cable end is reached when lowering the load hook via the
auxiliary winch (3 safety layers), the "Lower limit switch Auxiliary winch" symbol
starts flashing in the status display of the operation diagram.
The lowering direction of the load hook is blocked.
NOTE!
No diagonal pull is permitted with the auxiliary winch (via the auxiliary jib)!
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5. OPERATION
52
5.8.7 Feed system *
General
Due to the feed system, the universal carriage (fig. 52,
no. 4) and thus, the piling rig or drilling device is moved
up and down and along the leader. The feed system
allows retraction as well as application of pressure for
the desired alignment.
It comprises of
- the feed winch (1),
- the three upper deflection pulleys (2),
- the feed cable (3),
- the universal carriage (4) with tensioning cylinder and
- the two lower deflection pulleys (5),
The feed cable is reeved in accordance with the reeve

charts in chapter 8.
Principle of the feed system

The feed winch consists of two parallel running winches on which the feed cable runs. It serves the
drive of the feed system.
The feed cable is constantly tensioned via the tensioning cylinder. It is guided over the upper and
lower deflection pulleys in the leader to the upper and lower deflection pulleys in the universal
carriage.
When actuating the feed winch in the lifting direction (retracting), extend the upper tensioning
cylinder completely, and at the same time retract the lower tensioning cylinder accordingly. The
universal carriage is moved upwards.
NOTE !
Actuate the switch lever very gently until the universal carriage moves, in order that jerks in
operation are avoided.
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5. OPERATION
53
Actuating the feed (low gear)
The feed winch is adjusted from a standstill to maximum
speed directly proportional with the right-hand switch
lever (fig. 53, no. 1) .
• Move switch lever forwards = Lower universal carriage
• Switch lever in zero position = Universal carriage re-
mains in position
• Move switch lever backwards = Lift universal carriage
IMPORTANT !
Low speed is pre-selected as standard upon actuation of
the feed.
54 Actuating the feed (top speed)

Switch-over from low speed of the feed to top speed is
resulted
• via actuation of the pawl switch (fig. 54, no. 1) on the
right-hand switch lever.
IMPORTANT !
Should a pre-selected switch threshold be exceeded, low
speed is automatically switched to.
This symbol appears in the display field on the LCD-display screen, as soon as
low speed of the feed is switched to.
top speed of the feed is switched to.
NOTE !
Switch-over of the feed from top speed to low speed is possible at any time.
If the control is switched back into low speed, top speed is only authorised again when travel
operation is initiated anew.
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5. OPERATION
55
Limiting the maximum feed speed
The maximum feed speed can be limited by the poten-
tiometer (Figure 55) on the auxiliary panel (X25).
Movement limitations of the universal carriage (of the feed winch)
As soon as the universal carriage triggers the upper limit switch when lifting with
the feed winch, the "Upper limit switch feed" symbol starts flashing in the status
display of the operation diagram.
The lifting direction of the universal carriage is blocked.
As soon as the universal carriage triggers the lower limit switch when lowering
with the feed winch, the "Lower limit switch feed" symbol starts flashing in the
status display of the operation diagram.
The lowering direction of the universal carriage is blocked.
56
Storing the feed movement
The feed movement can be stored.
Procedure:
- Adjust the switch lever control setting
- press the key button (Figure 56, No. 1) on the
right switch lever
- put the switch lever back to the zero position
The feed winch automatically raises or lowers.
The stored feed speed can be limited by the potentiom-
eter (Fig. 55) on the auxiliary panel (X25).
The symbol "Movement stored" is displayed on the LCD screen.

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Deleting storage:
adjust right switch lever control setting
If several movements are stored, all the others will be deleted as well.
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5. OPERATION
57
Feed display
The crowd force is displayed in the display field on the
LCD-display screen as analogue (fig. 57, no. 1) and
digitally (2).
58
Pressure control
The pressure when lowering the feed can be regulated
via the potentiometer (fig. 58, no. 1) on the auxiliary
panel.
• Rotate potentiometer clockwise = Increase pressure
• Rotate potentiometer anti-clockwise = Reduce pres-
sure
If the potentiometer is active, the LED in the pre-selec-
tion display is lit.
Rope length measurement
Symbol "Reset feed"

Upon actuation of function key F6 , the "Cable length feed" display is reset to "0".
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5. OPERATION
59
5.8.8 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 there are always at
least three so-called safety windings remaining on the
winch.
The length of rope required for this purpose depends on
the leader configuration and the type of application.
WARNING !
Risk of accident and possible damage to the machine !

The 3-coil-limit switch and the optional rope length measurement adjust themselves impermis-
sibly of their own accord via
- empty running of the kelly winch, if the hoist cable has not been reeved,
- further winding down of the hoist cable, although the load hook is already laying on the
ground (loose, irregular cable winding onto the winch).
Actuating the kelly winch

The kelly winch is adjusted from the standstill up to maximum speed via the left-hand switch lever
(fig. 59, no. 1).
• Move switch lever backwards = Lift kelly winch
• Switch lever in zero position = Kelly winch remains in position
• Move switch lever forwards = Lower kelly winch
The adjustment range of the kelly winch is limited via the hoist limit switch and 3-coil-limit switch.
Movement limitations of the kelly winch
As soon as the load hook triggers the hoist limit switch when lifting with the kelly
winch, the "Upper limit switch kelly winch" symbol starts flashing in the status
display of the operation diagram.
The lifting direction of the load hook (of the kelly rod) is blocked.
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As soon as the hoist cable end (3 safety windings) has been reached with
lowering of the load hook (of the kelly rod) of the kelly winch, the "Lower limit
switch kelly winch" symbol starts flashing in the status display of the operation
diagram.
The lowering direction of the load hook is blocked.
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5. OPERATION
5.8.9 Rope length measurement *

11.5 m Display "Cable length measurement kelly winch" (in the display field-kelly
drilling)
• Setting the display to zero

Upon actuation of function key F7, special function key symbols appear for resetting the displayed
cable length.
Resetting to display value "0"
- is possible at any time,
- is used to determine differences in height (depths), can be resulted with two different types:
Symbol "Reset kelly winch"

Upon actuation of function key F4 , the "Cable length kelly winch" display is reset
to "0".
Upon actuation of this key on the PDE monitor, the "Cable length kelly winch"
display is reset to "0".
60
• Upon actuation of the pawl switch (fig. 60, no. 1) on
the left-hand switch lever the "Cable length kelly
winch" display is reset to "0".
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5. OPERATION
NOTE !
For a precise display of the cable length, a layer-change and reeving of the kelly winch must be
programmed.
Programming rope length measurement
• Programming reeving
As the kelly rope can be reeved, the reeving must be defined when calculating the cable length.
Procedure

Actuate assembly operation.
999 flow rate auger [l/min]

999 pile diameter [cm]
999 max. pressure [bar]

9 reevings main winch
9 number of pumps
99 range concrete press. sensor [bar]

99 scale conc. press. indication[bar]
99 concrete volume / impulse [l/Imp]
Page "Adjustments"
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5. OPERATION

Pre-select the reeving to be modified (the pre-selected number field appears
inverse) via actuation of the "Cursor further" key on the Litronic-service panel
Key "Cursor back"

mUpon actuation of the "Cursor back" key on the Litronic-service panel, an
entered value can be corrected.

Limit values
minimum: 1
maximum: 9
Key "Enter"
"Enter" key.
NOTE !
Turn off assembly operation. Setting mode is abandoned.
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5. OPERATION
• Programming layer-change
As the kelly rope can be reeved, the reeving must be defined when calculating the cable length.
The layer-change is
- already programmed with delivery of the machine,
- usually only has to be reprogrammed following a rope change or repairs to the winches.
If function key F7 is actuated a second time and at the same time the pre-selection key "Assembly
operation" is actuated, special function key symbols appear for programming the layer-change.
Description of function key symbols for programming the layer-change
Symbol "Set layer-change 1-2"

Upon actuation of function key F1 , the layer-change for the selected winch is
programmed from the 1st to the 2nd rope layer.
Symbol "Layer-change kelly winch"

Upon actuation of function key F5 , the kelly winch is pre-selected for program-
ming of the layer-change.
Procedure
• Actuate function key F7 twice and at the same time actuate the assembly key.
• Actuating the kelly winch.
An assistant monitors the kelly winch and informs the machine operator as soon as a layer-change
occurs.
• Stop the kelly winch precisely as a layer-change occurs. Should no layer-change be achieved due
to the cable length, raise the load hook to the highest point.
• Actuate the function key for layer-change kelly winch.
The respective display of the cable length starts flashing in the operation diagram.
NOTE !
Pre-selection only remains active for 5 seconds following actuation of the corresponding function
key. The layer-change must be programmed within this time.
• Actuate the function key for the actual layer-change (set layer-change).
The Litronic-control
- determines the transition point in the next rope layer,
- thus calculates all other layer changes,
- shows the cable length of the first layer, minus three safety windings on the LCD-display screen,
- can now display the actual cable length precisely.
NOTE !
Only a single layer-change must be programmed for each winch.
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5. OPERATION
5.8.10 Drilling free-fall *

General
For free-fall operation, the kelly winch is configured as a free-fall winch. The optional drilling free-fall
separates the drive from the load. The load can be braked under control via the brake pedal in the
operator's cab.
Constant pull
For automatic following on of the kelly rope a handwheel is installed in the operator's cab (constant
pull valve). The clutch pressure can be adjusted with this handwheel so that the rope is unwinded
from the winch by the load (kelly rod or drilling flight auger) without formation of a slack rope.
WARNING !
Operational errors in free-fall operation can cause damage to the kelly winch and the drilling
tool!
Application of the free-fall winches involves considerable risk, which the machine operator
must be fully aware of.
Countermeasure:
Free-fall operation must therefore only be carried out by experienced and specially trained personnel.
61
Authorise / block free-fall operation
Ball valve for free-fall authorisation

The ball valve
- is accessible after opening side doors at rear of oper-
ator's cab,
- enables the switching of lifting and free-fall operation
1 Position "Free-fall operation"
2 Position "Lifting operation"
3 Limit switch
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5. OPERATION
62
Activating drilling free-fall:
• Actuate the key on the left-hand switch lever (fig. 62,
no. 1) and hold pressed down.
• Apply brake pedal for the free-fall brake of the kelly
winch (fig. 63, no. 1) completely (push all the way
down)
IMPORTANT !
In order to prevent unwanted authorization of the drilling
free-fall, the key must be actuated first and then the
pedal.
63
The following symbol appears on the LCD-display screen following actuation of the brake pedal:
Symbol "Free-fall kelly winch"
• Lowering the load in free-fall:

Release the free-fall brake under control with the respective brake pedal.
• Stopping free-fall of the load:
Carefully and sensitively, push down the brake pedal.
Adjusting constant pull:

Adjustment of the constant pull is resulted via turning of the handwheel (fig. 63, no. 2).
Prerequisite: Drilling free-fall is activated
• Turning clockwise = Reduce constant pull
LRB255_V001 (mf) LWN - TD4/2/2010
the kelly rope (load) is wound out quicker/easier

• Turning anti-clockwise = Increase constant pull
the kelly rope (load) is wound out slower/heavier
NOTE !
Increase the constant pull until slack rope no longer occurs during kelly drilling operation. Should the
constant pull be increased too much, unnecessary loss is resulted due to heating up and wear of the
free-fall brake.
Should the constant pull be increased even further, the free-fall brake remains applied and the rope
will no longer be wound out by the kelly winch.
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5. OPERATION
CAUTION !
No automatic shut-down of the lowering direction is resulted via the 3-coil-limit switch during
free-fall operation!
With overrun of the hoist cable
- a dangerous formation of slack rope is possible,
- winding onto the kelly winch becomes loose and irregular,
- the 3-coil-limit switch and the rope length measurement * adjust themselves of their own accord.
Countermeasure:
• Stop the free-fall winch immediately via the respective brake pedal when the load has been set
down on the ground.
• Increase the constant pull accordingly via the handwheel.
• Lift load again: Actuate the corresponding switch lever. The brake pedal can be released. The
brake pedal can also remain actuated during lifting of the load.
NOTE !
A so-called winch standstill regulation monitors rotational movement of the free-fall winches. A load
can then be lifted again when the respective free-fall winch has come to a standstill.
Deactivating drilling free-fall:
Before leaving the cab, the machine operator must check that the free-fall function has been
switched off correctly.
• Fully depress and hold down the brake pedal until the winch has stopped moving.
• Drilling free-fall is erased automatically upon actuation of the left-hand switch lever in the lifting
direction.
Prerequisite: Winch standstill
The symbol in the status display on the LCD monitor goes out when the control
system has deactivated the free-fall.
• Raise the safety lever
WARNING!
Raising the safety lever is not the correct way to switch off free-fall; it is simply a safety
precaution. If the winches are not completely stationary when the safety lever is raised,
free-fall is not deactivated.
This can lead to fatal injury or serious damage to property if the free-fall releases the raised load.
NOTE !
Free-fall operation is deactivated immediately when the diesel engine is shut down.
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5. OPERATION
5.8.11 Mooring for assembly and dismantling *

General
The mooring is used to automate the running of the kelly winch during assembly and dismantling.
The rope end is fixed to the foot piece of the lead and, when a cylinder adjustment function is
activated, the kelly winch rotates in the hoisting direction with a certain rope pull and speed.
WARNING!
The mooring is intended solely for the assembly and dismantling of the ramming and drilling
plant.
Malfunction or incorrect operation can lead to serious accidents!
During assembly and dismantling, continually check that the mooring is functioning correctly
(check the tension and the running of the rope on the kelly winch).
Expertly fasten the kelly rope to the lead foot before switching on the mooring.
64
Switch on the mooring
• Switch on the assembly operation on the left-hand
control panel (X12) (fig. 64, no.1)
• Press the key button on the left hand switch lever (2)
and hold pressed down.
• Apply brake pedal for the free-fall brake of the kelly
winch (fig. 65, no. 1) completely (push all the way
down)
IMPORTANT !
In order to prevent unwanted authorization of the moor-
ing, the key must be actuated first and then the pedal.
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5. OPERATION
When the mooring has been selected, the following symbol appears on the LCD screen:
"Kelly winch mooring" symbol flashes
Mooring release
The mooring is released (the kelly winch winds) when the following cylinder adjustment functions are
activated:
- Basic arm-adjusting cylinder (Z4)
- Support arm brace-support cylinder (Z2)
- Leader lateral inclination cylinder (Z6)
- Leader height adjusting cylinder (Z5)
- Upper leader rotary cylinder (Z3)
The release is displayed on the LCD screen
"Kelly winch mooring" symbol does not flash
Turn off mooring

• Switch off assembly operation (fig 64, no. 1)
• Press the key button (2) on the switch lever to the left
• Raise the safety lever
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5. OPERATION
5.8.12 Parallel operation *

General
In parallel operation the rope of winch 2 is secured to the front of the add-on unit. Winch 2 runs in
parallel with the feed winch.
Parallel operation is used to
- increase the tensile force in the feed system during hoisting,
- achieve a uniform distribution of the weight of the add-on unit, relieving the load
on the guides.
Reeving the rope

Reeve the rope of winch 2 around the kelly beam correctly as described in Chapter 8 "Changing
kelly ropes" and secure it to the add-on unit.
WARNING!
The machine can be severely damaged!

When the rope is secured to the add-on unit
- winch 2 must not be actuated again,
- parallel operation must be switched on.
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5. OPERATION
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.
65
• Switch on drill free-fall
For safety reasons drill free-fall must now be switched
on.
Procedure:
Press and hold down the button on the left-hand joystick
(Figure 65, item 1) and fully depress the brake pedal for
the free-fall brake on winch 2 (Figure 66, item 1).
See "Drill free-fall" in Chapter 5
IMPORTANT!
Parallel operation is only selected when the LED in the
"Parallel operation winch 2" pre-selection key lights up.
66
Constant tension is adjusted by turning the handwheel
(Figure 66, item 2).
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5. OPERATION
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 66, 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. OPERATION
67
5.8.13 Pile locking
When working beneath or on the leader, the pile (pile
device) must always be set down on the ground or
locked.
Functional mode:
Lower nylon rope, adjust universal carriage downwards
and set down the pile.
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5. OPERATION
5.9 Notes on operation

5.9.1 General
DANGER !
An overload causes the leader to fail !

Buckling is a sudden failure which is not reported beforehand.
Prerequisites
• Only carry out operation to the respective intended use (see chapter 2).
• Assembly is concluded in accordance with chapter 6 (the leader is in the working position, the
counterweight (power pack) has been mounted).
• Check ground condition on the jobsite !
• The ground pressure underneath the leader can be considerably greater during the pulling
process. Note the underground !
• Set leader down on the ground via pulling of the sheet pile (auger).
• Refer to the load charts (see volume 2) !
CAUTION!
Exceeding the permitted limits (maximum capacity, working pressure, etc.) will result in
damage to the add-on unit!
Take note of the information provided by the manufacturer and adjust the values accordingly on the
Litronic control.
Technical data, special safety precautions, operating and maintenance instructions for the add-on
units can be found in the manufacturer's operating manual.
WARNING!
Risk of accident and possible damage due to cable!

Do not fasten cables to the basic machine or lead. Otherwise damage may occur when adjusting the
lead or turning the uppercarriage.
Only attach a cable to the hook garage when the corresponding winch is directly mounted on the
lead (do not attach to basic arm or uppercarriage). Otherwise damage may occur when adjusting the
lead.
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5. OPERATION
Drilling operation
• Drill only
- with the torque supports fitted,
- with the leader vertical.
(If the reach is short and the leader is inclined forwards, it will collide with the basic arm.)
Winch 2 for pulling (parallel operation)

If winch 2 is used for pulling the auger or pipe with a leader length of 27 m (or more) the line pull
or the reeving must be limited as follows:
Line pull winch 2: 200 kN

Leader length maximum pulling force at the drilling drive
single-fall two-fall
21 m 200 kN 400 kN
24 m 200 kN 400 kN
27 m 200 kN 200 kN
30 m 100 kN -
Line pull winch 2: 250 kN

Leader length maximum pulling force at the drilling drive
single-fall two-fall
21 m 250 kN 500 kN
24 m 250 kN 500 kN
27 m 250 kN 200 kN
30 m 100 kN -
See chapter 9 under "Line pull limitation"
DANGER!
Danger thru overloading of the leader!

From a leader length of 27 m on (and longer) the line pull or reeving of winch 2 must be limited
when pulling.
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5. OPERATION
Vibrator operation
• Piles located a considerable distance away should be brought closer to the machine using auxiliary
equipment.
• Only pick up the sheet pile with the leader in a vertical position.
• It is the responsibility of the operator to ensure that the clamping tongs being used are suitable for
the profile in question. Check out the technical data supplied by the manufacturer.
DANGER!
Piles can slip out of the clamping tongs (as the result of a broken hose, etc.).
- Do not stand in the danger area.
- Always set down the pile during work breaks.
- When the pile is hanging freely, the machine operator must always remain alert and in the cab.
Hammer operation
• Note the details of the manufacturer regarding hammer control !
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5. OPERATION
5.10 Drilling operation *

5.10.1 General
The functions described as follows apply for all drilling operation types.
68
"Drilling-ABS"
The "Drilling-ABS" (drill-anti-blocking-system) limits the
feed pressure above a certain drilling pressure.
The pressure set on the auxiliary panel via the poten-
tiometer (fig. 68) is automatically reduced.
If the potentiometer is activated, the LED lights up in the
pre-selection display.
69
Switching over torque of the drilling drive
Drilling drive can be operated with a little or a lot of
torque.
• Switch-over between a little and a lot of torque is

resulted upon actuation of the key (fig. 69, no. 1) on
the right-hand switch lever.
IMPORTANT !
Switch-over between a little and a lot of torque is re-
sulted fundamentally with standstill of the drilling drive.
As an option the switch-over can also be resulted
during operation. This is only made possible by the
control if the drilling gear is designed for this purpose.
little torque (top speed) of the drilling drive is actuated.
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5. OPERATION
70
Storing drilling movement
The drilling movement can be stored.
Procedure:
- Adjust the switch lever control setting
- press the key button (Figure 70, No. 1) on the right
switch lever
- put the switch lever back to the zero position
The drilling drive automatically moves right or left.
The symbol "Movement stored" is displayed on the LCD screen.
Deleting storage:
adjust right switch lever control setting
If several movements are stored, all the others will be deleted as well.
71
Limiting the drilling speed
The drilling drive speed can be limited by the potentiom-
eter (Fig. 71, No. 1) on the auxiliary panel (X25).
IMPORTANT!
In the case of double rotary drilling, the speed of drilling
drive 1 (screw) is limited by the potentiometer on the
auxiliary panel.
72
Vibrating the drilling drive
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Vibrating of the drilling drive is resulted via actuation of

the pawl switch (fig. 72, no. 1).
Quick reversal of the drilling flight auger makes it possi-
ble for the flight auger to be emptied.
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5. OPERATION
73
Flight auger cleaner *
Removal of the cuttings from the drilling flight auger can
be resulted either by vibration or with the aid of the flight
auger cleaner.
With the flight auger cleaner, a disc is guided to the
drilling flight auger so that the cuttings are scraped off
during rotation of the flight auger.
• Upon actuation of the pawl switch (fig. 73, no. 1) on
the left-hand switch lever, one direction is authorised
and remains active as long as the pawl switch remains
pressed. Reactuation changes the direction again.
IMPORTANT !
If the auger cleaner is not actuated, it is in free-wheel
operation.
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5. OPERATION
5.10.2 Kelly drilling

General
Kelly drilling is a procedure which connects the drilling tool with the drilling drive via a telescopic rod
(kelly rod). Depths which exceed that of the leader can thus be realised.
This is resulted as follows:
- the cuttings are conveyed step-by-step from the hole via the drill (kelly rod plus drilling flight auger).
The drilling flight auger must be entered every time. Additionally, an exterior tubing must usually
(depending on ground conditions) be fitted in order that the hole does not collapse in on itself.
- When the depth has been reached, the steel reinforcement (reinforcing basket) can be fitted.
- The hole is then concreted via a chute.
For kelly drilling you will require a:
- Kelly winch
- Auxiliary winch
- Feed winch (winch 1)
Kelly drilling is often carried out in connection with the optional casing oscillator . The casing
oscillator is auxiliary equipment for fitting the exterior piping.
Pre-selecting kelly drilling

Display "Kelly drilling"
See chapter 5 "Start-up".
The display field-kelly drilling is overlayed on the LCD-display screen.

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5. OPERATION
Setting the drilling drive

Procedure

999 flow rate [l/min] 999 auger length [cm]

9 number of pumps
999 flow rate case oscillator [l/min]
Page "Adjustments"
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5. OPERATION

Key "Cursor back"

NOTE!
With an adjusted flow rate of 600 l/min [158 gal/min] the number of pumps has to be set to two at a
minimum.
Key "Enter"
"Enter" key.
NOTE!

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5. OPERATION
74
Actuating the drilling drive.
The drilling drive is actuated proportional via the right-
hand switch lever (fig. 74, no. 1):
• Switch lever to the left = Drilling drive turns to the right
• Switch lever in zero position = Drilling drive remains in
position
• Switch lever to the right = Drilling drive turns to the left
75
Switching on rock gear
Switch on rock gear if you want to drill with high torque.
• Press the button (Figure 75, 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. OPERATION
5.10.3 CFA drilling

General
With the procedure for CFA drilling or continuous flight auger drilling, the pile is manufactured on-site
without piping.
- Turning of the flight auger to the final depth. The earth is partially displaced.
- When withdrawing, the concrete is inserted via the hollow flight auger. It is very important is not
withdrawn too quickly in order that the hole does not collapse in on itself and pile operation
interrupted (the optional concrete pressure display should prevent this).
- When the flight auger has been withdrawn, the steel reinforcement (reinforcing basket) is pushed in
or inserted via vibration.
For CFA drilling you will require a:
- Auxiliary winch
Pre-selecting CFA drilling

Display "CFA drilling"
The display field CFA drilling is overlayed on the LCD-display screen.
Display field CFA drilling

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5. OPERATION

Procedure

999 flow rate [l/min]

999 pile diameter [cm]

9 number of pumps

Page "Adjustments"
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5. OPERATION

Key "Cursor back"

NOTE!
minimum.
Key "Enter"
"Enter" key.
NOTE!

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5. OPERATION
76
Actuating the drilling drive
Drilling drive is actuated proportional via the right-hand
switch lever (fig. 76, no. 1):
position
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5. OPERATION
77
Double rotary drilling drive for CFA application *
In double rotary drilling the drives (auger and pipe) can
be bolted together. The drive torques of both the auger
and pipe are thus combined.
However, a ball valve must be used to equalize the
hydraulic pressure in both drives.
78
Procedure:
• Activate double rotary drilling
• Move the relative displacement cylinder downwards
• Connect adapter to the auger drive (Figure 77, 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 77)
• Move ball valve to position 1 (Figure 78)
• Activate CFA operation
Operation is as described above.
If the ball valve is not operated, the following symbol appears on the LCD:
LRB255_V001 (mf) LWN - TD4/2/2010
"Bolts withdrawn" symbol

Double rotary drilling drive: the auger and the pipe are not bolted together.
The drilling drive is stopped in CFA drilling.
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5. OPERATION
5.10.4 Double rotary drilling

The double rotary drilling procedure is similar to CFA drilling, in that two drilling drives are connected
via a proportional shifting cylinder. The first drilling drive powers the drilling flight auger and the
second drilling drive powers the exterior piping. The drilling drives can be pushed against each other
via the displacement cylinder (flight auger or pipe ahead).
- Penetration of the flight auger down to the final depth. The earth is channelled out via an ejector.
- When withdrawing, the concrete is inserted via the hollow flight auger. It is important that the flight
auger is not withdrawn too quickly in order that the hole does not collapse in on itself and pile
operation interrupted (optional concrete pressure display should prevent this).
- When the flight auger has been withdrawn, the steel reinforcement (reinforcing basket) can be
pushed in or inserted or vibrated in.
NOTE!
Switching over torque
Switch-over of the torque can be resulted separately for both drilling drives.
Drilling pressure and speed are displayed separately for every drilling drive.
Pre-selecting double rotary drilling

Display "Double rotary drilling"
The display field double rotary drilling is overlayed on the LCD-display screen.
Display field double rotary drilling
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5. OPERATION
Setting the drilling drives

Procedure

999 flow rate auger [l/min]

999 flow rate casing [l/min] 999 pile diameter [cm]
999 max. pressure auger [bar]

999 max. pressure casing [bar] 9 reevings main winch

Page "Adjustments"
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5. OPERATION

Key "Cursor back"

NOTE!
minimum.
Key "Enter"
"Enter" key.
NOTE!
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5. OPERATION
79
Actuating drilling drive 1 (flight auger)
Drilling drive one is actuated proportional via the right-
hand switch lever (fig. 79, no.1):
position
Adjust potentiometer on the switch lever all the way
down in order that drilling drive 2 can not be actuated!
80
Switching over torque drilling drive 1
Switch-over between a little or a lot of torque for drilling
drive 1 is resulted via actuation of the key (fig. 80, no.1).
Should operation be carried out with a little torque (top
speed), the corresponding symbol (the hare) appears on
the LCD-display screen.
81
Actuating drilling drive 2 (pipe)
Drilling drive two is actuated proportional via the left-
hand switch lever (fig. 81, no.1):
• Switch lever backwards = Drilling drive turns to the
right
position
• Switch lever forwards = Drilling drive turns to the left
82
Switching over torque drilling drive 2
LRB255_V001 (mf) LWN - TD4/2/2010
Switch-over between a little and a lot of torque for

drilling drive 2 is resulted via actuation of the key
(fig. 82, no.1).
Should operation be carried out with a little torque (top
speed), the corresponding symbol (the hare) appears on
the LCD-display screen.
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5. OPERATION
83
Actuating both drilling drives with one
switch lever
Both drilling drives can also be actuated simultaneously
via one switch lever.
• Drilling drive 1 is actuated via the right-hand switch
lever (as described previously left/right).
• Drilling drive 2 is controlled in the opposite direction
or proportional respectively via actuation of the poten-
tiometer (turn upwards) on the right-hand switch lever.
IMPORTANT !
Drilling drive 2 can be actuated again at any time via the
left-hand switch lever.
The control will not allow actuation of both drilling drives in the same direction with a lot of torque.
Proportional shifting cylinder

The drilling drives can be pushed against each other via the proportional shifting cylinder. The pipe
can thus be operated with the flight auger either ahead or inverted.
Pre-selecting the proportional shifting cylinder

Pre-selection key "Proportional shifting/Pile threading device"
The proportional shifting cylinder is pre-selected on the auxiliary panel by press-
ing this key.
It can either be actuated via the auxiliary panel or by pressing the pawl switch
(fig. 83, no. 1) on the left-hand switch lever.
Actuating proportional shifting cylinder via the auxiliary panel
Key "lift/open"
Extend proportional shifting cylinder.
Key "lower/close"
Retract proportional shifting cylinder.
84
Actuating proportional shifting cylinder via the left-
hand switch lever
By pressing the pawl switch (fig. 84, no. 1) on the left-

hand switch lever, the proportional shifting cylinder is
actuated in one direction and remains active for as long
as the switch remains pressed.
If the switch is pressed again, the direction changes.
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5. OPERATION
85
Recovery mode *
Recovery mode enables a jammed pipe to be removed.
The drives (auger and pipe) are bolted together. The
drive torques of both the auger and pipe are thus com-
bined.
A ball valve must be used to equalize the hydraulic
pressure in both drives.
86
Procedure:
• Bolt the auger and pipe together (Figure 85)
(actuate the relative displacement cylinder and auger
accordingly)
• Move ball valve to position 1 (Figure 86)
This modifies the following functions:

• Both drilling drives can be operated in the same direc-
tion under high torque conditions
• Both drilling drives are operated using the right-hand
joystick (auger)
• The oil volume is reduced for safety reasons
When finished, return the ball valve to position 2 (Fig-
ure 86) and remove the bolts
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5. OPERATION
5.10.5 Soil Mixing operation

Stabilizing agents and soil are mixed onsite when mixing soil. The existing pore spaces in the soil
are filled with a suspension of stabilizing agents. The result is a defined solidified soil due to the
auger geometry.
One, two or three drilling gears and/or augers can be used.
Work process:
Screw the auger(s) in up to the final depth. The solid soil is mixed during drilling and pulling the
screw and the stabilizing agent is placed into the liner.
The drilling pressure and the speed are displayed separately for each drilling gear.
Pre-selecting Soil Mixing
Display "Soil Mixing"

The display field-soil mixing is overlayed on the LCD-display screen.
Display field-Soil Mixing
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5. OPERATION

Procedure

999 flow rate auger 1 [l/min] 99 auger length [cm]

999 flow rate auger 2 [l/min] 999 pile diameter [cm]

9 number of augers
9 number of pumps

Page "Adjustments"
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5. OPERATION

Key "Cursor back"

NOTE!
minimum.
Key "Enter"
"Enter" key.
NOTE!
87
Actuating the drilling drives
The drilling drives are actuated proportional via the right-
hand switch lever (fig. 87, no. 1):
• Switch lever to the left = Drilling drives turns to the
right
• Switch lever in zero position = Drilling drives remains
in position
• Switch lever to the right = Drilling drives turns to the
left
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5. OPERATION
5.11 Vibrator *
5.11.1 General
NOTE!
Technical data, special safety precautions, operating and maintenance instructions for the accessory
Vibrator operation
Vibrator operation is a process that employs vibration to reduce the resistance between the pile and
the ground, consequently making it easier to drive in the pile. Other advantages compared with
driving are lower noise levels and less danger of building damage.
The fact that the weights are arranged in an eccentric manner (imbalance) means that the pile,
which is held in place by clamping tongs, starts to vibrate.
This is done as follows:
- Position pile and hold in place with clamping tongs
- Start up the vibrator; if eccentric adjustment is provided, the eccentric should be
retracted (no imbalance)
- Extend the eccentric when the final speed (frequency) is reached
- Drive pile in to the ground
The following are required for vibration:

- an auxiliary winch (for holding the pile)
- a feed system. This depends largely on the weight
of the vibrator. Light vibrators require the most pressure.
- Clamping tongs
- Eccentric adjustment (optional)
- Monitoring device (optional)
The following optional items of equipment can be fitted

- Eccentric adjustment
- Monitoring device
The vibrator can be operated in two ways:

- Vibrator with eccentric
- Vibrator without eccentric
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5. OPERATION
5.11.2 Pre-selecting vibrator operation

Display "Vibrator operation"
The display field vibrator operation is overlayed on the LCD-display screen.
Display field vibrator
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5. OPERATION
5.11.3 Setting the vibrator

Procedure


9 number of pumps
999 clamping tong pressure [bar]
999 eccentric adjustment time [s] 9 reevings main winch

Page "Adjustments"
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5. OPERATION

Key "Cursor back"

NOTE!
minimum.
Key "Enter"
"Enter" key.
NOTE!
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5. OPERATION
5.11.4 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.
The clamp system is switched off when the diesel engine is off and must be activated the first time
the clamps are closed after the engine is started.
Clamp system:
The clamp is reclamped automatically as soon as the clamping head pressure drops below the
specified value. This ensures that any pressure losses are compensated for. Automatic reclamping is
indicated both acoustically (warning tone) and visually (flashing symbol on the screen).
If reclamping occurs frequently, cease operations and rectify the fault.
88
Starting the clamping tongs system
Closing the clamping tongs
The clamping tongs can be closed in two ways:
Right joystick:
• Press button (Figure 88, 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

When the vibrator is switched on, a distinction is made between vibrators with and without eccentric
adjustment.
• Vibrator with eccentric adjustment

In the case of vibrators with eccentric adjustment, before the vibrator starts up the eccentric is
selected automatically and retracted in line with the selected eccentric adjustment time. Only then
is the vibrator ramped up continuously to the selected flow rate.
• Vibrator without eccentric adjustment

In cases where there is no eccentric adjustment, the vibrator is immediately ramped up to the
selected flow rate.
89
The vibrator can be switched on in two ways:
Right joystick:
• Press button (Figure 89, item 1):

• Press key (2)
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5. OPERATION
Adjusting the oil quantity

The LED in the "Additional hydraulics flow rate" preset display on the right control
panel (X23) lights up.
The oil quantity is adjusted with potentiometer 1 on the right control panel
(X23).
The flow of oil to the vibrator can be set to between 0 and the maximum flow
rate.
Adjusting the eccentric, variant 1 *

Prerequisite: An eccentric adjustment time must have been specified.
Eccentric adjustment time = 0 means there is no eccentric.
Possibility "1":
With the keys on the right control panel (X23):

"Extend eccentric / lifting cylinder" key
The eccentric is extended.
"Retract eccentric / lifting cylinder" key

The eccentric is retracted.
90
Possibility "2":
The eccentric can be adjusted using the rocker switch

(Figure 90, item 2) on the right joystick:
• Press button (Figure 90, item 1).

The "Eccentric" symbol (3) is shown on the LCD dis-
play.
• Push rocker switch to the left = extend eccentric

• Push rocker switch to the right = retract eccentric
If the eccentric is selected, it will not be possible to
adjust the speed of the diesel engine.
• Press button (Figure 90, item 1) again = rocker switch
is now used to adjust engine speed again..
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5. OPERATION
Monitoring device (optional)
The vibrator can be fitted with a monitoring device as an optional extra.

Monitoring device
An acceleration sensor is fitted to the vibrator. The sensor signal is converted into a frequency and
vibration amplitude signal. These signals are converted and displayed on the LCD screen in the
Vibrator display field.
Vibrator frequency and amplitude

Shows the frequency of the vibrator (e.g.: 33.5) in Hertz.
Shows the amplitude of the vibrator (e.g.: 10.6) in mm.
If the optional sensor is connected.
Adjusting the eccentric, variant 2 *

Prerequisites:
- An eccentric adjustment time must have been specified.
Eccentric adjustment time = 0 means there is no eccentric.
- The relevant sensors are fitted to the vibrator.
NOTE!
If the sensors are not connected or are apparently supplying incorrect values,
- the frequency and amplitude symbols in the vibrator display field will flash
- adjustment of the eccentric functions as described for variant 1 .
• Switch on the eccentric as described for variant 1 .
• Setting the maximum imbalance
The LED in the preset display on the right-hand control panel (X23) lights up
when the eccentric is switched on. The LED goes out when the eccentric is
switched off.
The oil quantity is adjusted using potentiometer 2 on the right-hand control

panel (X23).
The eccentric can be set to a value between 0 and maximum imbalance.
one turn of the potentiometer = 50% imbalance
two turns of the potentiometer = 100% imbalance
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5. OPERATION
Switching off the vibrator
• Vibrator with eccentric adjustment

When the vibrator is switched off, the eccentric is first automatically retracted in line with the
specified eccentric adjustment time and only when this operation is complete is the vibrator then
gradually shut down.
• Vibrator without eccentric adjustment

The vibrator starts to shut down immediately.

"Vibrator on/off" key
Switches the vibrator on and off.
Open clamping tongs (X23)
Prerequisite: The vibratory hammer is at rest, the pile is lowered to the floor and prevented from
tipping over.
"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
5.12 Special vibrator *

5.12.1 General
NOTE!
Technical data, special safety precautions, operating and maintenance instructions for the accessory
The special vibrator is automatically selected by the control system via a jumper in plug X13 (vibrator
mounted).
Prerequisite:
- plug X13 plugged into the bulkhead plate,
- vibrator operation selected.
The special vibrator differs in the following areas:
- external pressure sensor (0-600 bar) for the clamping tongs on the vibrator
- oil pressure gauge on the LCD display
The other functions are the same as those of the standard vibrator.
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5. OPERATION
5.13 Hammer *
5.13.1 General
Optionally, the LRB 255 can be equipped for hammer operation.
NOTE !
The technical data, special safety guidelines, the operation and maintenance of the attachments can
be obtained from the operating instructions of the respective manufacturer.
Hammer operation
Hammer operation is a procedure with which a drop weight is pulled or pushed to a pre-selected
height with the aid of a hydraulic cylinder and then dropped onto an impact cover. The sheet pile is
thus driven into the ground.
- Pick up sheet pile and mount hammer
- Activate hammer
- Insert sheet pile in the ground
For hammer operation you will require a:

- Auxiliary winch (sheet pile pick-up),
- Kelly winch (hammer winch) or
For hammer operation an additional hammer control (scope of delivery hammer manufacturer) is
usually required. This regulates the drop height and number of impacts. Only the oil flow is supplied
from the machine.
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5. OPERATION
5.13.2 Pre-selecting hammer operation

Display "Hammer operation"
The display field hammer operation is overlayed on the LCD-display screen.
Display field hammer
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5. OPERATION
5.13.3 Setting the hammer

Procedure


9 number of pumps
999 ram weight [kg] 9 reevings main winch

999 blows / depth step
Page "Adjustments"
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5. OPERATION

Key "Cursor back"

NOTE!
minimum.
Key "Enter"
"Enter" key.
NOTE!
5.13.4 Operating the hammer
CAUTION !
The hammer could damage the machine (in particular the ropes)!
The rope should always be relieved of tension during hammer operation (constant pull).
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5. OPERATION
91
Activating the hammer
Activation of the hammer can be resulted in two ways:
• Via actuation of the upper right-hand switch (fig. 91,

no. 1) on the left-hand switch lever .
• Via actuation of the switch (2) on the right-hand

control panel (X23) .
Adjusting oil flow

The oil flow can be externally regulated via potentiometer 1 on the right-hand control panel (X23) or
via an additional hammer control.
Right-hand control panel (X23):
The LED in the pre-selection display "Flow rate auxiliary hydraulics" lights up on
the right-hand control panel (X23).
Adjustment is done via the Potentiometer 1 on the right-hand control panel

(X23)
The oil flow for the hammer can be regulated from 0 - maximum flow rate.
Deactivating the hammer

Right-hand control panel (X23):
Key "Hammer On / Off"
Switching the hammer on and off.
5.13.5 Additional hammer control

The hammer control is installed in the upper, rear side of the operator's cab. A fixture has been
provided on the front right-hand side of the operating panel.
LRB255_V001 (mf) LWN - TD4/2/2010
The connecting cable is inserted to the front right-hand side of the uppercarriage.
With external regulation, an R/I converter must be installed in the operator's cab with which the oil
flow can be adjusted via the potentiometer of the hammer control.
Potentiometer 1 on the right-hand control panel (X23) must be set to 0.
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5. OPERATION
5.13.6 Hammer operation with energy measurement

In hammer operation with energy measurement, the speed of the drop weight and consequently the
energy of the hammer is measured externally using two sensors and a special counter module. The
speed of the hammer can also be transmitted to a remote control via a serial interface. Hammer
operation with energy measurement must be preset by the Liebherr Customer Service department.
This mode of operation is distinguished from normal hammer operation by the following
features:
• Oil is only supplied to the hammer when the feed winch is actuated. The main reason this is
necessary is to ensure that the universal slide can always follow the hammer and consequently
- guarantee that the depth per blow is recorded correctly,
- ensure that the hammer does not drop onto the free-wheeling support, thereby
transferring the energy to the universal slide or the feed winch rope,
- ensure that if the universal slide is stopped, the hammer is also stopped.
• If the hammer is switched on, fast feed operation of the winch is activated automatically. This
ensures that the winch runs quickly.
In addition, the machine operator must enter the following data:

- weight of the drop weight
This is required to calculate the amount of energy and must be entered in kg [lbs].
- maximum number of blows per depth step (conversion of pile formula).
This provides information on the load bearing capacity of the pile. As different pile formulae are
used from country to country, or even from site to site, the customer has the ability to convert
these so that the penetration/blow and the resulting blows/depth step can be entered as the result
on the LCD screen. All the machine operator has to know is the amount of energy that he should
be using when operating the hammer. The bar on the LCD screen starts flashing when this figure
is reached.
Depth step
The depth step is set by the Liebherr Customer Service department and should be agreed with the
customer. The default value is 100 mm; this should not be confused with the PDE trigger. The
difference with regard to the PDE trigger is that the energy or the blows are always converted to the
specified depth step. This step can be larger with the PDE trigger due to the high speed of the slide
and the cycle time of the PLC. The depth step should always be the same to allow values to be
compared.
The following data are displayed on the LCD screen:

- current blows per minute.
These are either measured using a special counter module or transmitted via a serial interface
- current hammer energy.
This is calculated from the speed and weight of the drop weight
- blows per depth step
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5. OPERATION
5.13.7 Hammer operation with serial communication

In the case of hammer operation with serial communication, some data:
- speed in mm/s [ft/s]
- blow count
are transferred and displayed via the RS 232 interface.
If required, the battery voltage of the hammer and the quality of the radio signal can also be relayed.
However, this option is only implemented in situations where remote controls with a radio link from
the hammer to the receiver are being used. If the voltage drops below a particular value, the control
issues an error message.
This threshold value can be set by Liebherr Customer Service.
The LCD screen shows exactly the same data as is shown with external speed measurement. Serial
transmission must be activated by the Liebherr Customer Service department.
5.13.8 Hammer operation with hoist cylinder

For hammer operation with hoist cylinder, the limit switch of the pile driver weight is adjusted in
free-fall via a cylinder, and the energy or impact rate is thus modified.
Vibrator operation must be activated via correction value in addition to hammer operation. The keys
for the eccentric adjustment are used for control of the hoist cylinder. The eccentric automatic is thus
shunted.
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5. OPERATION
5.14 Casing oscillator *

5.14.1 General
The casing oscillator can be used during boom operation as well as during LRB operation.
The casing oscillator an accessory needed mainly during kelly drilling to introduce the external
tubing. Therefore it can only be selected in kelly drilling mode.
5.14.2 Connect the casing oscillator

The casing oscillator is attached to the lower carriage using the optional guiding rails. Quick-fitting
unions are provided on the lower carriage for connection of the hydraulic pipes. Power is supplied to
the casing oscillator via an electric socket.
See (Fig. 92).
92
Attaching casing oscillator

1 Leak oil 5 Return flow
2 Control pressure 6 Return flow
3 High pressure P1 7 Plug socket 24V
4 High pressure P2 8 Guide rails
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5. OPERATION
5.14.3 Setting the casing oscillator

Procedure

999 flow rate [l/min] 999 auger length [cm]

9 number of pumps
999 flow rate case oscillator [l/min]
9 number of pumps
Page "Adjustments"
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5. OPERATION

Key "Cursor back"

NOTE!
minimum.
Key "Enter"
"Enter" key.
NOTE!
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5. OPERATION
5.14.4 Switch on the casing oscillator
"Casing oscillator on/off" key button

Press this key button to switch on the casing oscillator. The appropriate display
field appears on the LCD screen.
Kelly drilling display field with casing oscillator (leader)
The kelly drilling display field appears on the LCD screen if

- kelly drilling is selected on the screen and
- the Casing oscillator is selected
on the control panel right (X23).
The working pressure of the casing oscillator appears in the kelly drilling display field. The higher of
both pressures is displayed.
NOTE !
The other elements are already described in the kelly drilling display field.
Display field casing oscillator (boom operation)

If the casing oscillator is switched on, the display field "Casing
oscillator" is overlayed on the LCD display screen.
The actual high pressure to the hydraulic connections P1 and P2
are indicated via two bars.
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5. OPERATION
5.14.5 Operating the casing oscillator

Adjust 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 "Flow rate auxiliary hydraulics" *

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
- feed winch hoisting is running.
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. OPERATION
5.14.6 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 casing oscillator pump is
limited.
Then, if a user (cylinder) is operated, the pressure in the hydraulic circuit rises and the control
system turns the pumps back to the preset capacity.
5.14.7 Switching off the casing oscillator
"Casing oscillator on/off" key button

Press this key button (again) to turn the casing oscillator off.
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5. OPERATION
5.15 Shutting down the machine
5.15.1 Parking position boom

The parking position
- protects the machine against storm damage,
- applies for maximum wind speeds above those permissible for hoist operation with wind speeds
of up to 20 m/s [45 mph]; this equals wind speed 8,
- is determined for the different operation types under point 3.8.1, "Influences from wind and
storms".
DANGER !
With wind speeds above 20 m/s [45 mph], it is hazardous to remain in the immediate vicinity
of the machine !
Any occurring wind loads can lead to partial or complete damage to boom and may cause the
machine to tip.
Countermeasures:
With wind speeds expected to be above 20 m/s [45 mph] or wind force 8, the entire boom must be
laid flat on the ground.
Complete laying down of boom is always the safest measure that can be taken.
When laying down boom, the following safety guidelines and notes should be observed:
• Machine operator must ensure that he is always aware of the actual weather forecasted for the
job-site, in order to be able to set down boom promptly and safely.
• Always lay down main boom completely and flat.
Impact with elevated railing always represents grave danger.
If main boom is not laid down completely, (only lowered close to ground), this can lead to ruination
of boom or swing brake.
• Only lay down main boom with or against wind direction .
If main boom can only be laid crossways to wind direction due to lack of space, the boom must be
laid down before wind speeds can reach more than 20 m/s [45 mph].
• If storms are raging or are forecasted, and work is to be halted for the day, the entire boom is to
be laid down on ground.
• Should it be determined during actuation planning that the boom cannot be laid down completely
at the job-site due to lack of space and there is a possibility of storms:
Discuss special protective measures against storm damage with manufacturer punctually .
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5. OPERATION
Should the machine be shut down, it is to be decided as to whether it is
a short break in operation (maintenance, work-break), or

a longer pause in operation (overnight, or over several days).
DANGER !
The machine should be sufficiently protected against unauthorised use, damage caused by
vandalism and possible influences from the environment before being left unattended!
Short work-breaks
The machine operator as well as all other personnel familiar with laying down the boom, must remain
on the building site.
The following points should be noted:
• The machine may not represent a hindrance to other traffic.
• All loads are to be lowered to the ground and secured.
• Boom should be adjusted into the parking position .
• Diesel engine is to be shut down before leaving the operator's cab and operator's cab is to be
locked.
Manoeuvre machine with main boom into parking position:

• Swing min boom preferably into or against wind direction.
• Adjust main boom to a main boom angle of between 75° and 80°.
• Do not lay down load hook on ground
(it is recommended that the load hook should be lifted as high as possible).
Longer pauses in operation

With longer pauses in operation and if machine operator and assistants are present, boo must be
laid down on ground completely.
5.15.2 Parking position leader

Manoeuvring the machine into the park position:
• Set down and secure all loads
• Position the leader vertically
• Lower piling or drilling device to the ground
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5. OPERATION
93
5.15.3 Switch off diesel engine
CAUTION!
The turbo-charger's turbine wheel can no longer be

sufficiently lubricated following sudden shut-down of
diesel engine at high engine speed.
To protect turbo-charger, allow diesel engine to run
at idle speed for a short time and only then switch
off.
Shut-down stages :
• All switch levers are in zero position. Safety lever is

raised.
• Reduce speed via rocker switch (fig. 93, no. 1) down
to idle speed and allow diesel engine to run at idle
speed for a short time. If necessary, erase stored
constant speed first via actuation of key (fig. 93, no.
2).
• Switch ignition start switch to -0- position (fig. 94)
switching off diesel engine.
• Actuate Emergency-Off key in operator's cab.
94
IMPORTANT !
After shutting down the Litronic-control, wait at least 5
before starting up again, otherwise error reports may
occur.
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5. OPERATION
95
5.15.4 Parking position of ignition start switch
The ignition start switch has a parking position (fig. 95,
position - P -), which shuts down the Litronic-control.
Thus, the battery does not become so loaded.
The parking position has been provided for longer
pauses in operation where the machine operator must
remain in the operator's cab.
The following electrical devices are featured :
- Interior lighting for uppercarriage

- Cab lighting
- Windshield wiper
- Horn
- Radio
- Fan for heating
- Plug socket in operator's cab
- Cigarette lighter
See chapter 5 under "Operateing the machine - auxiliary
functions".
5.15.5 Checks when leaving machine

The following points should be noted when leaving the machine :
• Load is lowered to ground and professionally secured.
• The machine is in parking position (see chapter 5 "Parking position") on even ground (see chapter
3 "Soil condition on job site").
• No devices for open safety (emergency exits, entrances and exits for auxiliary vehicles, heli-pads,
hydrants, etc.) may be impaired.
• The shut-down machine may not represent an obstacle to any other vehicles (on the building site).
• Supply of additional safety devices is ensured (e.g.: Helicopter lights).
• The ignition start switch is extracted and put away for safekeeping. The operator's cab is blocked.
• Optional auxiliary heating is switched off or is correctly programmed for next operation.
• The machine is completely blocked.
• Positioning of machine is sufficiently secure.
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5. OPERATION
96
5.16 Catch belt and fall protection runner
DANGER !
With maintenance or repair tasks to the mounted

leader, there is a risk of falling!
Countermeasures:
• Only access the leader via the leader ladder with
catch belt secured professionally to the fall protection
runner.
• Position the leader vertically.
• The leader ladder is folded in the working position and
the ladder sections are screwed.
• The leader is lowered to the ground and the piling rig
or drilling device has been lowered.
• The diesel engine of the machine is switched off.
97
5.16.1 Securing the catch belt
The catch belt is stored in the operator's cab behind the
operator's seat.
A detailed description can be found in the bag.
Securing the catch belt

1.) Lift the catch belt on the rear catch hook (fig. 97, no.
2) (align erratic elements) and put on the shoulder strap
(orange) (fig. 98, no. 4) as one would with a rucksack.
2.) Fasten chest strap (fig. 98, no. 6) via the buckle
(fig. 98, no. 5).
98 3.) Fasten the abdominal strap (fig. 98, no. 8) via the
catch strap (fig. 98, no. 7).
4.) Guide the leg strap (blue, fig. 98, no. 11) from be-
hind, beneath the crotch to the front and fasten via the
catch strap (fig. 98, no. 7).
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5. OPERATION
Adjusting the catch belt
• Check that the catch hook (fig. 98, no. 9) on the abdominal strap (fig. 98, no. 8) is central, and
align if necessary.
• Adjust the chest strap (fig. 98, no. 6) so that there is enough freedom of movement. Adjust the
length of the shoulder strap at the (fig. 98, no. 7) catch straps in accordance with bodily size so
that the abominable strap (fig. 98, no. 8) is roughly at the hip bone.
• The back plate (fig. 97, no. 1) should be at the height of the shoulder blades and the front catch
hooks (fig. 98, no. 9) at the middle of the body.
• Tighten abdominal strap (fig. 98, no. 8) so that the fall protection runner functions flawlessly.
99
5.16.2 Function of the fall protection runner
The fall protection runner (fig. 99, no. 2) runs along the
guide rail (3) of the leader ladder. The fall protection
runner is connected with the professionally secured
catch via the snap hook (1) and is dragged along when
raised.
Should a person fall, the fall protection runner gets
jammed with the guide rail within a few centimetres.
Functional checks before use

Before initial utilisation, familiarise yourself with the catch
belt and the individual functional elements. Hook yourself
to the fall protection runner in close proximity to the
ground (fig. 99, no. 1) and strain the catch belt as a test.
Should difficulties arise, check and correct the belt ad-
justment.
CAUTION !
Catch belt and fall protection runner must be

checked regularly, but at least once a year by a
specialist.
Do not use faulty or incomplete catch belts. Ex-
tremely hazardous !
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5. OPERATION
NOTES:
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5. OPERATION
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6. ASSEMBLY AND DISASSEMBLY

6.1 General
This chapter describes
- assembly and disassembly of the LRB 255,
- initial assembly of the piling rig and drilling system *,
- conversion work in accordance with the respective operation type,
- assembly/disassembly of the piling rig or drilling attachment,
- transport between jobsites.
Assembly and disassembly of the LRB 255 involves numerous hazards and dangerous tasks and
thus may only be carried out by trained personnel .
The safety guidelines in chapter 3 and particularly in this chapter must be noted and adhered to.
The illustrations in this chapter have been represented partly- simplified for the interests of clarity and
do not entirely correspond with the steps for assembly and disassembly connected to them. For
example, the undercarriage of the basic machine may be represented without an uppercarriage.
The direction details for "right/left, forward/backward" always relate to the seating position of the
machine operator in the operator's cab.
The exact dimension details are quoted in the ISO- system of units. Dimensions quoted in square
brackets were partly rounded off during the conversion.
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6.2 Application planning
WARNING !
Incorrect application planning can lead to dangerous situations and accident! The machine
operator must familiarise himself punctually and absolutely with the application!
The application planning, alongside a well trained team, is a further important basis for safe and
sound operation of the LRB 255. The machine operator must obtain all necessary information
concerning the application punctually before beginning operation. The details are as follows:
- Type of application and necessary operation type
- Clearance heights and widths (for transport)
- Position of electrical power lines with details of voltage or safe clearances
- Location of ground cables, water and gas pipes
- Spacious prerequisites at the jobsite (e.g.: movement limitation due to buildings)
- Load bearing capacity of ground at jobsite
- additional influences on the jobsite (weather, air-traffic, transmission and radar stations, etc.)
- Weight and dimensions of load to be lifted (piling rig element, drill casing, etc.)
- Required hoisting height and reach
Based on these details, the application planner or machine operator must arrange the necessary
equipment for the respective application. They are:
• Leader extensions and corresponding feed cable

• Working attachments (drilling gear, vibrator, corresponding adapter, etc.)
• Optional auxiliary equipment (torque stay rods, etc.)
• Counterweight
• Tools and accessories (torque wrench, impact wrench, etc.)
• Lifting tackle
• Additional safety devices, etc.
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6.3 Safety guidelines for assembly and disassembly
WARNING !
Assembly and disassembly of the LRB 255 involves numerous hazards and dangerous tasks
which can lead to fatal injury and serious damage.
The most common causes of accident are:
• Insufficient knowledge of the equipment for the LRB 255 as well as lack of training.
• Safety precautions and protective measures insufficiently carried out or not carried out at all to
save time.
• Assembly or disassembly with unsuitable surrounding conditions (incorrect selection of site, bad
weather, fading light, etc.)
6.3.1 Requirements of the assembly team

At least three persons are necessary for safe assembly and disassembly, comprising the machine
operator and two assistants .
The machine operator
- familiarises himself with national and local guidelines, valid for assembly, disassembly and
conversion of the LRB 255,
- instructs his assistants in a briefing,
- assumes management and supervision in the assembly team.
The assistants are
- experienced in piling rig and drilling machine assembly and specially trained for correct and
safely assembly, disassembly or conversion of the LRB 255,
- informed of possible injury via mechanical effects in accordance with point 3.7.1.
The assembly team is equipped with
- the personal protective equipment in accordance with point 3.3,
- radio equipment if communication becomes impossible due to noise.
6.3.2 Requirements of the set-up site
WARNING !
Uneven ground, as well as slippery or soft ground at the set-up or disassembly site of the
LRB 255 can lead to serious accidents with fatal injuries and serious damage to property.
Incalculable dangers can arise due to instability and sudden shifts in weight of the basic
machine or from parts of the machine.
LRB255_V001 (mf) LWN - TD4/2/2010
The basic requirements for the set-up site

- are described under point 3.8.2 "Soil conditions at the site,
- also apply for disassembly and conversion of LRB 255.
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NOTE !
With insufficient ground resistance, the standing area of the basic machine should be enlarged.
Following consultation with an officially recognised geologist or expert, excavator plates or steel
plates of suitable size are to be laid under the support plates.
The set-up site must be big enough for
- delivery of the basic machine and the attachment pieces with a flat-bed trailer and HGV,
- operation of an auxiliary crane,
- the hindrance-free carrying out of all assembly work.
The set-up site should be secured against unauthorised access from persons visiting the building-site
regularly, preferably with boundaries 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 Performance guidelines
WARNING !
Errors made during assembly or disassembly could lead to serious accidents with fatal
injuries and severe damage to property!
Countermeasures:
• It is therefore imperative that all activities and assembly procedures described in this chapter are
carried out in the order described.
• Arising questions or uncertainty should be explained immediately by the assembly team.
Any auxiliary cranes used must feature the necessary load bearing capacity.
Lifting tackle (straps, chains, etc.) must be checked and must feature the necessary load bearing
capacity.
The tools included in delivery, as well as the assembly gear should be fundamentally used for
assembly and disassembly of the LRB 255.
When working on the upright leader, the safety equipment provided (leader ladder with guide rail, fall
protection runner and the catch belt) is to be used.
Working on the uppercarriage and on the laid down leader is only permitted with sufficient safety.
All required winches and cylinders should be actuated slowly and carefully in order to,
- be able to stop the respective movement should any dangers occur,
- avoid high dynamic forces.
Do not fasten winch cables to the basic machine or to the leader
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 Assembly of basic machine

6.4.1 Prerequisites
• The set-up site must be selected and prepared in accordance with point 6.3.2.
• The basic machine is on a flat-bed trailer and is ready to be unloaded.
• The basic machine has been inspected in accordance with point 5.3 "Checks before start-up" and
is ready for operation.
• The glass panes in the operator's cab and all exterior mirrors have been cleaned.
• The assembly team has been instructed in accordance with point 6.3.1 and are ready for
operation.
6.4.2 Summary of assembly stages

• Start up machine in accordance with chapter 5
• Fold platforms into working position
• Drive machine down from flat-bed-trailer
• Remove uppercarriage locking
• Adjust crawler track carrier to operating track width
• Mount counterweight
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1
6.4.3 Prepare basic machine
check: shunting plug and connecting cable inserted
CAUTION !
Only change shunting plugs and connecting cables

with the machine switched off (ignition key in the 0
position)
The plugs are located left hand side in the uppercarriage

(fig. 1).
• Check plug position in accordance with fig. 1. If neces-
sary, change the shunting plug.
Usage of the sockets
X1 Boom
X1.1 Leader
X1B, X1.1B Dummy socket for the shunting plug of the
boom or leader
X21 Cable reeving winch *, jib luffing winch *
The shunting plugs

- are fastend securely with a chain,
- must be inserted in the electric box.
The dummy sockets are used for protection of the shunt-
ing plugs.
Close covers and secure with retaining clips.
2
check: connecting cables on the bulkhead plate front
right-hand side are inserted (depends on application)
Usage of the sockets
X12, X13, X14 Leader
X17 Hammer *
X18, X19 Push&Pull *
The plugs of the connecting cables and the sockets are
labeled and coded. The connecting cables can therefore
not be exchanged unintentionally.
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3
Mount platforms
• Push in platform * (fig. 3, no. 3) at the operator's cab
• Screw on platform * at the front
• Platform right rear: pull platform upwards and swing
down.
4
Mount access ladder
• Hang in access ladder at the pins on the upper car-

rigage right and secure with plugs (fig 4, no. 1)
DANGER!
The ladder has to be checked before usage for dam-

age and cracks. It is not allowed to use damaged
ladders.
Risk of falling!
Secure the access ladder with plugs and check correct
mounting of the platforms.
check: Auxiliary panel (X25) is inserted - leader operation
5
LRB255_V001 (mf) LWN - TD4/2/2010
Starting the diesel engine (fig. 5)

Prerequisite with Liebherr Diesel engine: The "Oper-
ational readiness confirmed" symbol is displayed on the
LCD-display screen.
• Turn ignition key briefly to position 2 and release as

soon as the diesel engine is running.
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6.4.4 Driving the machine down from the flat-bed-trailer
WARNING !
When driving the machine down from or onto the flat-bed-trailer, serious accidents could be
resulted !
Countermeasures:
- Push leader all the way forward (set down),
- Drive machine forwards when driving down from, and backwards when driving onto, the
flat-bed-trailer,
- During loading or unloading, do not use any functions other than the travel gear,
- use the manual control of the travel gear,
- drive slowly and evenly,
- do not rotate the uppercarriage via the chain,
- note the operating instructions of the flat-bed-trailer!
- Secure transporter against rolling away or tipping,
- Before driving the machine on the loading ramp, clean chains and track pads of the machine of
dirt, snow or ice,
- the loading ramp must be provided with a slip-resistant covering (wood covering),
- loosen all lashings, remove chains and wedges,
- maximum gradient with piling rig and drilling device mounted: 10°
- an assistant monitors the unloading procedure and relays the respective instructions.
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7
6.4.5 Removing uppercarriage locking
The uppercarriage locking prevents undesired turning of
the uppercarriage.
It must be actuated
- during transport,
- when shutting down and
- for maintenance and repair tasks to the rotary connec-
tion
.
CAUTION !
Danger of crushing and risk of damage to the ma-

chine !
The swing gear may not be actuated when the
uppercarriage is locked.
Exception: when dismantling the butt strap of the upper-
carriage locking if the pins are fitted securely.
CAUTION, if the swing gear must be actuated for re-
moval of the pins, or when dismantling the butt strap on
the undercarriage. Danger of crushing !
Procedure:
• Remove safety spring (fig. 7, no. 3) and remove pins
(4) from the butt strap on the uppercarriage (2).
• Dismantling the butt strap on the undercarriage.
• Reinsert pins in the butt strap and secure via safety
spring and washer.
CAUTION!
Danger of tipping!
The superstructure must not be allowed to turn with
the lead laid down and the counterweight mounted.
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6.4.6 Adjusting the crawler track carrier to operating track width

The crawler track carrier can be adjusted between transport and operation track width via the track
adjustment cylinder integrated in the undercarriage.
CAUTION !
Risk of damage to the machine !

Notes on safety and operation:
• The transport track width (narrow track) has been provided exclusively for transport.
For commencing any application, both crawler track carriers are to be adjusted to operating
track width (wide track).
Turning of the uppercarriage with transport track width and mounted rear counterweight is
prohibited, it may cause the machine to tip over !
• Track adjustment may only be carried out on firm, level ground. The crawler track carriers may not
be lowered, or when carrying out track adjustment, may not get caught on obstacles such as the
edges of rocks.
• The crawler track carriers should be adjusted one after the other.
NOTE !
The undercarriage width is dependent on the width of the track pads. The track width or track pad
widths are detailed in chapter 2, "Technical data".
DANGER !
Risk of crushing !
Ensure that unauthorised personnel remain a safe distance from the machine during this
procedure.
Pay particular attention for any possible crushing and clamping during adjustment.
Notes on operational safety:
When adjusting the track width, three persons (machine operator and two assistants) are
necessary for safety reasons.
• The machine operator

remains in the operator's cab,
only operates the machine under instruction from the assistants at the front.
• The assistant at the front of the undercarriage
is responsible for pinning the front struts,
relays instructions to the machine operator and the assistant at the rear,
monitors the procedure and warns the machine operator of any dangerous situations.
• The assistant at the rear of the undercarriage
is responsible for pinning the rear struts,
remains in constant contact with, and receives instruction from, the assistant at the front.
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CAUTION!
It is imperative that the procedure for adjusting the

crawler track carriers be adhered to:
Always extend the crawler track carrier first!
Extending the left-hand crawler track carrier
• Loosen all four strut wedgings on the left-hand side of

the undercarriage centre section (fig. 8).
With every strut wedging:
• First loosen nut (1).
• Then turn screw (2) clockwise, until the wedge is
sufficiently loosened
9
• Check or actuate "Cylinder adjustment function On/Off"
pre-selection key in the operator's cab on the right-
hand control panel: The LED in the keyboard must
light up. (fig. 9).
10
LRB255_V001 (mf) LWN - TD4/2/2010
• Remove pins at front and rear of the left-hand under-

carriage centre section. (fig. 10).
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11
• Extend track adjustment cylinder evenly via the control
levers. Push and align crawler track carrier to the
outer pinning points of the strut. (fig. 11).
12
• Pin left-hand crawler track carrier to both struts (fig.
12).
Extending right-hand crawler track carrier

The assembly stages match those of the first crawler track carrier and are therefore not described or
illustrated in detail.
NOTE!
The right-hand crawler track carrier may not be telescoped out beyond the prescribed distance (wide
track), as there is no mechanical stop available. There is a risk of damage to the hydraulic hoses.
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13
• Wedge left and right-hand crawler track carriers to
both struts respectively (fig. 13).
With every strut wedging:
• First unscrew screw (2) (anti-clockwise), wedging the
strut,
maximum tightening torque: 120 Nm
• then tighten nut (1).
14
• Mount cover on the four struts (fig. 14, no.2). The
covers are placed for transport on the left side near
the pins (fig. 14, no.1).
IMPORTANT!
After extending, lightly grease all exposed smooth sur-
faces of the struts.
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15
Folding down the platforms on the undercarriage
• Lift up and fold down platforms on the undercarriage
(fig. 15)
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6.4.7 Mounting the rear counterweight
DANGER !
Counterweight assembly may only be carried out with extended crawler track carriers (opera-
tion track).
When lifting the rear counterweight, it is prohibited to remain underneath, immediately
alongside, or behind the rear counterweight.
Carry out movements of the auxiliary crane slowly and concentrated.
NOTE!
A counterweight assembly device is available as an option. Counterweight assembly is carried out
during mounting of the piling rig and drilling device (see chapter 9, "Options").
NOTE!
If the piling rig and drilling device has been mounted, counterweight assembly can also be resulted
via auxiliary crane following alignment. It should be noted that the leader
- is not inclined forward,
- is guided forward as close to the ground as possible.
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Procedure
• Fasten rear counterweight to the eye bolts (fig. 16, no. 2) and position on the rear of the
uppercarriage (use suitable auxiliary crane)
16
Securing the rear counterweight
• Insert pins (fig. 16, no. 2) in both sides and secure accordingly (washers and cotter pins)
• Install tensioning bolts (1) and secure accordingly. When the rear counterweight has been secured,
dismantle the assembly ropes.
• Then fix the rear counterweight at the sides with the screws (4)
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6.5 Assembly of the piling rig and drilling system

6.5.1 Prerequisites
• The set-up site selected and prepared in accordance with point 6.3.2.
• The machine is positioned on a flat-bed trailer ready to be unloaded.
• The machine has been inspected in accordance with 5.2 "Checks before start-up" and in accor-
dance with point 5.3 "Checks before starting" and is ready for operation.
• The glass panes of the operator's cab and the exterior mirrors have been cleaned.
• The assembly team has been instructed in accordance with point 6.3.1 and is ready for operation.
• The equipment is or is getting checked continued for
- transport damage,
- completeness and
- function.
NOTE !
Initial assembly of the piling rig and drilling system with optional pin retraction device is described in
chapter 6 under "Initial assembly piling rig and drilling system".
6.5.2 Summary of assembly stages

• Initial assembly of piling rig and drilling system **
• Assembly stages with piling rig and drilling system laid down
- Modify leader length (if necessary)
- Check and mount hoist limit switch (if not already mounted)
- Move auxiliary jib into working position *
- Move kelly jib into working position *
• Mount piling rig and drilling system
* Option
** Should the piling rig and drilling system has been dismantled for transport.
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17
6.5.3 Assembly stages with piling rig and drilling
system laid down
DANGER !
Danger of falling !
Working on the uppercarriage and on the leader is
only permitted with sufficient safety.
Modifying the leader length

The piling rig or drilling device has been removed. The
piling rig and drilling system has been set down (leader
horizontal, adjusted all the way forward and turned up-
wards).
Procedure:
• Remove feed cable (see chapter 8 "Changing feed
cables").
• Unplug connecting cable.
• If necessary, separate leader ladder sections.
• Turn leader into transport position (see chapter 6 un-
der "Setting down piling rig and drilling system")
• Mounting or dismantling leader extension. An auxiliary crane with sufficient load bearing capacity.
- Release the slide and screw locking (fig. 17, no. 2) and screws of the leader clamp pieces (1)
at the leader foot piece.
- Pull the leader clamp pieces apart, they are guided via screws.
- Remove leader foot piece and mount or dismantle leader extensions.
Up to three (3 m [10 '] long) leader extensions can be mounted.
- Push the leader clamp pieces all the way together again and tighten the screws crosswise
hand-tight until the end plates are lying fully on top of each other.
Then tighten the screws crosswise with the torque wrench.
- The skid and screw locking (2) must be installed. They must not project, otherwise the
spring-loaded connecting pins remain suspended when the leader is repositioned.
Tightening torques, see chapter 7 "Maintenance piling rig and drilling system".
• Mount corresponding feed cable (see chapter 8 "Changing the feed cable") and plug in connecting
cable for the limit switch again.
• Mount the lower of the two piling rig lockings to the lower leader extension respectively.
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Reeving the cables

Independent of the application type or the installed options, the kelly rope and the auxiliary rope are
to be reeved before mounting the piling rig and drilling system (see chapter 8 "Start-up").
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 there are always at least three so-called safety windings
The length of rope required for this purpose depends on the leader configuration and the type of
application.
Adapt hose packages

The hose packages are designed for the mounting of two leader extensions *. When mounting the
third leader extension the hose packages
- to the add-on unit and
- to the auxiliary- and feed winch
have to be lengthened.
WARNING!
The machine can be severely damaged if the hose packages are not adapted.
With the third leader extension additional hose packages have to be mounted.
Hoses must only be installed by appropriately trained personnel.
- shut down machine, place container to catch in the oil,
- lengthen/shorten all hoses,
- check for leaks
When the leader is in working position
- carefully adjust the leader and the add-on unit to their end positions,
- swing the machine (uppercarriage) and always check the hose package.
If the third leader extension is dismantled the additional hose packages are not necessary any more.
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18
Mounting the hoist limit switches
Independent of the application type or the installed op-
tions, hoist limit switches are to be installed for the kelly
rope and the auxiliary rope before mounting the piling rig
and drilling system (see chapter 8 "Start-up").
Mechanical shunting of the limit switches
The limit switch rope (fig. 18, no. 2) is suspended on the
pin (1) and secured via a cotter pin. The limit switch is
thus shunted. No function shut-down is resulted.
DANGER!
19
Shunting of the safety devices can lead to serious
accident!
Limit switches may only be shunted briefly during as-
sembly and disassembly.
The limit switch chain may not be shortened!
The length of the limit switch chain is synchronized with
the speed of the winches and the shut-down time.
20
Mounting the limit switch weight kelly jib
• Suspend limit switch rope (fig. 18, no. 1) by the pin (2)
• Assembly the limit switch weight (fig. 20) around the
hoist cable
• Fix limit switch chain to limit switch rope and limit
switch weight
• Tighten spring hooks
Check assembling position!
• Check or simulate function of the limit switch
IMPORTANT!
The hoist limit switch is to be considered as an emer-
gency limit switch and should not be actuated during
regular operation.
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21
Mounting the limit switch weight
• Suspend limit switch rope (fig. 18, no. 1) by the pin (2)
• Assembly the limit switch weight (fig. 21) around the
hoist cable
• Fix limit switch chain to limit switch rope and limit
switch weight
• Tighten spring hooks
Check assembling position!
• Check or simulate function of the limit switch
IMPORTANT!
The hoist limit switch is to be considered as an emer-
gency limit switch and should not be actuated during
regular operation.
22
Moving the auxiliary jib into the working
position *
CAUTION!
Risk of accident!
The auxiliary jib could
- clamp with diagonal pull and
- could begin oscillating if pulled out too far.
Pull out the auxiliary jib and pin and secure in the
required position.
23
IMPORTANT!
LRB255_V001 (mf) LWN - TD4/2/2010
When locking the support arm brace, the auxiliary jib is

best accessible with the basic arm-adjusting cylinder
completely retracted.
An auxiliary crane is required for this task.
Maneuvering kelly jib into the working posi-

tion *
Unpin kelly jib, fold into working position and pin and
secure.
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6.5.4 Mounting the piling rig and drilling system
DANGER !
Risk of accident and injury !

Errors during assembly or falling parts when mounting can cause serious accidents.
- Check assembly of piling rig and drilling system before mounting,
- remove loose parts, tools and accessories,
- at least one assistant monitors the mounting procedure.
Prerequisites
• Inspection and maintenance tasks have been completed.
- necessary ropes have been reeved (auxiliary rope on the leader foot or universal carriage secured)
- Hoist limit switches * are mounted (check function and allocation)
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Summary of assembly stages
DANGER !
Danger of tipping !
When mounting, the leader must
- always be guided forward as close as possible to the ground,
- be repositioned to the rear/up if necessary,
The leader may not be set down on the ground in front when mounting.
Risk of damage due to tensioning of the kelly rope!

Observe the kelly rope when mounting the leader. The kelly winch must be
- followed on manually,
- Switch on the mooring or
- activate the free-fall or constant pull.
The kelly rope may not be tensioned. Too much slack rope can also cause damage to the ropes.
NOTE !
Starting position: Piling rig and drilling system is set down in the transport, the universal carriage has
been adjusted all the way forward/down.
After initial assembly of the piling rig and drilling system, the leader has already been turned
upwards or forwards.
Operation is resulted via the auxiliary panel or via the switch lever.
• Shift leader as far forward/down as possible (reposition)

stability is thus increased
• Turn leader upwards/right
• Fold leader ladder into the working position
• Retract basic arm-adjusting cylinder until the support arm brace can be locked
The support arm brace (and thus the leader) is adjusted to the rear/down
• Locking the support arm brace
• Position lateral adjustment kit exactly central
• Mount upper torque stay rod *

for drilling operation
• Changing over the rotary cylinder

if operation should be carried out with turned leader
LRB255_V001 (mf) LWN - TD4/2/2010
• Extend basic arm-adjusting cylinder completely

the support arm brace support is lifted from the uppercarriage, and if necessary, the leader shifted
to the rear/up (repositioned)
• Extend support arm brace-support cylinder

if necessary, the leader shifted to the rear/up (repositioned)
• Manoevring the leader into the working position
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Procedure
Shift leader as far forward/down as possible (reposition)
24
CAUTION !
Danger of collision !
The universal carriage may only be adjusted upwards (to the rear) if the leader ladder is
folded in its working position.
When turning the leader, an assistant is always required to monitor the procedure.
Turn leader upwards (fig. 24, no.1)

Pre-selection key "Turn leader"

Key "lift/right"
The leader is turned to the right or upwards.
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Folding the leader ladder into the working position (fig. 25, no.1)
25
DANGER !
Danger of falling !
Working on the uppercarriage and on the leader is only permitted with sufficient safety.
• Transport position of the leader ladder (fig. 25, no.1)

• Working position of the leader ladder (fig. 25, no.2)
- Remove safety springs and pins,
- Fold leader ladder 90° downwards (three persons are required for this task),
if possible, do not separate the ladder sections
- Insert and secure pins.
- Check: Leader ladder sections are bolted to each other (3).
NOTE!
Release the hose package for the piling rig or drilling device and lay it out in front of the machine.
For transport, it is usually laid out on the platform at the front of the operator's cab and secured.
26
Checking:
LRB255_V001 (mf) LWN - TD4/2/2010
The holding arm support cylinder is fully retracted!
WARNING!
If the holding arm support cylinder is not fully re-

tracted, the holding arm may collide with the holding
arm guide block.
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Retracting the basic arm-adjusting cylinder (fig. 24, no.3)

For pre-selection of the basic arm-adjusting cylinders (Z4).
Key "lower/left"
Retracting the basic arm-adjusting cylinder.
27
Locking the support arm brace
Unpin the support arm brace locking (fig. 27, no. 1), fold
down out of the transport position and pin.
Insert the pins from the top down (from the rear to the
front) and secure via spring plugs.
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28
Position lateral adjustment kit central; the leader is
positioned parallel to the uppercarriage
Mount upper torque stay rod *

The upper torque stay rod is only mounted for drilling
operation. If drilling is to be carried out with turned
leader (with the optional adjustable torque stay rod), the
upper torque stay rod should not be mounted!
• remove pins (fig. 28, no.2) and pipes (3) from the
transport position
• remove pins (1)
• move the torque stay rods up and mount pins (1) and
(3)
• secure all pins via spring plugs
Changing over the rotary cylinder
IMPORTANT !
If the leader must be turned to the left for a subsequent
application, the rotary cylinder should be changed over.
• Stabilize the leader with the upper torque stay rods.
• Changing over the rotary cylinder (see chapter 5 un-
der "Turning the leader").
NOTE!
Manoeuvre auxiliary and kelly jib * into the working position if this has not already been resulted
before turning of the leader.
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29
Extending basic arm-adjusting cylinder (fig. 29, no. 4 and 5)

Key "lift/right"
Extend the basic arm-adjusting cylinder completely. The piling rig and drilling
system is lifted from the uppercarriage.
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Adjust/reposition leader forwards/upwards (fig. 30, no. 7)

When mounting forwards, always guide the leader as close as possible to the ground, and if
necessary, adjust to the rear/upwards.
Reposition the leader through the possible range (cylinder stroke).
NOTE !
See chapter 5 under "Adjusting leader height".

For pre-selection of the leader height adjusting cylinder (Z5).
Key "lift/right"
Extend leader height adjusting cylinder.
Key "lower/left"
Retract leader height adjusting cylinder.

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30
Extending the support arm brace-support cylinder (fig. 30, no. 7)

If the basic arm-adjusting cylinder has been completely extended, extend the support arm brace-
support cylinder. Guide the leader forward as close to the ground as possible, and if necessary,
adjust to the rear /upwards (set down).

For pre-selection of the leader-support cylinder (Z2).
Key "lift/open"
Extend support arm brace-support cylinder.
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31
Manoeuvring the leader into the working position (fig. 31, nos. 8 and 9)
Manoeuvre the leader into the desired working position via automatic vertical adjustment, automatic
parallel adjustment or via actuation of the corresponding cylinders one after the other.
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32
Secure the auxiliary cable on the hook garage
(Fig. 32, No. 1) on the lead base
- Fold the hook garage down from the transportation
position and bolt it
- Secure the auxiliary cable on the hook garage on the
lead base
CAUTION!
The auxiliary cable must not be under strain.
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6.6 Assembly stages with mounted piling 33
rig and drilling system

6.6.1 Mounting/dismantling the foot plate
- Remove the spring plugs and pins in the foot plate.
- Position foot plate under the leader, lower the leader
until the ball is resting in the foot plate.
- Insert pins and secure via spring plugs.
Dismantling is carried out accordingly in reverse order.
34
6.6.2 Mounting/dismantling the piling rig or drilling
device
For mounting the piling rig or drilling device on the
universal carriage a corresponding adapter (fig. 34, no.
1) is used. The adapter remains mounted on the piling
rig or drilling device.
The adapter is suspended above on the universal car-
riage and pinned at the bottom via the locking pins (3).
Locking pins:
The locking pins are extended or retracted by turning the
inner threaded rod via the crank (5). The crank is lo-
cated on the first door in the uppercarriage behind the
operator's cab.
Fix the locking pins when extended. Screw in and
tighten the lock screws (4).
IMPORTANT !
Always retract or extend the locking pins completely.
Fix diaphragm (2) for the supply of the piling rig or

drilling device on the adapter.
Dismantling is resulted accordingly in reverse order.
IMPORTANT !
Depending on the piling rig or drilling device, a cor-
responding adapter or drilling gear carriage must be
mounted.
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35
Vibrator adapter *
On the vibrator adapter (fig. 35, no.1), a holder has been
mounted with the diaphragm for the hydraulic connec-
tions (2).
For the mounting of a vibrator a corresponding adapter
(3) is necessary (two parts).
36
Hammer adapter *
On the hammer adapter (fig. 36, no.1), a holder has
been mounted with the diaphragm for the hydraulic con-
nections (3).
37
Drilling gear carriage kelly drilling *
On the drilling gear carriage-kelly drilling, a holder has
been mounted with the diaphragm for the hydraulic con-
nections (3).
Pin the drilling drive with four pins to the drilling gear
carriage kelly drilling and secure respectively via washer
and cotter pin.
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Connecting the hose package
38
Diaphragm on the adapter (universal carriage), view: user side
The following is to be noted when connecting the hose package:

• Open clamping tongs of the vibrator *
• Shut down machine
• Connect all hoses
• Note colour markings
• Do not cross the hoses (whenever possible)
• Mount strain relief (chain)
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39
6.6.3 Mounting/dismantling the torque stay rods *
General
The torque stay rods can only be mounted after mount-
ing of the piling rig or drilling system.
Before setting down the piling rig and drilling system, the
leader must be extended out of the torque stay rod or
the torque stay rod dismantled.
Initial assembly of the torque stay rods

• Assemble the torque stay rods (fig. 39, no. 1). Use a
suitable accessory device and squared timbers for
stabilising.
CAUTION !
Danger of crushing !
The torque stay rods can tip! Use square timbers for
stabilising.
40
• Position the leader vertically with medium reach.
• Position the leader approx. 1.5 m above the ground,
as precisely as possible above the mounted torque
stay rods.
The leader is aligned at the rear with the guide claws
of the torque stay rods.
• Lower leader slowly and carefully via the leader height
adjusting cylinder (Z5) into the guide claws until all
guide claws of the torque stay rods have been pushed
open and one of the boreholes in the leader rear wall
is aligned with the connecting pins of the torque stay
rods.
• Insert the connecting pins (fig. 40, no. 2) in the correct
leader borehole and secure via safety bolts and spring
plug.
• Raise leader with inserted torque stay rod via the
leader height adjusting cylinder (Z5) until the insertion
borehole is aligned with those of the support arm
brace.
• Insert pins (1) and secure respectively via locking
plate.
• Retract the connecting pins (2) and lock in retracted
position via safety bolts. Secure the safety bolts via
spring plug.
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CAUTION !
The leader may no longer be turned following mounting of the torque stay rods.
Drilling may only be carried out with the leader positioned vertically. The possible lateral
inclination correction of +/- 3° only serves mounting of the leader in the vertical position.
Dismantling the torque stay rods

Disassembly of the torque stay rods is resulted accordingly in reverse order to assembly.
NOTE !
In order that the torque stay rods must not be dismantled for transport (when setting down the piling
rig and drilling system), the leader must be taken out of the guide claws of the torque stay rods.
Extending the leader out of the torque stay rod:

• The leader is positioned vertically, at maximum reach, and turned forward. Die Foot plate has been
dismantled (see chapter 6 under "Setting down the piling rig and drilling system").
• Raise leader until it has been taken out of the guide claws of the torque stay rod.
• Incline leader to the rear (retract leader-support cylinder) and adjust downwards/to the front as
soon as possible (danger of collision !).
• Setting down the piling rig and drilling system see chapter 6 under "Dismantling the piling rig and
drilling system".
Retract leader into torque stay rod:

Retraction of the leader into the guide claws of the torque stay rod is resulted accordingly in reverse
order to extending.
CAUTION !
Inclination of the leader with mounted torque stay rod causes damage to the machine !
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6.7 Dismantling the piling rig and drilling device

6.7.1 Prerequisites
• The machine has been inspected in accordance with point 5.2, "Checks before start-up" and in
accordance with point 5.3, "Checks before starting", and is ready for operation.
• The glass panes of the operator's cab and the exterior mirrors have been cleaned.
• The assembly team has been instructed in accordance with point 6.3.1 and are ready for
operation.
6.7.2 Summary of disassembly stages

• Disassembly counterweight **
• Set down piling rig and drilling device
• Disassembly stages with piling rig and drilling device set down
- Dismantle leader extensions **
- Manoeuvre auxiliary jib into the transport position *
- Manoeuvre Kelly jib into transport position *
• Disassembly of piling rig and drilling device **
* Option
** In case necessary for transport.
NOTE!
Initial assembly of the piling rig and drilling device with optional pin retraction device is described in
chapter 6 under "Initial assembly of piling rig and drilling device".
WARNING!
Danger of tipping!
Mount/dismantle rear counterweight (22.3 t [49200 lbs]):
- with auxiliary crane only when leader is in upright position
- with optional counterweight assembly device: see chapter 9 and refer to "General Drawings" in
volume 4!
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6.7.3 Disassembling the counterweight

NOTE!
If the machine is to be transported with mounted counterweight, the following point can be
overlooked.
A counterweight assembly device is also available as an option. Counterweight assembly is carried
out during setting down of the piling rig and drilling device (see chapter 9, "Options").
NOTE!
The counterweight may only be dismantled with mounted piling rig and drilling device if the leader
- has not been inclined forwards,
- is being guided to the front as close to the ground as possible.
DANGER !
Risk of accident when disassembling the counterweight!

- Carry out movements of the auxiliary crane slowly.
- It is prohibited to remain between counterweight and basic machine or below the counterweight.
Disassembling the rear counterweight
• Fasten rear counterweight to the two eye bolts

• Tension lifting tackle (chain, belt, etc.) slightly
• Loosen both screws for the side fastening (12.3 t counterweight)
• Remove lower tensioning bolts
• Lift rear counterweight slightly and extract both pins
• Lift rear counterweight and load onto transporter or set down on the ground
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6.7.4 Setting down the piling rig and drilling device

Prerequisites
• The piling rig or drilling device (drilling drive, vibrator, etc.) has been dismantled,
- The adapter has been removed from the universal carriage,
• The lower torque stay rod has been dismantled or the leader has been extracted from the torque
stay rod (optional, see chapter 6 under "Assembling/disassembling torque stay rods").
• The foot plate has been dismantled or the optional leader foot has been retracted.
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Summary of disassembly stages
DANGER !
Danger of tipping !
When setting down, the leader must
- be guided forward as close to the ground as possible,
- be set down to the front wherever possible.
The leader may not be set down on the ground to the front.
Risk of damage due to tensioning of the kelly rope!

Observe the kelly rope when adjusting the leader. The kelly winch must be
- followed on manually,
- Switch on the mooring or
- activate the free-fall or constant pull.
The kelly rope may not be tensioned. Too much slack rope can also cause damage to the ropes.
NOTE!
Operation can be resulted via the auxiliary panel or via the switch lever.
• Adjust the universal carriage all the way down

Shunt limit switch "Lower feed".
• Turn leader to the front
if the leader is turned
• Set lateral adjustment package all the way to the left
• Extract leader from the torque stay rod (optional)
• Set leader to maximum vertical reach

Extend basic arm adjusting cylinder completely.
• Retract supporting arm support cylinder

If necessary, push leader forwards/down
• Retract basic arm adjusting cylinder until the supporting arm can be unlocked
The supporting arm (and thus the leader) is adjusted to the rear/downwards
• Unlock supporting arm
• Extend basic arm adjusting cylinder completely

The supporting arm base is set down on the uppercarriage
• Fold leader ladder into transport position

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• Turn leader into transport position
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Procedure
41
Adjusting the universal carriage all the way down

Adjust the universal carriage all the way down in order that the leader ladder can be folded into its
transport position.
Shunt the "Limit switch lower feed" via actuation of the pre-selection key "Assembly operation" on
the right-hand control panel (see chapter 5 under "Actuating the feed").
Secure the auxiliary rope on the universal carriage (to the upper butt strap) using a shackle and
tension slightly. If the hook and the chain have been dismantled, secure directly with the thimble.
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Turning the leader to the front

If operation is to be carried out with the leader turned, turn the leader to the front. See chapter 5,
"Operation".
CAUTION !
Risk of collision !
Setting down of the piling rig and drilling device is only permitted if the leader has been
turned to the front.
Adjusting the lateral adjustment package to the left (fig. 41, nos. 1 and 2)
CAUTION !
Risk of collision !
If the lateral adjustment package has not been turned to the left, damage will be caused when
turning the leader into its transport position.
Procedure:
- Incline leader all the way to the right (lateral adjustment package is adjusted to the left)
- Position leader central/vertical
Extracting the leader from the torque stay rod (optional)

If a torque stay rod is mounted and is to remain mounted for transport, the leader can be extended
upwards out of the torque stay rod using an optional turnbuckle.
See chapter 6 under "Assembling/ disassembling torque stay rods".
Adjust leader to maximum vertical reach (fig. 41, no. 3)

Position the leader vertically via the automatic vertical adjustment and automatic parallel adjustment
(or via actuation of the individual cylinders) to the maximum reach.
Always guide the leader as close to the ground as possible.
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42
Retracting the supporting arm support cylinder (fig. 42, nos. 4 and 5)
If the basic arm adjusting cylinder has been completely extended (maximum reach), retract the
supporting arm support cylinder. Guide the leader forwards as close to the ground as possible and if
possible, adjust to the front/downwards.
Pre-selection key "Supporting arm adjustment"

For pre-selection of the leader support cylinder (Z2).
"Lower/close" key
Retracting the supporting arm support cylinder.
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Adjust/reposition leader downwards/to the front (fig. 42, no. 4)

When setting down, always guide the leader forwards as close to the ground as possible and if
possible, reposition to the front/downwards.
NOTE !
See chapter 5 under "Adjusting leader height".

For pre-selection of the leader height adjusting cylinder (Z5).
"Extract upper pins" key T5
"Lift/right" key
Extend leader height adjusting cylinder.
"Lower/left" key
Retract leader height adjusting cylinder.
"Extract lower pins" key T14

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43
Retracting basic arm adjusting cylinders (fig. 43, nos. 6 and 7)

If the supporting arm support cylinder has been completely retracted, retract the basic arm adjusting
cylinder and set down the supporting arm onto the uppercarriage.

For pre-selection of the basic arm adjusting cylinder (Z4).
"Lower/left" key
Retract basic arm adjusting cylinder.
Adjust leader all the way down/to the front (reposition) until the limit switch "Limit switch
lower leader height adjustment" has been activated.
Retract the basic arm adjusting cylinder until the supporting arm can be unlocked.
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44
45
Unlocking the supporting arm
Unpin the supporting arm lockings (fig. 45, no. 1), fold
into the transport position and pin again. Secure the pins
via the spring plug.
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46
Changing the rotary cylinder
IMPORTANT !
If necessary, change the pins (fig. 46, no. 1) of both
rotary cylinders (2) to a 90° position (fig. 46) in order that
the leader can be turned into its transport position (see
chapter 5 under "Turning the leader").
The upper torque stay rods serve to stabilize the leader.
47
Dismantling the upper torque stay rod *
The upper torque stay rod is mounted for drilling opera-
tion only.
ATTENTION
Danger of crushing!
Hold the torque stay rods when removing the pins.
• remove pins (fig. 47, no.2 and 3) and pipes (1)

• move stay rods (4) downwards
• mount pins (2) and pipes (1) in transport position (5)
• install pin (3) again
• secure all pins and pipes via safety springs
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48
Checking:
The holding arm support cylinder is fully retracted!
WARNING!
If the holding arm support cylinder is not fully re-

tracted, the holding arm may collide with the holding
arm guide block.
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Extending the basic arm adjusting cylinder

For pre-selection of the basic arm adjusting cylinder (Z4).
"Lift/right" key
Extend the basic arm adjusting cylinder completely. The piling rig and drilling
device are set down on the uppercarriage.
Folding the leader ladder into the transport position

Folding of the leader ladder is described under mounting of the piling rig and drilling device.
CAUTION !
Risk of collision !
If the leader ladder has been folded into its transport position, the universal carriage may not
be adjusted any further upwards.
Turn leader into the transport position
WARNING !
Risk of collision !
When turning the leader, an assistant is necessary to monitor the procedure.

Pre-selection key "Turning the leader"

Key "lower/left"
The leader is turned to the left.
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6.7.5 Disassembly stages with piling rig and drilling device set down
Various components can be dismantled and folded into their transport position for transport of the
machine.
Dismantling leader extensions *

See chapter 6 under "Assembly stages with piling rig and drilling device set down".
49
Manoeuvre auxiliary jib into the transport
position *
Turn the auxiliary jib completely to the right, push into
the transport position and pin and secure.
Use an auxiliary winch to push in the auxiliary jib
Prerequisite: Leader has been turned into its transport
position
- Loosen the auxiliary rope slightly
- Tighten the auxiliary rope and push in the auxiliary jib
completely
- Insert and secure pins
50
Manoeuvre Kelly jib into the transport posi-
tion*
Fold the Kelly jib into the transport position, pin and
secure.
Dismantling piling rig and drilling device

Disassembly of the piling rig and drilling device is re-
sulted in the opposite order than the initial assembly
(see chapter 6 under "Initial assembly of the piling rig
and drilling device").
Securing the hose package

Set down the hose package at the front on the cab
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platform and secure.
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6.8 Dismantling the basic machine

Dismantling and loading of the basic machine is resulted in reverse order to assembly.
6.8.1 Prerequisites
• The set-up site is selected and prepared in accordance with point 6.3.2.
• The basic machine has been inspected and is ready for operation in accordance with point 5.3,
"Checks before start-up".
• The assembly team has been instructed and are ready for operation in accordance with point
6.3.1.
6.8.2 Summary of disassembly stages

• Adjust the girder to transport width
• Drive the machine onto the flat-bed trailer
• Mount the uppercarriage locking
• Shut down the machine
6.8.3 Adjusting the crawler track carrier to transport width

Retracting the width of the crawler track carriers to transport width is resulted in reverse order to
extending the width to operation width
(see chapter 6 under " Adjusting the crawler track carriers to operating track width ").
The smooth surfaces of the spars must be cleaned of dirt and dust and greased before retracting the
width.
6.8.4 Driving the machine onto the flat-bed trailer

Driving of the machine onto the flat-bed trailer is resulted in reverse order to driving down.
(see chapter 6 under " Driving the machine from the flat-bed trailer ").
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51
6.8.5 Mounting uppercarriage locking
DANGER !
Risk of accident due to undesired rotation of the

uppercarriage !
The uppercarriage locking must be mounted
- for transport,
- when shutting down the machine and
- for maintenance and repair tasks to the rotary connec-
tion
.
CAUTION !
Danger of crushing and risk of damage !

The swing gear should not be actuated when the
uppercarriage is locked.
Exception: for dismantling the butt strap of the uppercar-
riage locking if the pin is secure.
Caution when inserting the pin. Danger of crushing !
Procedure:
• Remove the safety spring (fig. 51, no. 3) and extract
the pin (4).
• Rotate the uppercarriage so that it is exactly parallel to
the undercarriage (travel drive at the rear).
• Pin the butt strap (1) to the uppercarriage (2) and
secure via safety spring and washer.
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6.8.6 Shut down the basic machine

• Switch off the diesel engine: Turn ignition key to the "0" position and remove.
• Clean out the operators cab and close all windows and cab doors; lock cabin doors.
• Lock all side doors on the uppercarriage. If necessary, take all precautions against falling rocks,
theft and vandalism.
• Dismantle the platform at the operator's cab
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6.8.7 Transport position of the LRB 255 on the flat-bed trailer

The following requirements must be met for transport of the basic machine on a transporter (flat-bed
trailer):
• Working attachment and adapter have been dismantled.
• The hose package is stored in the hose storage compartment on the uppercarriage or secured to
the leader.
• The piling rig and drilling device are laid down in their transport position.
- Universal sliding carriage is adjusted all the way down,
- Leader ladder is in the transport position,
- Leader is turned to the left,
- Auxiliary jib pushed into the transport position and adjusted all the way to the right,
• Ropes have been removed or secured for transport.
• The operator's cab is locked and the side platform has been dismantled.
• The access ladder at the rear right has been dismantled and the platform has been folded
upwards.
• The uppercarriage locking has been mounted.
• The foot plate has been dismantled.
• The counterweight has been dismantled, regardless of the permissible transport weight.
• The two platforms on the undercarriage have been folded upwards.
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6.9 Initial assembly of the piling rig and drilling device
DANGER!
The initial mounting of the piling rig and drilling device

- involves numerous risks,
- may only be carried out by appropriately trained personnel.
Prerequisites
• Uppercarriage parallel to undercarriage
• Leader is secured against turning (connecting pin for leader sliding locking carriage has been
installed)
• Dismount bracket on the uppercarriage (fig. 52, Nr.4) for mounting of the A-frame (optional with
boom equipment)
• The transport pins on the basic arm (fig. 52, no.1) has been installed. Leader and supporting arm
are bound together via chain or belt (2). Use edge protection !
6.9.1 Mounting the piling rig and drilling device
52
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Procedure
• Removing the transport pins on the basic arm (1).
• Suspend the piling rig and drilling device to the fixing points represented on the auxiliary crane
(truck crane, assembly-hall crane). The basic arm hangs down vertically. It is advantageous to use
two cranes.
• Guide the piling rig and drilling device over the support frame and pin the basic arm with the
support frame (3). Push in the pins using the hydraulic pin retraction device.
• Set down the piling rig and drilling device onto the consoles on the uppercarriage. Then tighten the
fastening bolts of the screw blocks using a torque wrench.
NOTE!
The respective rear pins on the consoles (4) are tightened with mounted piling rig and drilling device.
• Dismantle chain between leader and supporting arm.

• Establish hydraulic and electrical connections.
6.9.2 Dismantling the piling rig and drilling device

General
The piling rig and drilling device is disassembled with the support frame laid down. As opposed
setting down in the transport position completely, the leader remains and is not swung 90° to the
side.
NOTE!
The respective rear screws of the consoles (4) are loosened with mounted piling rig and drilling
device as they are difficult to access later.
Procedure
• Loosen hydraulic and electrical connections and set down for transport.
• Tension leader with supporting arm via chain or belt. Use edge protection !
• Suspend the piling rig and drilling device to the fixing points represented on the auxiliary crane
(truck crane, assembly hall crane). It is advantageous to use two cranes.
• Remove screws of the consoles (4).
• Lift piling rig and drilling device carefully until the basic arm is pointing down vertically.
• Remove the pins on the basic arm (3) via the hydraulic pin retraction device.
• Set down piling rig and drilling device on suitable supports or suitable holder.
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6.9.3 Pin retraction device basic arm

General
The pin retraction device
- serves the insertion and extraction of pins between basic arm
and the pivot points on the uppercarriage,
- is mounted to the basic arm via the holder,
- functions with the aid of a hydraulic cylinder
53
Pin retraction device basic arm
1 Cylinder 6 Basic arm

2 Axle 7 Quick-change coupling on the cylinder
3 Stop plate (Operating position) 8 Stop plate (Transport position)
4 Pins 9 Hexagonal screws
5 Grease nipple 10 Allen screws
The cylinder is supplied via two hydraulic hoses. The hydraulic hoses are mounted between the
quick-change couplings on the rear of the undercarriage, directly alongside the operating levers of
the track adjustment and of the cylinder.
The axle (2) is used respectively for rotational securing of the pins (4).
Either the basic arm of the piling rig and drilling device or the main boom pivot piece is mounted to
the pivot points.
The stop plate is mounted in accordance with:
- Operating position (3): the basic arm is or will be mounted
- Transport position (8): the pivot piece is or will be mounted
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Procedure for change-over:

- Loosen hexagonal screws (9)
- Fold stop plate into the required position
The Allen screws (10) allow precise positioning.
- Secure stop plates via hexagonal screws
CAUTION !
Danger of crushing !
It is prohibited to remain beneath the basic arm as the cylinder is being actuated.
54
6.9.4 Extracting pins
Prerequisite
• The piling rig and drilling device is fixed accordingly
and can be dismantled.
Procedure
• Switch off the machine
• install the hydraulic hoses, included in delivery, be-
tween the quick-change couplings alongside the op-
erating levers of the track adjustment and the cylinder
of the pin retraction device (do not turn uppercarriage
any further!)
• Press pre-selection key "Cylinder adjustment functions
On / Off" on the right-hand control panel (X23) and
lower safety lever
• Retract cylinder by adjusting the operating lever
(fig. 54, no.1) until both pins have been extracted
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CAUTION !
Remove the hydraulic hoses following application of the pin retraction device.
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6.9.5 Inserting pins

Prerequisite
• The pin retraction device is mounted on the basic arm
• The basic arm is positioned correctly
Procedure
• Switch off machine
• install the hydraulic hoses, included in delivery, between the quick-change couplings alongside the
operating levers of the track adjustment and the cylinder of the pin retraction device (do not turn
uppercarriage any further!)
• Start machine
• Press pre-selection key "Cylinder adjustment functions On / Off" on the right-hand control panel
(X23) and lower safety lever
• Extend cylinder by adjusting the operating lever (fig. 54, no.1) until both pins have been inserted
CAUTION !
Remove the hydraulic hoses following application of the pin retraction device.
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6.10 Transport
6.10.1 Safety guidelines for loading and unloading
• Basic machine and its attachment parts should be prepared in accordance with details given in this
chapter concerning transport (Transport positions).
• Flat-bed trailer and transporter must be equipped with suitable fixtures and lashings for loading
safety.
• Maintain a safe distance with the transporter from edges of crevices, ditches, dumps and
embankments as well as ramps in order that there is no danger of tipping.
• The operator must leave the cab of the transporter for the duration of loading/unloading duties, and
may not remain within the danger area.
Exceptions:
The operator's cab is protected against falling pieces of attachment components via a protective
roof.
No loads are swung over the operator's cab and the operator's cab is protected from the loading
area by a front wall reinforcing or impact wall.
• Above all else when loading or unloading, it should be ensured that
- an assistant is available,
- persons are not endangered by falling, tipping or rolling attachment components,
- a sufficiently safe distance from electrical overhead cables or contact lines is maintained (see
point 3.8.5 "Electrical overhead cables"),
- the transporter can not roll away, tip or fall,
- sufficient space is available for lighting equipment for operation in poor light conditions.
• When loading or unloading the attachment using basic machine as assembly crane
- only use original assembly gear,
- try to keep the attachment components as close to the ground as possible.
• Lash or retain basic machine and attachment so that no persons are endangered in normal traffic
conditions.
• Mark all parts protruding over the loading area in order that they can be instantly noticed by other
traffic.
• Do not exceed permissible values for total weight, axle loads, supporting load and trailer load
when loading the transporter.
• Take the same amount of care unloading the attachment, as was taken when loading. Clear away
all loose chains and wedges before unloading.
Safety regulations for transport on public roads
• Note national traffic laws and all local guidelines (relative transport weight, width, height, descrip-
tion, escort vehicle, idle time and unattended time, etc.) - this also applies for transiting through
other countries!
• All necessary approvals for transport must be on hand before beginning transport.
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• Check transport route beforehand and in particular, familiarise yourself with

- road widths,
- entrances to tunnels and underpasses,
- load capacity of bridges, roads and street fixtures,
- safe distances from electrical power lines.
• With regard to transporter guidance, the operator must
- be physically and mentally suitable,
- show sufficient training, knowledge and career experience,
- be qualified in personal characteristics (e.g. age, reliability, etc.).
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6.10.2 Transporting basic machine with flat-bed trailer

Should a flat-bed trailer be requested by a transporting firm, the following details must be given
about the basic machine:
Transport weight: kg
Transport height: mm
Transport width: mm
These details apply to the basic machine with crawler, without rear counterweight. The transport
weight is dependent upon winch design, ropes, tank content and options.
Transport position for basic machine

The following points have already been carried out for disassembly of basic machine (in accordance
with chapter 6):
• Rear counterweight has been disassembled.

• A-frame is set down.
• The main boom foot is supported on the flat-bed trailer.
• The uppercarriage is positioned parallel to the undercarriage.
• The uppercarriage locking is mounted.
Loading basic machine
NOTE !
Depending on flat-bed trailer, the basic machine can be loaded so that the main boom foot is either
at front or back of the loading area.
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55
Lash and secure basic machine to flat bed trailer
• Four steel chains in accordance with fig. 55

- hang from shackles at both sides on undercarriage
centrepiece,
- fix crossways onto flat-bed trailer,
- tension with ratchet load tightener.
56
Lashing flaps on the undercarriage (Figure 56, optional)
Observe the angle of the chains!
CAUTION !
Deviations in lashings: Under no circumstances lay

steel chains over hydraulic lines and do not damage
painted surfaces.
WARNING !
The basic machine can slide on the flat-bed trailer!

Countermeasures:
Deck out loading area with non-sliding underlay.
Check and retighten lashing on basic machine after every day of travelling.
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6.10.3 Transporting the attachment
NOTE!
Dimensions and weight of attachment components are specified under point 2.9 "Technical data".
When transporting with fork-lift truck, cover forks with wooden supports to protect against damage.
CAUTION !
There is a risk of danger when loading boom intermediate pieces with a fork-lift truck: The
diagonal struts may bend when they are loaded onto the forks.
Countermeasures:
Only use fork-lift truck with sufficient fork length or fork extension.
Transport boom intermediate pieces carefully with fork-lift truck, so that they can not slide off.
The forks may not come into contact with the struts of the boom intermediate piece.
NOTE!
Transportation belts are to be used for transporting boom parts, never use chains or ropes.
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6.10.4 Loading basic machine with auxiliary crane
DANGER !
If the determined minimum requirements of transport gear and auxiliary crane are not met,
serious accident and write-offs may occur.
Countermeasures:
• Under no circumstances lift basic machine with mounted rear counterweight.
• The transport gear must
- be in perfect condition,
- be permissible for this application,
- meet the minimal values for load bearing capacity and single-cable lengths.
• The auxiliary crane must feature sufficient boom length, lifting height and load capacity for the
respective application.
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57
58
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6.10.5 Transporting overseas

Included in delivery by the manufacturer,
- the operator's cab is protected against transport damage via sturdy wooden shuttering,
- attachment and accessory parts packed in wooden crates, wrapped in polythene, giving protec-
tion against water penetration,
- additional desiccants to protect electrical components.
CAUTION!
The basic machine and attachment components can be exposed to saltwater or atmospheres
containing salt-water due to
- inappropriate transport,
- damage to transport container,
- unsuitable or incorrect packaging.
Possible outcome
- partial or total ruination of electronic control,
- corrosion damage, which influences efficiency of safety and functioning.
Countermeasures:
The basic machine may exclusively only be transported below deck .
Only contract qualified haulage companies for the packaging.
All boom sections which have been exposed to saltwater during the transport overseas, must be
rinsed thoroughly with fresh water before assembling or putting into intermediate storage.
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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.
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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
Service/Inspection
according to WORK TO BE CARRIED OUT
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
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 season
* *
8 hrs / daily
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 capacity.
All cylinders must be retracted.
Exception: Tilting back support cylinders on LR/HS.
x o Analyze hydraulic oil. Depending on the result, change the oil. If an oil
change is not carried out after 2000 hrs, a new oil analysis must be
carried out every 500 hrs
o Change the hydraulic oil if no analysis has been carried out, otherwise
be guided by the results of the analysis.
o Check hydraulic system for leaks
o Test all hydraulic hoses
o Change all the hydraulic hoses every 12000 hrs; time interval dependent
on imprinted 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 magnetic rod in the return filter (weekly for the first 250 operating
hrs)
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 pressure accumulator
o Replace the pressure accumulator
o Grease the piston rods for all freely accessible cylinders
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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
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 MAN D 2842 LE

o Check the engine externally for oil, fuel and coolant leaks
o Check the coolant level
o Check the concentration of the antifreeze/anti-corrosive agents
o Check the engine oil level
o Check the V-belt tightening roller and replace if necessary
o Check the condition and tension of the V-belt (replace if necessary)
o Check fuel prefilter, if necessary drain condensation water
o Check the injector nozzles every 10,000 hrs, replacing them if neces-
sary
x Tighten the cylinder head screws
o Adjust the valve clearance
o If necessary, tighten any detachable connecting elements (screws, hose
clamps, pipe connectors)
o Check the compression pressure every 10000 hrs
o Change engine oil
o Replace the engine oil filter cartridge
o Replace the fuel pre/fine-mesh filter (do this earlier in the event of an
error message/drop in performance)
o Check dry air filter and test vacuum indicator
o Empty dry air filter and dust collector (earlier if required)
o Replace the filter element in the dry air filter
o Change the filler cap on the equalizing reservoir every 4 years
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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 Check winch gearbox for leaks and if necessary carry out an oil analysis
x o Change winch gearbox oil
o Change feed winch oil
o Lubricate the counter bearing if possible
o Check rope end fastening for tight fit
o Check the 3-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 Check the standstill monitor for tight fit and correct operation
o Conduct visual inspection; record running time for the winches
o Check that stopping brakes are working
o Check that the free-fall brakes are working (if present)
o Check that the constant pull of winches 1 and 2 operates properly (if
present)
o Check that the free-wheel works properly (if present)
x o Hydraulic motor and planetary drive gear: Check toothed profile for wear
and change if necessary
o Check that the rope pull limitation is working properly
o Check the rope pull limitation for correct operation using test weights
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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
LOAD MOMENT LIMITATION (LML)
o Check that the system shuts down 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
TRAVEL GEARBOX
o Check the oil level
x o Change the oil
o Change the oil (if the travel gear is used a lot, more than 15% of the
engine operating hours)
o Check fastening screws for tight fit
o Check tumbler wheel and travel gear engine fastening screws for tight fit
o Check gearbox and hydraulic connections for leaks
TRAVEL GEAR
o Visually inspect travel gear parts (carrying rollers, running rollers, guide
wheels, floor plates)
o Clean travel gear, earlier if necessary
o Check screws, nuts and bolts for tight fit
o On telescopic undercarriages, check the locking screws on the chords of
the crawler carriers for tight fit and tighten if necessary.
o Check chain guides for wear and tight fit
o Check chain tension and re-tension if required (earlier if necessary).
Note: In the case of hydraulic pretension the re-tensioning is done
using the travel gear
o Check 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
MAIN BOOM
o Check boom pivot piece, bolt joint and retaining spring for tight fit
o Check that the angle indicator for the boom pivot piece or A-frame 1 is
working and lubricate if necessary
o Check the pendant straps or pendant ropes, including bolts, for damage,
wear and check that the retaining springs and cotter pins are present
(depending on material: cracks, notches, corrosion, plastic deformation,
wear, lubrication, etc.)
o Check the connecting shackle of the pendant straps for damage, cracks,
plastic deformation
o Check the boom pivot piece and intermediate piece for damage and
wear (cracks, notches, corrosion, plastic deformation, wear)
o Check the screw and bolt connections of the main boom head for tight
fit, check the rope fixation for cracks, check for ease of movement and
wear of the pulleys, check that the rope guard and the retaining springs
are present and undamaged
o Visually inspect force measuring strap for damage and check electrical
connections for tight fit
o Check and test anemometer, hoisting limit switch and proximity switches
of jib tilting-back supports for tight fit
o Check the screw and bolt connections of the tip boom for tight fit, check
the rope fixation for cracks, check for ease of movement and wear of the
pulleys, check that the rope guard and the retaining springs are present
and undamaged
o Replace the pendant ropes
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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 oil level
Only check engine oil when the machine is positioned
on level ground.
• Switch off diesel engine and wait for 2 - 3 minutes
until the oil has collected in the oil pan.
• Open the rear maintenance door on the left-hand side
of the uppercarriage.
• Pull out oil dipstick (fig. 2, no. 1), wipe with a clean
cloth and reinsert to the stop. 2
• Pull out oil dipstick again and check the oil level.
• The oil level must be between the MIN. and MAX.
markings on the oil dipstick, fill in oil as required
(fig. 1).
- For the total amount of oil and specification of the
engine oil to be used, see chapter 7
"Filling amounts"
and "Lubricant requirements".
Check oil pressure
• Start diesel engine, see chapter 5
• Check the oil pressure in the operating diagram

"Aggregate monitoring" (chapter 4).
The following values must be attained:
- Engine running in idle while cold;
5 bar
- Engine running in idle while warm;
3 - 4 bar
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7. MAINTENANCE
7.4 Fuel system (MAN engine)
WARNING!
Avoid direct contact with the fuel and/or the condensate/diesel mixture.
Risk of chemical burns and eye injuries.
• Wear protective clothing, especially safety goggles.
DANGER!
Danger from hot engine parts and hot engine oil.

Risk of burns and cuts.
Always wait until the diesel engine has stopped before inspection.
Never touch leaks or the engine itself with bare hands.
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7. MAINTENANCE
7.4.1 Check the water separator on the fuel prefilter, drain off the condensate if
necessary
Ensure that the following conditions are satisfied:
- The engine has been switched off and secured against unauthorised starting.
- There is an acid-resistant container ready for the condensate/diesel mixture to be drained off into.
- Protective clothing is being worn.
Water separator (Figure 3)
1 Vent screw 3 Drain plug (ball valve)

2 Fuel sight glass 4 Drain opening
- Check the fuel using the sight glass (Figure 3, item 2) on the water separator.
LRB255_V001 (mf) LWN - TD4/2/2010
- All the fluid visible in the sight glass is of the same colour - no indication of any appreciable levels
of condensate in the system. The result is OK and no further action is required.
Troubleshooting Two different colours can be seen in the fluid in the sight glass.
• Drain off the condensate/diesel mixture at the drain opening (Figure 3, item 4).
- Position the acid-resistant container underneath the drain opening (Figure 3, item 4).
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7. MAINTENANCE
NOTE
Note the maximum fill level in the container.
- Unscrew the vent screw (Figure 3, item 1).
- Turn the drain plug (Figure 3, item 3) to the left to open.
- Leave the drain plug open until only pure fuel runs out of the drain opening.
- Retighten the drain plug and the vent screw.
CAUTION!
Risk of damage to the environment.

Dispose of the condensate/diesel mixture according to the relevant national and international regula-
tions.
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7. MAINTENANCE
7.4.2 Draining condensate from the fuel filter

Fuel filter (Figure 4)
1 Drain plug
- Open the drain plug.
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LIEBHERR
7. MAINTENANCE
NOTE
- Retighten the drain plug.
CAUTION!

Dispose of the condensate/diesel mixture according to the relevant national and international regula-
tions.
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7. MAINTENANCE
7.4.3 Draining condensate from the fuel tank

Fuel tank (Figure 5)
1 Drain plug
- Open the drain plug.
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7. MAINTENANCE
NOTE
- Unscrew the drain plug.
- Drain off the condensate/diesel mixture.
- Retighten the drain plug.
CAUTION!

Dispose of the condensate/diesel mixture according to the relevant national and international
regulations.
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7. MAINTENANCE
7.4.4 Cleaning the fuel prefilter

- An original LIEBHERR strainer is available.
Fuel prefilter with unscrewed tappet (Figure 6)
1 Hand pump tappet

2 Filter housing
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7. MAINTENANCE
- Unscrew the filter housing (Figure 6, item 2).

- Remove the filter housing and strainer.
- Rinse the filter housing and strainer using pure diesel fuel.
- Blow out the filter housing and strainer with compressed air.
- Refit the filter housing with a new seal.
- Screw on filter housing and torque to 10-12 Nm.
- Unscrew the vent screw on the water separator (Figure 3, item 1).
- Unscrew the hand pump tappet (Figure 6, item 1) and leave open until bubble-free fuel runs out.
- Tighten the vent screw on the water separator while still pumping.
- Screw in and tighten the hand pump tappet.
- Start up the engine and check the fuel prefilter for leaks.
CAUTION!

Dispose of the contaminated diesel that was used for rinsing according to the relevant national and
international regulations.
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7. MAINTENANCE
7.4.5 Replacing the fuel filter

- Two original LIEBHERR fuel filter cartridges are available.
DANGER!
Risk posed by damaged filter cartridges.

Filter cartridges with deformed steel jackets, dents or damaged sealing rings must be replaced
immediately.
7
LRB255_V001 (mf) LWN - TD4/2/2010
Changing the fuel filter (Figure 7)
1 Filter cartridge
- Loosen the fuel filter cover and unscrew together with the filter cartridge.
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7. MAINTENANCE
CAUTION!
Pre-used filter cartridges are dangerous.

• On no account refit removed filter cartridges.
- Remove the filter cartridges from the cover.

- Clean the cover.
- Replace the sealing ring.
- Screw on a new filter cartridge and cover and torque to 25 Nm.
- Bleed the fuel system.
WARNING!
Escaped fuel is a fire hazard.

Thoroughly clean any escaped fuel off the engine.
- Check the filter for leaks.
CAUTION!

• Dispose of the used fuel filters according to the relevant national and international regulations.
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7. MAINTENANCE
7.4.6 Bleeding the fuel system

The fuel system must be bled after:
- Running out of fuel

- Commissioning the diesel engine
CAUTION!
Risk posed by improper handling.

• Any work on Common Rail System components should only be carried out by specially-trained
personnel.

- The ignition must be turned on.
NOTE
The system can only be bled when the ignition is turned on.
- An acid-resistant container is available.

8
LRB255_V001 (mf) LWN - TD4/2/2010
Bleeding the fuel system (Figure 8)
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LIEBHERR
7. MAINTENANCE
1 Vent screws
2 Hand pump tappet
- Position the acid-resistant container underneath the fuel filter.

- Unscrew the vent screw (Figure 8, item 1) of the first filter in the system by one to two complete
turns.
- Unscrew the hand pump tappet (Figure 8, item 2) and leave open until bubble-free fuel runs out.
WARNING!
Escaped fuel is a fire hazard.

• Thoroughly clean any escaped fuel off the engine.
- Screw in and tighten the hand pump tappet.

- Retighten the vent screw and torque to 25 Nm.
- Repeat this procedure for the second vent screw.
- Start up the engine and check the fuel system for leaks.
CAUTION!

Dispose of any objects and tools that have been contaminated with fuel according to the relevant
national and international regulations.
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7. MAINTENANCE
7.5 Cooling system

7.5.1 Coolant, check filling level and fill as required
CAUTION !
Risk of burning due to hot coolant!

At operating temperature, the engine's cooling system is extremely hot and highly pres-
surised!
Avoid coming into contact with parts carrying coolant!
Only check the coolant level when the system has cooled!
9
• The coolant level must be in the middle of the inspec-
tion glass when the diesel engine is cool (fig. 9, no.
4), fill as required.
Filling in coolant
NOTE !
The cooler cap with overpressure valve (fig. 9, no. 3) on
the compensator reservoir (fig. 9, no. 1) is lead sealed
and must not be opened! It serves to bleed the cooling
system!
• The cooling system is cold

- Open cooler cap with underpressure valve (fig. 9, no. 2).
- Fill in coolant to the middle of the inspection glass.
• The cooling system is hot (Risk of burning , wear protective gloves)!

Should the filling level sensor respond during operation, the coolant level must be checked
and refilled.
- First turn the cooler cap with underpressure valve (fig. 9, no. 2) carefully around 90°,
to release any possible excess pressure.
- Fill in coolant until the inspection glass is completely filled.
NOTE !
The cooling system should be filled with the respective coolant all year round. This coolant
comprises 50 % fresh water and 50 % anticorrosive/antifreeze.
Specification see chapter 7 "Filling amounts" and "Lubricant requirements".
LRB255_V001 (mf) LWN - TD4/2/2010
The cooling system has been filled with anticorrosive/antifreeze effective down to -37 °C.
• Filling amount for the entire cooling circuit: approx. 70 litres
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7. MAINTENANCE
10
Temperature regulation
The cooler motors of the water cooler and intercooler
are temperature regulated. When the coolant is cold, the
fan turns slowly. Maximum speed is only reached when
the coolant is hot. This regulation can be shunted man-
ually. Upon actuation of the ball valve (fig. 10, no. 1),
the fan always turns at maximum speed.
7.6 The dry-air filter

7.6.1 Arrangement of the central assembly
11
1 Main element 4 Clamping fasteners

2 Safety element 5 Dust discharge valve
3 Plastic cover
7.6.2 Emptying the dust collection container

• The dust collection container should be emptied if the error report "M 0003 Air filter dirty" appears
on the "Error display" page.
• Fold back the four clamping fasteners (fig. 11, no. 4), remove plastic cover (fig. 11, no. 3), empty
and clean inside and out.
• Remount the plastic cover so that the dust discharge valve (fig. 11, no. 5) is pointing downwards.
Tighten all clamping fasteners again.
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7. MAINTENANCE
12
7.7 Splitterbox
7.7.1 Checking gear oil level
Check gear oil with the machine positioned horizontally.
After switching off the diesel engine, wait 2 - 3 minutes
for the oil to collect.
• Pull out oil dipstick (fig. 12, no. 1), wipe with a clean
rag and reinsert to the stop.
• Pull out oil dipstick and check the oil level.

markings on the oil dipstick, fill as required (fig. 13).
- For the overall amount of oil and specification of
the oil to be used, see chapter 7 "Filling amounts"
7.7.2 Gear oil cooler

The gear oil is channelled through a gear oil cooler and cooled.
The fan of the gear oil cooler is driven via a small electric motor (24 V).
The gear oil temperature is monitored via a temperature switch. With a gear oil temperature of
approx. 90 °C, the electric motor is initiated automatically.
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7. MAINTENANCE
7.8 Travel gear

7.8.1 Cleaning the travel gear
NOTE!
Contamination, trapped stones and other foreign bodies on the sprocket or idler or on the track pads
lead to an increase in chain tension. This in turn leads to reduction in life-expectancy of travel gear
components.
• Before shutting down the machine, or at the latest every 40 operating hours, the following should
be carried out:
- all travel gear components, especially the sprocket, are to be cleaned thoroughly.
The easiest way to do this is by spraying with a water hose.
Trapped stones and other foreign objects must be removed
13
7.8.2 Check chain tension, tighten as required

• Unscrew the outside cover on the (fig. 14, no. 1)
crawler track.
• Connect the hose of the manual press (fig. 14, no. 4)
to the grease nipple (fig. 14, no. 3) of the tensioning
cylinder on the idler to the stop. Inject grease until the
required chain tension has been achieved.
Pressure displayed on the pressure gauge: approx.
180-200 bar [2600-2900 psi]
• The travel gear has been correctly tensioned when the
chain sags approx. 25 mm [1'].
• To remove the pressure hose, loosen it slightly at the
manual press and release the pressure. Only then can
the pressure hose be removed from grease nipple!
• Screw on the (fig. 14, no. 1) cover on the crawler
track carrier again.
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7. MAINTENANCE
14
7.8.3 Releasing tension in the chain
WARNING !
The grease in the tensioning cylinder of the idler is

pressurised and could shoot out of the grease nip-
ple! When loosening the grease nipple, never look
directly into the inlet! High risk of accident !
• Unscrew the inside cover (fig. 14, no. 1) on the

crawler track carrier.
• Carefully screw out the grease nipple (fig. 14, no. 3)
on the tensioning cylinder 2 to 3 complete turns until
the grease is exuded from the channel (fig. 14, no. 2)
directly on the grease nipple.
• Tighten the grease nipple (fig. 14, no. 2) again.
• Screw on the cover (fig. 14, no. 1) on the crawler
track carrier again.
15
7.8.4 Track pads
The fastening bolts and connections for the individual
track pads are to be checked for secure seating, and if
necessary, replaced with new original parts.
7.8.5 Track adjustment of the crawler track carrier

LRB255_V001 (mf) LWN - TD4/2/2010
Before adjusting the track of the crawler track carrier, for

transport
- clean the struts,
- grease sliding surfaces and pins.
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7. MAINTENANCE
16
7.9 Swing gear / Rotary connection
7.9.1 Swing gear, Check oil level
NOTE !
When checking the oil level, the machine must be posi-
tioned horizontally.
• Open maintenance door on the front, right-hand side .

• Pull out oil dipstick (fig. 16, no. 1) wipe with a clean
rag and reinsert to the stop.
• Pull out oil dipstick again and check oil level.

markings on the oil dipstick, fill in oil as required.
- For the total amount of oil and specification
of the oil to be used, see chapter 7,
"Filling amounts"
7.9.2 Lubricating the spur gear / pinion
The pinion and the spur gear are to be lubricated daily

using graphite spray or grease.
17
7.9.3 Lubricating the rotary connection, ball tracks
• Open the maintenance door on the rear, right-hand

side.
• Remove protective cap. Lubricate grease nipple (fig.
17, no. 2) identified with "KUD").
CAUTION !
During the rotary movement, no one may remain

within the swing range of the machine!
• Swing the uppercarriage around a further 45° and lubricate the grease nipple again.
Repeat this procedure over the entire circumference. Remount the protective cap.
• Turn the uppercarriage once more around 360 ° in order that the grease is better distributed,.
• A collar of grease must form on the sealing lip, thus, grease must be exuded evenly around the
entire circumference.
• Close the maintenance door on the rear, right-hand side again.
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7. MAINTENANCE
18
7.10 Winches
7.10.1 Winches 1 and 2 and main boom adjusting

winch; Check oil level
• Turn the oil dipstick (fig. 18, nos. 1) around a few full
turns anticlockwise and pull out.
• Wipe the oil dipstick using a clean rag, reinsert to the
stop and remove again.
The oil level must be between the MIN and MAX
markings on the oil dipstick.
If necessary, fill in gear oil (oil amount and specifica-
tion, see chapter 7 "Filling amounts" and "Lubricant
19
requirements".
• Reinsert oil dipstick and tighten in a clockwise direc-
tion.
20
7.10.2 Main boom adjusting winch; Lubricate
• Open the rear, right-hand maintenance door.
• Remove protective cap. Lubricate grease nipple (fig.
20, no. 1) identified with "EZW").
• Close rear, right-hand maintenance door again.
7.10.3 Main boom adjusting winch and A-frame;

Rope deflection pulleys
• Check rope deflection pulleys for:
- Freedom of movement
- Secure seating of the threaded unions
- Wear; the surface should not display any grooves.
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7. MAINTENANCE
21
7.11 Auxiliary winch *
7.11.1 Check oil level
When checking the oil level, the machine must be stand-
ing on level ground.
The oil level can be checked in the lowered (lead point-
ing upwards) or erected condition.
For correct checking the lead must be horizontal or
vertical.
The oil level should appear in the centre of the sight
glass.
Components of the auxiliary winch (Fig.21)

1 Sight glasses
2 Drive motor
3 3-winding limit switch
4 Rope end fastening
5 Guiding claws
22
7.12 Feed winch *
When checking the oil level, the machine must be stand-
ing on level ground.
The oil level can be checked in the lowered (lead point-
ing upwards) or erected condition.
For correct checking the lead must be horizontal or
vertical.
The oil level should appear in the centre of the sight
glass.
Components of the feed winch (Fig.22)

1 Drive motor
2 Sight glasses
3 Winch fastening
4 Rope length measuring sensor
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7. MAINTENANCE
23
7.13 Kelly winch *
NOTE !
To check the oil level, adjust the lead to maximum
outreach (dipstick stands vertical).
• Remove the dipstick (Figure 23, no.1), wipe it with a

clean cloth and re-insert it as far as possible.
• Take out the dipstick again and check the oil level.
markings on the dipstick. Top up oil if necessary.
- For the total oil quantity and specifications of the oil
to be used, see Chapter 7 "Filling quantities"
24
Components of the kelly winch (Fig.23)

1 Dipstick
2 Oil drain plug
3 Cable protection
4 Screw
5 Cable wedge
6 Kelly rope
7 Drive motor
8 Securing of winch
9 3-windings limit switch/sensor rope length measuring
10 standstill indicator
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7. MAINTENANCE
7.14 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.
7.14.1 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 length of time the rope has already been in use
NOTE!
.
Action following prolonged shutdown of the machine 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 break!

• 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.
Make sure that the following requirements are met:

- the engine has been switched off and secured against unauthorized starting
• Check ropes for all possible damage and deformation.
NOTE!
Check the rope in particular around the end connection as it is subject to increased mechanical
stresses at this point.
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7. MAINTENANCE
7.14.2 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 gage with wide jaws is available
Figure 25 shows the correct way to measure the diameter of the rope (left-hand side).
25
• 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
26 7.14.3 Check for rope deformations
Pockets: these can occur when the outer layer of wires

loosens or the outer wire braids are longer than the
inner ones. Movement of the outer wires or strands in
relation to the inner ones causes movement of the ex-
cess length at a particular location.
27
Loop formation: single wires or groups of wires emerge

from the rope structure. The loops usually lie in a series
of braids.
28
Contractions: are reductions in the diameter of the wire

rope over short lengths. Rope sections immediately be-
fore the end attachment must be checked for contrac-
tions with particular care. The contractions are often
difficult to recognize at these points.
29
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
30
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.
7.14.4 Check ropes for corrosion
31
Corrosion: occurs mostly in corrosive and salt water

atmospheres (e.g. prolonged storage of ropes in the
open air, salt water atmospheres, etc.). Two types of
corrosion occur: atmospheric corrosion (causes "even"
rust) and localized corrosion, such as pitting (forms deep
holes in places where the protective sheath is missing or
damaged). The photographs both show atmospheric cor-
rosion.
32
LRB255_V001 (mf) LWN - TD4/2/2010
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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LIEBHERR
7. MAINTENANCE
• Checking ropes for corrosion.
Troubleshooting:
..
7.14.5 Check ropes for abrasion
33
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:
..
7.14.6 Check ropes for the effects of heat
34
Heat damage: if the temperature rises above 300 °C,

the tensile fiber structure of the wire rope caused by
cold deformation recrystallizes and the wire loses around
2/3 of its original strength.
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7. MAINTENANCE
35
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:
..
Is there evidence of external heat damage, such as recrystallization, localized melting of steel, etc.?
.
NOTE!
For permitted operating temperatures for ropes and end attachments, please refer to EN 12385-3.
LRB255_V001 (mf) LWN - TD4/2/2010
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7. MAINTENANCE
7.14.7 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 braids of the wire Regular lay Lang lay
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 8 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 braids, 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 braid, only the braids in
the outermost layer are deemed to be outer braids. In the case of steel-reinforced steel ropes the inner braids are the
reinforcement.
2
The numbers calculated should be rounded up.
.
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 braids of the original rope. Likewise the wire rope must comply with the
relevant national and international regulations.
Example: If the measured diameter of D 99-D is 30 mm, 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 [3'] 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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7. MAINTENANCE
Troubleshooting:
..
Does the number of wire breaks exceed the number of permitted wire breaks?
7.14.8 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 machine manufacturer's specifications poses a threat
to life!
• Always use ropes that conform to LIEBHERR specifications.
DANGER!
Damage to the rope.

• The fitting of swivellers 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 tendency is not encouraged by the rope drum or the reeving, but is
compensated for by them instead. For example, a rope with left-hand lay direction can be wound
around a left-hand drum, a right-hand drum, however, would counteract the rope's tendency to
untwist.
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 deflection between the rope
LRB255_V001 (mf) LWN - TD4/2/2010
pulleys is greater than the influence of the rope 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 rope 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 36). 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 37).
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.
36
- 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.
37
- 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 rope 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:
- Rope with right-hand lay direction
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7. MAINTENANCE
Rope lay direction on a multi-layer rope 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:
- Rope with right- hand lay direction
Low-twist ropes
.
NOTE!
Ropes described as "low twist" vary considerably with regard to the turning moment or twist when
under stress.
There are two types of low twist ropes:

Low-twist ropes
Low-twist 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 low-twist ropes, the use of a twist arrestor is prohibited.
Extremely preformed ropes

The extremely low-twist ropes have a separate twisted steel reinforcement that is twisted in the
opposite direction to the outer layer, which nowadays consists of 15 and more outer braids. Under
stress, the steel reinforcement twists in one direction, while at the same time the exterior layer twists
in the opposite direction. This largely compensates for the turning moment that occurs in the rope
when it is under stress.
Due to these special properties, only extremely low-twist ropes are used:
- for hoisting winches with high lifting heights
- when lifting unguided loads in one line operation
..
NOTE!
Despite this, the use of twist arrestors is not recommended by Liebherr.
Exceptions to this are ropes onto which turning parts are attached, e.g. kelly ropes on drilling
machines.
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7. MAINTENANCE
Non-twist-free ropes
..
NOTE!
Non-twist-free ropes create high turning moments when under stress.
The ends of the ropes must therefore be secured to prevent them twisting.
Non-twist-free ropes may be used:

- for guided loads
- for paired use of similar right and left hand laid rope structures
Under these conditions non-twist-free ropes achieve a higher fatigue life compared with low-twist
ropes.
WARNING!
Damage to property, severe injury or death.

• Never combine several non-twist-free ropes with different lay directions in succession (e.g. with
retaining ropes)!
• Never use these rope structures with a twist arrestor or having one or both rope ends without an
anti-twist device.
Non-twist-free ropes for hoisting winches:

In exceptional cases, non-twist-free ropes may be used for hoisting winches in the following
applications:
- drag bucket
- diaphragm wall grab
- handling twin-rope grab (paired right and left hand laid ropes)
..
NOTE!
Twisting of max. 180° is desired with the diaphragm wall grab.
The guy ropes are not designed as twist-free ropes.
Decision table
In the following decision table, which uses an example of the choice of most suitable wire rope
structure for the hoisting gear of a machine, 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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7. MAINTENANCE
Decision Yes Yes/No No

1 Do you require a Special rope, twist-free Special rope, twist-free 6, 8 or 10-stranded rope
twist-free rope?
2 Is a high break- Special rope SES, poss. SES -
ing force re- sealed
quired?
3 Is a high alter- Multi-stranded, thin Multi-stranded, thin out- -
nating bending outer wires er wires
strength re-
quired?
4 Is a high degree Thick outer wires Thick outer wires -
of abrasion re-
sistance re-
quired?
5 Does the rope Lang lay, sealed - Regular lay
operate with
multi-layer
spooling ?
6 Are structural Plastic intermediate lay- Plastic intermediate lay- -
changes expect- er er
ed?
7 Do large deflec- Plastic intermediate lay- Plastic intermediate -
tion 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?
7.14.9 Storing ropes
.
NOTE!
Ensure that rope drums and ropes are not damaged during storage.
CAUTION!
There is a risk of ropes being mixed up.

LRB255_V001 (mf) LWN - TD4/2/2010
• If the label is missing or is no longer clearly legible, label the affected rope 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 rope 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. MAINTENANCE
7.14.10 Transporting ropes

Ropes are very susceptible to external damage, therefore great care must be taken when they are
lifted, transported or unloaded.
38
Figure 38 shows a rope drum being transported correctly (left) and incorrectly (right) on a forklift
truck.
Correct procedure to avoid damage to ropes during transport:

• Lift rope drums using textile slinging equipment (flat lifting slings or round slings).
• Ideally, rope drums should be lifted with a spindle through the center of the drum.
• Lift rope drums using forklift forks, Figure 38.
7.14.11 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 rope pulleys are therefore checked for
wear using test templates. In addition, the condition of the rope pulley bearings, the draw rolls on the
winch drums, etc. are checked to ensure the rope drive works correctly.
.
NOTE!
Test templates are available in many different shapes. The best are round templates manufactured
on a lathe.

- the engine has been switched off and secured against unauthorized starting.
Checking winch drum groove base for wear

- a suitable test template is available
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7. MAINTENANCE
39
1 Test template
2 Winch drum
• Check each individual groove on the winch drum (Figure 39).

- If the test template fits easily into each groove, the diameter of the measuring device more or
less coincides with the groove base and the diameter of the grooves in the winch drum is roughly
4 - 8% larger than the diameter of the test template: the inspection is OK and no further action is
required (Figure 39).
Troubleshooting:
Does the diameter of the test template not coincide with the groove base of the winch drum? Is there
a crescent-shaped gap between the test template and the groove base? (Figure 40)
The rope has become thinner through use over time and must be withdrawn from service. Before
using a new rope, the worn grooves must be machined to ensure that the groove base returns to
specification.
40
1 Test template
2 Winch drum
• Inform LIEBHERR Customer Service and seek advice on the precise action to be taken.
LRB255_V001 (mf) LWN - TD4/2/2010
.
NOTE!
The grooves of the winch drum often become patterned as a result of marks on the rope:
• When changing the rope, smooth the surface of the grooves.
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7. MAINTENANCE
Checking for wear and replacing steel rope pulleys
The steel rope pulleys are checked in exactly the same way as the winch drum groove base, in
other words the radius of the grooves is checked using a test template.
.
NOTE!
The rope grooves often become patterned as a result of marks in the rope. The impressions of the
individual braids in the rope grooves are normal and not undesirable, since these produce a greater
rope supporting surface, which increases the service life of the rope. When the rope is changed, the
ridges must be removed and any sharp edges on the surface of the rope pulley smoothed.

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

• Check the groove base of the rope pulley for wear.

- If the rope groove base is worn by less than the rope diameter: the result is OK and no further
action is required.
..
Troubleshooting:
Is the rope groove base worn by less than the rope diameter?
Replace the rope pulley.
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LIEBHERR
7. MAINTENANCE
Checking rope pulleys for damage 41
1 Crack
2 Nicks
.
NOTE!
Rope pulley are very susceptible to external damage: Chafing must be avoided at all times and
rope pulleys must not be placed on the ground without protective equipment.
• Check rope pulley for all types of damage, such as nicks, wobble, cracks and notches, etc.
- If the rope pulleys are aligned with the direction in which the rope is running and there is no
evidence of wobble or other damage: the result is OK and no further action is required.
Troubleshooting:
.
Does the rope pulley show any sign of damage?
Replace the rope pulley immediately.
Lubricating the rope pulley bearings
Manually lubricate the rope pulleys:
.
NOTE!
The grease must not leak from between the rope pulleys.

- A lever-type grease gun filled with the appropriate grease type as stated on the lubrication chart
is available
- The boom is lowered
LRB255_V001 (mf) LWN - TD4/2/2010
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 rope pulleys
When in use, plastic rope pulleys in particular can become very dirty, resulting in excessive wear. It
is therefore important to clean gum, etc. off plastic rope pulleys.
.
NOTE!
Only clean plastic rope pulleys with suitable cleaning agents.
Plastic rope pulleys are resistant to:

- mineral oil
- petrol
- kerosene
- diesel
Plastic rope pulleys are not resistant or not fully resistant to:
- concentrated mineral acids (e.g. sulfuric acid, hydrochloric acid, nitric acid)
- concentrated organic acids (e.g. formic acid)
- concentrated bases (e.g. sodium, caustic potash solution or corrosive potassium salts)
- alcohol other than ethyl alcohol, methyl alcohol and propyl alcohol
- inorganic chlorides, e.g. calcium, lithium chloride, magnesium chloride and zinc chloride
• Clean plastic rope pulleys using a cleaning cloth and suitable cleaning agents.
7.14.12 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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7. MAINTENANCE
CAUTION!
Destruction of rope.
• If the winding area of the rope is more in the upper rope layer when operating winches with
multi-layer winding, the lower rope layer may become loose.
• This results in a slight ovalization 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 winding behavior and
increases rope wear.
• To improve the winding behavior 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 as it will get dirty (Figure 42).
42
• Unwind ropes from the rope drum in the winding direction (Figure 43).
LRB255_V001 (mf) LWN - TD4/2/2010
Unwinding to the side causes the rope to twist until it is destroyed by kinking.
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7. MAINTENANCE
• Unwind ropes from a jacked up rope drum (Figure 42).

43
• Unwind ropes from a rope drum that is braked (Figure 43).
Troubleshooting:
.
Does the rope show signs of damage, deformation, wear, etc.?
Withdraw the rope from service and replace it with an intact one.
7.14.13 Luffing ropes
When luffing a new rope, ensure that the rope is not twisted or untwisted. The rope can be luffed
using an old rope or ideally using an auxiliary rope. If an auxiliary rope is used, it must have
sufficient permitted tensile 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 excessive lateral angle of rope (greater than 4°)!
• Position the rope pulley some distance away and, if possible. without any lateral deflection.

- The machine is secured to prevent unauthorized 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 rope 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 rope pulley.
• Have the rope limit switch checked and adjusted by personnel authorized 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. MAINTENANCE
7.14.14 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 rope pulleys.
Grease is normally applied using a brush. In exceptional cases, high pressure lubricating devices are
used (if these are used, the manufacturer's instructions must be 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.
7.14.15 Check rope suspensions and fastenings
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 welding or hardening), assuming the rope
structure is not separated by the type of fastening (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. Damage to the rope.

• When fitting a new wire rope, no adjustments may be made or attachments added to the rope
suspensions and fastenings.
• 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 off the rope head and recast.
• Check rope attachments 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 attachments (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:
.
Does the rope show signs of wire break or corrosion?
Shorten and refasten the rope.
Troubleshooting:
.
Is there rope slippage at the termination and the clamping bolts are loose?
Tighten the connection.
7.14.16 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 sealing sleeve
44
1 Locking pin
LRB255_V001 (mf) LWN - TD4/2/2010
2 Bolt
3 Wire clamp or sealing sleeve
4 Pocket locks
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 (item 5, figure 44).
• Check the ease of movement of the safety button for the safety latch.
• Check that the safety bolt is present (item 2, Figure 44).
7.14.17 Check the rope fixation and rope thimble
Rope lock
45
1 Rope lock
2 Rope fixation
3 Intermediate connector
4 Hoisting rope
• Check the rope lock for damage and proper operation.

• Check rope clamp for tight fit.
Troubleshooting:
.
Does the rope show signs of wire break or corrosion?
Remove the rope.
Troubleshooting:
.
Is the rope lock cracked?
Immediately replace the rope lock with an original LIEBHERR spare part.
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7. MAINTENANCE
Rope thimble with ferrule 46
1 Wire clamp
2 Ferrule
3 Rope thimble
• Check the ferrule for cracks and splitting.

• Check the ferrules on the anchoring and tensioning ropes.
Troubleshooting:
.
Is the ferrule 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?
Replace the rope thimble.
• Check the wire clamps for cracks and corrosion.

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7. MAINTENANCE
47
7.15 Load hooks
The load hooks should undergo a visual inspection be-
fore beginning operation.
7.15.1 Load hooks with one or more pulleys

• Lubrication of the axles at the respective lubrication
points (fig. 47, nos. 4 and 5) in weekly intervals or as
required.
• Check locating end of rope (1) for cracks.
• Check freedom of movement and wear of the pulleys
(2).
• Check rope protection and safety elements (3).
• Check correct functioning of the safety flaps (6).
• The hook (7) must be able to rotate freely.
48
7.15.2 Individual hooks

• Lubrication of the bearing (fig. 48, no. 1) at weekly
intervals at the lubrication points (4).
• The hook (3) must be able to rotate freely.
• Check correct functioning of the safety flaps (2).
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7. MAINTENANCE
49
7.16 Maintenance boom
7.16.1 Boom pivot piece
• Inspection of the boom fastening pins and the safety
elements (fig. 49, no. 1).
• Visual inspection of the pivot piece welded construc-
tion for mechanical damage. Bent or damaged pipes
must be replaced or repaired by qualified personnel in
accordance with the repair instructions.
• Lubrication via the grease nipple on the boom fasten-
ing pins (fig. 49, no. 2).
50
7.16.2 Boom intermediate pieces

• Visual inspection for all mechanical damage. Bent or
damaged pipes must be repaired in accordance with
the repair instructions or replaced. This may only be
carried out by personnel authorised by LIEBHERR
WERK Nenzing.
• Worn rope supports (fig. 50, no. 1) on the boom inter-
mediate pieces must also be replaced.
7.16.3 Main boom head

• Rope pulleys (fig. 51, no. 1):
- check for freedom of movement 51
- bearing on main boom head.
lubricate via the grease nipples
Grease must be exuded from the bushes around the
entire circumference.
• Check rope protection (2) for damage and corrosion.
• Check hoist limit switch (3) for correct functioning.
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7. MAINTENANCE
52 7.16.4 Inspection of boom threaded unions and re-

taining rope connections
• The connection of all boom intermediate pieces on the

main boom are comprised of pins (fig. 52, no. 3),
washers (no. 1) and cotter pin (no. 2), with the excep-
tion of the connection between the first intermediate
piece and the main boom pivot piece, which features
two double taper pins for safety reasons.
• Damaged areas of the paint on the boom sections

should be repainted by a specialist. This is a precau-
tionary measure to prevent more serious damage due
to corrosion.
• The connecting pins of the retaining and tensioning
53
ropes (fig. 53, no. 1) must be checked once a week.
These comprise of pin ( 5), washer (4), nut (3) and
cotter pin (2).
• No welding work is to be carried out on the boom
sections without authorisation from the manufacturer!
The installation of secondary profiles and pipes is also
prohibited! This could lead to major damage! Risk of
fatalities !
• Special attention must be paid to professional securing
of the pins via cotter pins.
• Damaged or corroded cotter pins are to be replaced
with new ones.
CAUTION !
Damaged retaining ropes can lead to serious accident!

Should damage be determined to the retaining ropes, the ropes should not be used again and
must be replaced immediately with original LIEBHERR retaining ropes.
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7. MAINTENANCE
54
7.16.5 Overtopping guard struts on the pivot piece
• The spring at the end of the overtopping guard struts
(fig. 54, no. 1) must be lubricated regularly.
• Check for freedom of movement.
• Old or hardened grease must be removed.
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7. MAINTENANCE
7.17 Maintenance of the hydraulic system

7.17.1 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 interval for the hydraulic oil filter.
Condensate must be drained off regularly.
55
• The oil level in the hydraulic tank should be checked
daily by means of the sight glasses (Fig. 55).
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 (max) shows the maximum oil
level when all cylinders are retracted.
• The lower sight glass (min) shows the minimum oil
level when all cylinders are extended.
• The level must not be below the centre of the lower sight glass or above the centre of the upper
sight glass.
• Hydraulic fluid must always be topped up via the return filter (see Changing hydraulic oil).
NOTE !
Prior to a change over to another hyraulic oil (e.g. synthetic hydraulic oil) the Liebherr customer
service has to be informed.
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7. MAINTENANCE
56
7.17.3 Topping up hydraulic oil
• Remove filter cover (Fig. 56, no.5)
• Fill with hydraulic oil via the return filter (1) until the
hydraulic oil is visible in the centre of the lower sight
glass
For specification, see Chapter 7 "Lubricant require-
ments")
• Check the sealing ring (3) and renew if necessary.
• Replace the filter cover and tighten.
• 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 (Fig. 56,
no.2) around the filter centring pipe (1) is also com-
pletely filled.
Drain off condensate

• Condensate must be drained off regularly. Place the
supplied drain hose on the drain valves (5) until water-
free oil runs out.
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7. MAINTENANCE
57
7.17.4 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 tap on the hydraulic tank.
• The shut off tap is open when the hand-lever is par-
allel to the suction pipe (Fig. 58, pos.A).
7.17.5 Shut off valve on the 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 A = shut off valve open (Fig. 57)

• Position B = shut off valve closed (Fig. 57)
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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7. MAINTENANCE
58
7.17.6 Clean the magnet plug
CAUTION!
For the first 250 operating hours clean the magnet

plug daily, thereafter weekly.
• Undo the 4 fixing screws (Fig. 58, no.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 (Fig. 58)

1 Filter element
2 O-ring (2)
3 Sealing ring (3)
4 Magnet plug
5 Filter cover
6 Screws
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7. MAINTENANCE
7.17.7 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 depressurise the hydraulic system.
Defective hydraulic hoses must always be replaced immediately by

LIEBHERR CUSTOMER SERVICE .
7.17.8 Special maintenance activities

• For transport over long distances or by sea and when putting into intermediate storage, the
machinery and equipment must undergo preservation measures. Such measures should be taken
in consultation with LIEBHERR CUSTOMER SERVICE.
• Before prolonged shut-down periods, the hydraulic systems must be protected against corrosion.
Contact LIEBHERR CUSTOMER SERVICE for information.
• Before restarting after a prolonged shutdown, the preservation measures, such as coats of paint,
must be removed carefully.
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7. MAINTENANCE
59
7.18 Electrical system
7.18.1 General
• The electrical system is to be checked regularly for
sound condition.
• Faulty fuses and components are to be replaced im-
mediately with original parts following rectification of
the fault.
• All clamping screws in the switch cabinets and termi-
nal boxes should be checked once a year and tight-
ened as required. Furthermore, all
EMERGENCY-OFF-BUTTONS should be checked for
proper functioning at regular intervals.
• Switch off the battery main switch if tasks are to be
carried out to the electrical system, or if welding work
is to be carried out!
7.18.2 Wet cleaning

• A wet cleaning of the switch cabinet is prohibited!
When wet cleaning the machine, it is imperative that
no water penetrates switch cabinet X1. The valve plug
on the hydraulic pumps and magnet valves, and all
electrical parts in the uppercarriage should not be
directly exposed to the water jet.
7.18.3 Batteries
CAUTION !
Protective gloves and protective glasses are pre-

scribed for tasks to the batteries. The battery acid is
highly corrosive! Naked flames are forbidden when
working on the batteries.
Only transport or store batteries vertically, safe-
guarding them from tipping over otherwise the bat-
tery acid can leak out.
General
LRB255_V001 (mf) LWN - TD4/2/2010
The batteries should be kept clean and dry at all times.

Terminal heads and cable clamps should be cleaned
regularly every 500 operating hours and then lubricated
with terminal grease (Vaseline). Do not mix oil and
grease with the batteries sealing compound. Do not lay
tools on the batteries!
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7. MAINTENANCE
60
Checking acid level
The acid level should be checked with initial start-up and
then regularly every 500 operating hours. To check the
liquid level, unscrew and remove battery cover. Remove
battery cell cover (fig. 60). The liquid level should be at
the maximum acid level marking, this means approx. 15
mm [0.6"] above the upper edge of the plate. Should
liquid level be too low, fill in distilled or desalinated
water .
Charging the batteries
NOTE !
To protect against overcharging of the batteries, use automatic battery chargers only. (Observe
operating instructions for the charger)
The automatic battery charger must be configured for 24 V battery voltage.
• Before connecting the automatic battery charger, switch off the battery main switch (key van be
removed).
• Connect automatic battery charger correctly to the batteries.
Both 12 V batteries are serially switched, generating an on-board supply voltage of 24 V. This means
that the automatic battery charger should be connected so that both batteries are charged together.
An individual, dismantled battery can only be charged with an automatic battery charger configured
for 12 V battery voltage.
The charging current (amperes) should total a max. 1/10 of the battery capacity (Ah). Before the
build-up of gas occurs, the value may be briefly exceeded, whereby the acid temperature may not
exceed 55 °C [131 °F].
• Check the acid level after charging and if necessary, refill distilled or desalinated water.
NOTE !
In order to increase life-expectancy, the batteries should be charged as soon as possible when flat.
Water consumption is influenced by the operating conditions and the battery charger used. Check
the acid level therefore, and ensure that it does not fall considerably below the maximum acid level
marking. If necessary, fill in distilled water.
The batteries feature central de-gassing with back-fire protection.
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7. MAINTENANCE
61
DANGER !
Risk of accident !
Before beginning operation, check functioning of all limit
switches via careful actuation.
7.18.4 Boom limit switch

Function inspection
Functioning of the boom limit switch on the uppercar-
riage (fig. 61, no. 2) can be checked in advance by
pressing in the control cam.
• Upon completion of mounting of the boom, adjustment
of the limit switch can be checked via careful actuation
of the main boom. The minimum reach of 82° may not
be fallen short of.
• Check correct fastening and alignment of the bow (1).
62
7.18.5 Hoist limit switches
Functional inspection
• Raising of the hoist cable and careful actuation of the
load hook against the weight (fig. 62, no. 2) of the
hoist limit switch (1).
• If functioning correctly, the lifting movement of winch
1 as well as the lowering movement of the boom
adjusting winch must be blocked.
• Check freedom of movement of the limit switch tackle.
If necessary, spray with adhesive lubricant.
63
7.18.6 Slip ring unit *
LRB255_V001 (mf) LWN - TD4/2/2010
Check the optional slip ring units (fig. 63, no. 1) and the
connected cable for damage.
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7. MAINTENANCE
7.19 Personal protective equipment

• Check personal protective equipment for:
- availability
- damage
- entirety.
Missing or damaged parts are to be replaced immediately with new ones
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7. MAINTENANCE
7.20 Maintenance piling rig and drilling device

Entire impression, noise generation, heat, etc.
Should any abnormalities be discovered during inspection or during daily operation, they must be
remedied immediately. If problems occur, please contact the manufacturer.
Lubricating the piling rig and drilling device

The different components (leader and support arm brace guides, rope pulleys, cylinder joint heads,
pins, etc.) are to be lubricated regularly in accordance with the details in the lubrication chart.
Checking leader impact

Check fastening of the leader clamp pieces.
Screws M30x250 (10.9)
Tightening torque: 1900 Nm [1400 ft lbs]
All slide and screw lockings must be installed.
Checking the guides

Too great a clearance in the guide claws and bearings influences the precise and secure guidance
of the piling rig or drilling elements. Ensure therefore, that they are repaired punctually.
Screws for universal carriage: M20x45 (8.8)
for all other guides: M20x50 (8.8)
Tightening torque: 430 Nm [317 ft lbs]
Replace the guide strips if wear become too excessive (max. 3 mm per guide strip).
Checking the polyamide strippers

The polyamide strippers for the feed ropes have to be replaced if wear appears. Otherwise material
accumulation can result at the lower rope pulleys and that can cause the rope to jump out of the
pulleys.
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7. MAINTENANCE
64
7.20.1 Limit switch feed
Functioning of the limit switch for the feed (fig. 64, no.
1), can be checked in advance via actuation of the
control cam.
• When mounting of the piling rig and drilling system
has been completed, check adjustment of the limit
switches via careful actuation of the universal carriage.
• Before beginning operation, functional capability of this
limit switch as well as all other installed limit switches
is to be checked.
• If functioning correctly, the the lifting movement
65 must be blocked by the upper limit switch and the
lowering direction must be blocked by the lower
limit switch .
7.20.2 Lower limit switch leader height adjustment

Functioning of the limit switch for the leader height ad-
justment (fig. 65, no. 1) can be checked in advance via
actuation of the control cam.
• During, or upon completion of mounting of the piling
rig and drilling system, adjustment of the limit switch is
to be checked via careful actuation (repositioning the
66
leader).
• Before beginning operation, the functional capability of
this limit switch, as well as all other installed limit
switches is to be checked.
• If functioning correctly, the lifting movement must be
blocked by the upper limit switch and the lowering
direction must be blocked by the lower limit switch
.
7.20.3 Maximum outreach limit switch

Functional testing
The operation of the limit switches for maximum out-
reach (Figure 66) can be checked by operating the trip
cam.
Prerequisite: the drilling operation has been switched
on.
• While erecting the leader, or on completion, approach
the limit switch carefully to check it is set correctly.
• If it is working properly, extending of the basic arm-
adjusting cylinder should be blocked.
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7. MAINTENANCE
7.21 Lubricant requirements

No. Lubrication Outside temperature Type: ISO VG/SAE Specification LIEBHERR lubricants
points
Engine year-round to -20 °C SAE 10W-40 ACEA E4 Liebherr Motoroil 10W-40
below -20 °C with API CF ID no. 10330246
preheating
1 Oil bath air filter year-round to - 20° C SAE 10W-40 ACEA Liebherr Motoroil 10W-40
E4/E6/E7 low ash
below -20 °C with API ID no. 10326111 soot par-
preheating CF-4/CG-4/ ticles
CH-4/CI-4
year-round to -30 °C SAE 5W-30 ACEA E4 Liebherr Motoroil 5W-30
below -30 °C with API CF ID no. 10425715
preheating
to -20 °C SAE 90/ SAE Liebherr Gear Basic 90 LS
85W-90 ID no. 10285702
2 Mechanical gears SAE 85W-140 API GL-5 Liebherr Hypoid 85W-140 ID
and winches no. 10301680
to -40 °C SAE 75W-90 Liebherr Syntogear Plus
75W-90 ID no. 10330288
to -20 °C SAE 90/ SAE Liebherr Gear Basic 90 LS

85W-90 ID no. 102885702
3 Drive shafts SAE 85W-140 API GL-5 Liebherr Hypoid 85W-140 ID
no. 10301680
to -40 °C SAE 75W-90 Liebherr Syntogear Plus
75W-90 ID no. 10330288
to -25 °C ATF1) DEXRON II Liebherr Hydraulic Gear ATF

D/E ID no. 10330283
4 Hydrostatic drive year-round to -15 °C ISO VG 46 DIN 51524/3 Liebherr Hydraulic HVI ID no.
unit 2) HVLPD 10330270
Hydraulic steering year-round to -10 °C ISO VG 68 DIN 51524/2 Liebherr Hydraulic Basic 68
2)
HLPD ID no. 10330259
to -25 °C ISO VG 46 DIN 51524/3 Liebherr Hydraulic Plus ID
HVLPD HC no. 10330276
HEPR ISO
6743T4
to -40 °C VG 15-46 Rapidly biodeg- Liebherr Hydraulic Plus Arc-
radable in ac- tic ID no. 10330278
cordance with
CEC-L-33-A-93
LRB255_V001 (mf) LWN - TD4/2/2010
Roller- friction to -25 °C lubrication Lubricating grease DIN 51502 KP Liebherr Universal grease
bearing- ball- or system 2 K-30 9900 ID no. 10296812
5 Roller-bearing Lithium saponified KPF 2 N-25
mounted slewing
rings
Cardan pivots - to -60 °C lubrication DIN 51502 Liebherr Universal grease
other grease lubri- system KPFHC 1N-60 Arctic ID no. 10296824
cation
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7. MAINTENANCE
No. Lubrication Outside temperature Type: ISO VG/SAE Specification LIEBHERR lubricants
points
Open gear wheels to -25 °C lubrication Lubrication and DIN 51502 Liebherr Universal grease
and crown gears system OGPF 2 9900 ID no. 10296812
6 Ropes to -60 °C lubrication Preservation media OGPF 1 Liebherr Universal grease
system Arctic ID no. 10296824
all areas OGPF 00 Liebherr spray paste ID no.
10330311
7 Telescopic boom all areas Special regulation DIN 51502 Liebherr telescope grease
9613
KP 2 K-30 Plus ID no. 861305308
Lubricant table Table 7-02
1) Absolutely essential in the case of excavator hydraulics.

2) At lower temperatures observe the warm-up rules in the operating manual.
Amounts of lubricants and consumables and maintenance intervals are given in the operating manual.
NOTE!
For authorisation to use oils from other manufacturers, please contact:
Liebherr-Lubricant-Hotline: +49 (0) 7354/80-6060 or lubricants@liebherr.com
7.21.1 Rapidly biodegradable hydraulic oils
NOTE!
Damage to the hydraulic system may occur!
Mixing of ester-based rapidly biodegradable hydraulic oils with mineral oils can cause aggressive
reactions which subsequently cause damage to the hydraulic system.
Do not mix rapidly biodegradable hydraulic oils from different manufacturers and do not mix rapidly
biodegradable oils with mineral oils.
The rapidly biodegradable hydraulic oils recommended by Liebherr are restricted to polyalphaolefin
(PAO)-based oils, HEPR.
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 resistance.
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67
7.22 Hydraulic oil (initial filling)
The information sign (Fig. 67) next to the filling nozzle

indicates the hydraulic oil with which the machine was
initially filled.
NOTE!
The machine is initially filled with hydraulic oil of specification DIN 51524/3 HVLPD (corresponds to
AVILUB FLUID LWE 46 and Liebherr Hydraulic HVI) as standard.
In exceptional cases (e.g. cold conditions package, ...) the machine is initially filled with a
special hydraulic oil!
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7.23 Diesel fuels

Specification
Diesel fuels must satisfy the minimum requirements of the following fuel specifications.
Permitted fuel specifications:
- EN 590
- ASTM D 975 (89a) 1D and 2D
Further fuel specifications may be followed only after consultation with LIEBHERR Customer
Services.
Sulfur content of diesel fuel

Use commercial diesel oils with a sulfur content below 0.5% by weight. Higher sulfur contents affect
the oil-change intervals and engine life.
NOTE!
Any additives should be added by the fuel supplier.
Take advice from your fuel supplier or LIEBHERR Customer Services.
Diesel fuels at low temperatures

As outside temperatures fall, diesel fuel deposits paraffin crystals which increase the flow resistance
in the fuel filter to such an extent that an adequate fuel supply to the diesel engine is no longer
guaranteed.
CAUTION!
Addition of petroleum/normal petrol is prohibited for safety and technical reasons.

We recommend the use of fuel filter heating if the low temperature flow properties of the diesel fuel
are inadequate or at outside temperatures below -20°C [-4°F].
Special diesel fuels are available for use in arctic climates.
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7.24 Diesel engine lubricating oils

Lubricating oil quality
Modern diesel engines use only high-alloy lubricating oils. They consist of basic oils mixed with
additives.
The Liebherr diesel engine lubrication guide is based on the following specifications and require-
ments:
• ACEA (CCMC) Association des constructeurs Européens de l'Automobile
• API (American Petroleum Institute) Classification
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 information about the quality of a lubricating oil.
If viscosity is too high, this can make the engine difficult to start. If viscosity is too low, lubricating
efficiency may be impaired.
The temperature ranges in the following table are shown as a guide, and temperatures may go
above or below these values for short periods.
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Oil change intervals

First oil and filter change at 500 operating hours.
Oil change intervals depend on the oil quality, sulfur content of the fuel and climatic zone according
to the following table.
Oil filter change intervals every 500 operating hours.
If the stated number of operating hours is not reached within a year, the engine oil and filters must
be changed at least once a year.
Aggravating factor Oil quality
CH-4 E4
Cl-4 E5
E6
E7
Operating condi- Sulfur content in fuel Interval

tions
Normal climate
to -10° C up to 0.5% 250 OH 500 OH
up to [17° F] over 0.5% 125 OH 250 OH
below -10° C up to 0.5 % 125 OH 250 OH

below [17° F] over 0.5 % - 125 OH
OH...operating hours
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7.25 Coolant
To ensure adequate corrosion protection, the coolant must contain at least 50 % by volumeanti-
corrosive agent/anti-freeze throughout the year. This prevents freezing down to approx. -37 °C [-35
°F].
Filling procedure:
It is recommended to mix the coolant in the correct mixing ratio prior to filling using a commercial
mixing device and then add it to the cooling system.
Mixing ratio of water to anti-corrosive agent/anti-freeze:
A = proportion in % of anti-corrosive agent
Do not use more than 60% anti-corrosive agent/anti-freeze, as the cooling effect rapidly de-
creases with higher proportions.
7.25.1 Fresh water guidelines:

When preparing coolant, use water that is clean and if possible not unduly hard. Drinking water
often, though not always, satisfies the necessary requirements.
Do not use sea water, brackish water, brine or industrial waste water.
Fresh water quality when using anti-corrosive agent/anti-freeze:

Total alkaline earths (water hard- 0.6 to 3.6 mmol/dm³ (3 to 20 ° dH)
ness)
ph value at 20 °C [68 °F] 6.5 to 8.5
Chloride ion content max. 80 mg/dm³
Sulfate ion content max. 100 mg/dm³
NOTE!
A list of manufacturers of approved anti-corrosive/anti-freeze agents is obtainable from Liebherr
Customer Services.
LRB255_V001 (mf) LWN - TD4/2/2010
Do not combine different products.

Mixing of different anti-corrosive and anti-freeze agents can impair the coolant properties.
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7. MAINTENANCE
7.26 Filling amounts

NOTE !
The filling amounts listed in the following table are approximate values.
For the actual filling amounts, the oil dipstick or the inspection glass is always definitive.
Components Amount Vol. Comment

[l] [gal]
US
Diesel engine 35 9.25 D 2842 LE (12 Zylinder)
Splitterbox 11 2.9 incl. gear oil cooler
Travel gear 6 1.58 per item
Swing gear 11 2.9 ---
Winch 1 * 18 4.75 20 t line pull (winch featuring free-fall)
Winch 2 (Kelly winch) * 18 4.75 20 t line pull (winch featuring free-fall)
Winch 2 (Kelly winch) * 26 6.87 25 t line pull (winch featuring free-fall)
Main boom adjusting winch * 3,3 0.87 -
Auxiliary winch * 6 1.58 -
Feed winch * 2x6 2 x 1.58 -
Hydraulic tank 1000 264 ---
Fuel tank 800 211 ---
Cooling system 70 18.5 Only fill in coolant with antifreeze
NOTE !
Data of all installed components, see under "Technical data" in chapter 2 of this operating manual.
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7.27 Lubrication chart

The lubrication chart displayed serves as an overview for all lubrication points. The maintenance
intervals quoted should be adhered to.
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Lubrication- and maintenance chart, part 1, LRB 255 fig. 7-01
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7.28 Repair welding

7.28.1 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.
7.28.2 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!
LRB255_V001 (mf) LWN - TD4/2/2010
DANGER !
Failure to observe these instructions, especially disregard of the welding regulations can lead to
serious injuries and property damage!
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7. MAINTENANCE
NOTES:
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7. MAINTENANCE
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8. REPAIR WORK
8. REPAIR WORK
8.1 General
• This chapter contains:

- Specifications on changing the hoisting cables.
- Specifications on changing the adjustment cables for the main boom.
- Specifications on changing the cables for the piling rig and drilling system.
- Specifications on how to troubleshoot problems with the diesel engine.
These repairs may only be carried out by personnel
trained by LIEBHERR!
• Only original spare parts may be used. If other spare parts are used, no assurance of safe
operations can be given.
LIEBHERR refuses any liability in such a case. Any damage is to be borne by the user.
• The safety instructions of chapter "3" are to be adhered to.
• When end switches must be bridged to change cables, then they must be tested by LIEBHERR-
SERVICE PERSONNEL (function and settings tests)before being started up again.
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8. REPAIR WORK
8.2 Changing ropes
NOTE!
When changing ropes, the regulations for handling wire ropes must generally be observed (see
"Ropes" in Chapter 7).
8.2.1 Safety instructions

In addition, it is essential to adhere to the following rules:
• Wire ropes must only be changed and inspected by qualified personnel.
• The luffing of a new wire rope should only be done from a reel.
• Wire ropes must not be pulled on the ground. Foreign bodies (such as small stones) must be
removed when luffing the rope.
• When luffing the rope, relevant components such as rope pulleys and rope guard must be checked
to ensure they work properly and are not worn.
• When luffing into the rope drive, the wire rope must not twisted or untwisted, otherwise the rope
structure will be destroyed. This can result in kinks, distortions or other deformations of the rope.
• When changing a rope, ensure that a wire rope of the same type and strength is fitted, in
accordance with the winch pulling force and the safety regulations. Care must also be taken to
ensure that the rope diameter matches the grooves of the rope drum and the rope pulleys.
• If the rope in the slack condition is dragged over any components, sharp edges must be
appropriately covered when laying the rope.
8.2.2 Unwinding wire ropes from the reel

The correct way of unwinding wire ropes from a reel is illustrated in Figure 1.
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8. REPAIR WORK
8.2.3 Laying ropes

Wire ropes are very sensitive to external damage.
Therefore they must be transported and unloaded with care.
Wire ropes kept in reserve must be stored under clean, cool and dry conditions.
They must be protected against contact with the earth.
Hoisting ropes will only work smoothly if they are laid without twisting and without external damage.
The ropes must be unwound in the winding direction from the reel or ring (Figure 1). Unwinding to
the side causes the rope to twist until it is wrecked by kinking. It is best to wind the rope onto the
rope drum concerned from a raised reel. Winding in the same bending direction prevents additional
tensions in the rope and results in the best laying on the drum. Ropes must not be pulled along the
ground and soiled.
For the actual winding process itself, the new rope is laid on the existing rope or fastened to a
leading rope. The two ropes can be connected by a cable sock or by means of welded eyes.
Care must be taken to ensure that the old or leading rope does not cause any twisting in the new
rope. Twist-free hoisting ropes must be protected from forced twisting by intermediate swivels.
Multi-layer winding
The cable must be pulled in under pretension when coiling up the cable on the winch for the
first time. The pretension force should be 1 - 2% of the minimum tensile strength of the cable.
This pretension force is obtained by slowing down the cable drum. However, a direct braking
of the cable is not permissible!
For winches with multi-layer coiling, the lower cable layers can loosen up during operation.
This results in a slight ovalization of the cable, which changes the coiling diameter over the
drum width. This causes gaps in the cable layers above, which impair the coiling behaviour
and increase cable wear.
NOTE!
To improve the coiling behaviour and reduce cable wear, the cable must be uncoiled in
regular intervals and recoiled under pretension (1 - 2% of the tensile strength of the cable)!
With multi-strand reeving, the hoisting rope should be reeved in the same lay direction as that
exhibited by the drum. If a limited length of rope must be laid on the ground for reeving in the hook
block, make sure that the rope runs into the rope pulleys on the boom head without twisting.
Non-twist-free ropes must only be used with fixation points at both ends.
After the rope has been laid, start by winding in the rope with small partial loads, and then alternate
between a loaded and unloaded hook block, in a series of lifts. This allows the rope to adapt in a
more flexible manner to the bending direction and bending radii of pulleys and drums.
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8. REPAIR WORK
8.3 Changing cable winches 1 + 2

8.3.1 General
NOTE !
When changing cables on the hoist winches it should be ensured that the steel cable is fitted in the
same way and with the same sturdiness in correlation with the traction of the winches and the safety
regulations.
8.3.2 Procedure
• Setting down main boom
When changing a cable, it is necessary to set down all loads and to position the boom in a
horizontal position (see chapter 6 under "Setting down main boom"). The optional Hoist limit
switch must thus be bridged.
• Winding out hoist cable

Then reel out the old hoist cable from the winch completely. The optional 3-coil-limit switch must
thus be bridged (see chapter 9 under "3-coil-limit switch ").
It should be ensured when winding the cable with the winch that no twists form on the drum.
• Drawing out hoist cable

Disassemble cable guard from the right-hand winch and release the hoist cable at the locating
point of cable. Then draw out hoist cable completely.
• Pulling in hoist cable

Pulling in of the new hoist cable is carried out in accordance with reeving diagram (see chapter 6
under "Reeving diagrams"). Reeving can be achieved via the aid of an auxiliary cable (e.g. hemp
chord) or with the help of an optional cable reeving winch .
Reeve hoist cable to the winch, ensuring that the cable is running correctly through the pulley.
• Secure hoist cable to the winch

Before securing the new hoist cable to the winch, the optional 3-coil-limit switch is to be adjusted
(see chapter 9 under "3-coil-limit switch "). Then guide the end of the cable into the winch's
locating point of cable and secure via the fixing screws (tightening torque of the 5 screws: 50 Nm).
Then reassemble cable guard.
• Winding on hoist cable

Wind hoist cable slowly onto the winch. When winding up, the optional cable length dimension
should be adjusted via programming of the layer change (see chapter 9 under "Cable length
dimension").
It should be ensured throughout the entire winding on procedure that the hoist cable runs through
the pulley correctly and that no twists form in the cable on the winch drum. Furthermore, observe
correct tensioning to the cable reel. The first layer of cable in particular must be wound onto the
winch correctly.
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8. REPAIR WORK
8.4 Replacing the feed rope
DANGER!
Ropes must only be changed by appropriately trained personnel.
8.4.1 General
When replacing the feed rope, it should be observed in particular that the new steel rope being
mounted is of the same type and strength as the original in accordance with the winch line pull
and the safety guidelines.
Replacement of the feed rope is also necessary if the leader length has been modified.
Notes on replacing the feed rope:

• Use original ropes only !
• The feed rope is a wear part, the life-expectancy of which is highly dependent upon maintenance,
care and requirements. Rope change will be necessary after approx. 500 operating hours.
• Assembly: Leader has been turned upwards and horizontally.
• When winding on, pay particular attention that no twisting of the rope occurs, and that sufficient
tension is maintained.
Leader length in m [ft] Length of feed rope in m [ft]

21.20 [70'] 93.70 [307 5'']
24.28 [80'] 106.00 [347 9'']
27.36 [90'] 118.30 [388 1'']
30.44 [100'] 130.60 [428 6'']
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8. REPAIR WORK
Reeving chart feed system LRB 255
Notes on rope change

When replacing the feed rope,four persons (machine operator and three assistants) are neces-
sary for safety reasons. The machine operator and three assistants are equipped with walkie-
talkies.
Work distribution
• The machine operator

is located in the operator's cab
- monitors unintentional movement of the machine
- actuates the feed winch
• The assistant at the front
- monitors the rope run at the front of the leader
- warns the machine operator and the and the auxiliary machine operator of any dangerous
situations
• The assistant at the rear
- monitors the rope run at the leader head and on the feed winches
- actuates the tensioning cylinder on the universal sliding carriage
• The operator of the auxiliary machine
- is responsible for winding on and off of the feed rope using the auxiliary machine
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8. REPAIR WORK
3
8.4.2 Procedure
Pulling out the feed rope
• Removing piling rig or drilling device
It is necessary when replacing the rope, to set down
any loads and to remove the piling rig and drilling
device.
• Setting down the piling rig and drilling device
Set down the piling rig and drilling device (fig. 2, no.
2) (see chapter 6 under "Setting down the piling rig
and drilling device"). The leader is positioned horizon-
tally and turned upwards on the uppercarriage.
• Setting the mechanical stop
Threaded rods featuring lock nuts (fig. 3, no. 5) have
been installed in the universal sliding carriage along-
side the tensioning cylinder. Before easing the ten-
sioning cylinders, the lock nuts (fig. 3, no. 4) are to be
loosened and turned all the way to the rear.
• Easing the tensioning cylinders

Ease the tensioning cylinders in the universal sliding carriage by folding down the ball valve (fig.
3, no. 3) . Switch position (ball valve lateral). Tensioning cylinder extended (tension eased in feed
rope).
• Clamping the universal slide carriage (fig. 2, no. 3)
• Releasing the locating point of rope
Loosen the upper and lower locating point of rope on the universal slide carriage and remove the
thimble (fig. 3, no. 1).
• Extracting the feed rope

Connect the upper and lower locating points of rope using the auxiliary machine. Secure the new
feed rope to the other locating point of rope (via a nylon rope or similar). Actuate the auxiliary
machine and activate the feed winch on the piling rig and drilling device. (Observe the notes on
safety).
NOTE !
Reeving of a new feed rope is resulted directly following extraction of the feed rope being replaced,
wherever possible. The reeving procedure is thus eased considerably.
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8. REPAIR WORK
Reeving the feed rope

• The feed rope replacing the original rope is to be mounted using a hemp rope in accordance with
the reeving chart (fig. 2).
• Guide the hemp rope from the beginning of the leader foot to the feed winch
Begin the luffing procedure at the front left-hand side of the leader foot. Guide the hemp rope
through the plastic collars on the deflection pulley (fig. 2, no. 4) to the feed winch (fig. 2, no. 6) via
the deflection pulley (fig. 2, no. 5).
It should be constantly ensured during the luffing procedure that the hemp rope is running
smoothly through the pulleys. No entanglement of the rope may occur on the winch drum.
NOTE !
When the hemp rope has been guided over the feed winch, the winch can then be initiated for easier
retraction of the hemp rope onto the leader. Actuate the feed winch carefully.
• Guide the hemp rope over the deflection pulleys (fig. 2, no. 7/9/8) towards the universal
sliding carriage (fig. 2, no. 3) to the auxiliary machine.
• Securing the hemp rope to the auxiliary machine.

• Secure the beginning of the new feed rope to the other end of the hemp rope (using a
nylon rope or similar).
• Reeving the feed rope
Actuate the auxiliary machine carefully and actuate the feed winch. The feed rope is wound out
from the reel and guided to the universal sliding carriage via the deflection pulleys. Observe the
rope run during the luffing procedure and brake the reel as required.
• Releasing the feed rope from the hemp rope's locating point of rope
• Requirements of the universal sliding carriage
- Lock nut on the mechanical stop adjusted all the way to the rear
- Ball valve for easing of the tensioning cylinder has been folded down
(switch position of the ball valve pointing downwards)
- Tensioning cylinder eased of tension (tensioning cylinder extended all the way)
- Universal sliding carriage adjusted to the front
• Securing the thimble to the locating point of rope
Mount upper thimble (fig. 3, no. 1) to the locating point of rope and secure to locating point of
rope. Note mounting position of the thimble! Secure connecting pins via spring plug and mount
clamp (6) to the end of the rope.
• Guide the other locating point of rope from the feed rope over the deflection pulleys (fig. 2,
nos. 10 and 11) to the universal sliding carriage (fig. 2, no. 3).
Mount the second locating point of rope (fig. 3, no. 2) in the rope clamp on the lower part of the
universal sliding carriage.
Tightening torque 560 Nm [413 ft lbs]
Tight all bolts.
Mount clamp (6).
The feed rope should be tensioned as much as possible. Release the secured universal sliding
carriage.
• Tensioning the tensioning cylinder
Start up the machine and retract the tensioning cylinder in the universal sliding carriage by folding
down the ball valve (fig. 3, no. 3), thus tensioning the feed rope. Switch position (ball valve turned
downwards). Tensioning cylinder retracted (feed rope tensioned).
Checking the rope run.
• Mechanical stop
After tensioning the feed rope using the tensioning cylinder, screw in the lock nuts all the way to
the stop.
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8. REPAIR WORK
4
8.5 Changing auxiliary ropes
8.5.1 General
When changing ropes on the auxiliary winch, it should
be noted that a wire rope of the same type and strength
is mounted in accordance with the winch traction and the
safety guidelines.
8.5.2 Procedure
• Setting down the piling rig and drilling system
It is necessary when changing the ropes to lay down
all loads. Then set down the piling rig and drilling
system (see chapter 6 under "Setting down piling rig
and drilling system ").
• Winding out the auxiliary rope
Wind out the auxiliary rope (fig. 4, no. 2) completely from the winch. The optional 3-coil-limit
switch must be shunted upon actuation of the pre-selection key, "Assembly operation" (see
chapter 4 under "Right-hand control panel").
It should be noted when winding out the auxiliary rope from the winch that no entanglements occur
on the winch drum.
• Pulling out the auxiliary rope
Loosen the auxiliary rope on the locating point of rope (1) and pull out completely.
• Luffing the auxiliary rope
Luffing of the new auxiliary rope is resulted in accordance with the reeving plan (fig. 4).
Luff the auxiliary rope to the winch, ensuring that the rope is running correctly in the rope pulleys.
• Secure the auxiliary rope to the winch
Before securing the auxiliary rope to the winch, the optional 3-coil-limit switch should be set.
Then insert the rope end into the locating point of rope of the winch and tighten via fastening
screws.
• Winding on the auxiliary rope
Wind the auxiliary rope slowly onto the winch.
During the winding procedure, ensure that the auxiliary rope is running correctly in the rope pulleys
and that the rope does not become entangled on the winch drum. Furthermore, ensure correct
tensioning to the rope reels. The first rope layer in particular must be correctly wound onto the
winch.
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8. REPAIR WORK
5
8.6 Changing kelly ropes
8.6.1 General
When changing ropes on the kelly winch, it should be
noted that a wire rope of the same type and strength is
mounted in accordance with the winch traction and the
safety guidelines.
8.6.2 Procedure
• Setting down the piling rig and drilling system
It is necessary when changing the ropes to lay down
all loads. Then set down the piling rig and drilling
system (see chapter 6 under "Setting down piling rig
and drilling system ").
• Winding out the kelly rope
Then wind out the old kelly rope (fig. 5, no. 5) com-
pletely from the winch. The optional 3-coil-limit
switch must be shunted upon actuation of the pre-
selection key, "Assembly operation" (see chapter 4
under "Right-hand control panel").
It should be noted when winding out the kelly rope from
the winch that no entanglements occur on the winch
drum.
• Pulling out the kelly rope
Loosen the kelly rope on the locating point of rope
and pull out completely.
• Luffing the kelly rope
Luffing of the new auxiliary rope is resulted in accordance with the reeving plan (fig. 5).
Note the optional rope guides
- on the lateral inclination device (fig. 5, no. 1),
- on the leader guide carriage (2),
- on the support arm brace support (3,4).
Luff the kelly rope to the winch, ensuring that the rope is running correctly in the rope pulleys.
• Securing the kelly rope to the winch
Before securing the kelly rope to the winch, the optional 3-coil-limit switch should be set. Then
insert the rope end into the locating point of rope of the winch and tighten via fastening screws.
• Winding on the kelly rope
Wind the kelly rope slowly onto the winch. The layer-change and the rope length measurement
are to be programmed anew (see chapter 5 under "Actuating the kelly winch").
It should be ensured throughout the entire winding procedure:
- the kelly rope is running correctly in the rope pulleys,
- the rope does not become entangled on the winch drum,
- correct tensioning to the rope reel.
The first rope layer in particular must be correctly wound onto the winch drum.
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8. REPAIR WORK
8.7 Diesel engine

Only personnel explicitly authorised may carry out maintenance and repair work to the diesel engine.
Always shut down the engine during repair work and remove the ignition key.
The following charts will help remedy any occurring faults. Do not attempt to carry out any repair
work that you are not completely competent with.
NOTE !
Ignition start system with Liebherr engines only !
Fault Cause Remedy
1) Engine will not Fuel tank empty Refill fuel tank and bleed fuel system
start
Water separator blocked Change filter
Fuel filter blocked, in winter due to paraffin Replace fuel filter and bleed fuel system.
deposition Use winter fuel.
Fuel line leaking Check line connections for leaks and re-
tighten threaded unions
Starter faulty Dismantle and have inspected or repaired

in a specialist workshop
Battery flat Check battery and charge
Electrical connections to battery, starter or Check cable and retighten

ignition switch loose
Ignition start system faulty (at cold tem- Check solenoid valve and flame-type heat-
peratures) er plug and replace if necessary
2) Engine starts, all causes specified under point 1, apart see point 1)
but cuts out again from electrics and ignition start system
Aeration in fuel tank's cover lid blocked Clean cover lid
3) Engine running all causes specified under point 1 and 2, see points 1 and 2
irregularly apart from electrics and ignition start sys-
tem
not maximum
output Air filter clogged Clean air filter
Valves in the fuel conveyor pump leaking Have conveyor pump checked in a spe-
cialist workshop and if necessary replaced
LRB255_V001 (mf) LWN - TD4/2/2010
Intercooler contaminated Clean intercooler
Diesel engine fault chart Chart 8-01
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8. REPAIR WORK
Fault Cause Remedy
3) Engine running, Charge pressure too low Check exhaust turbo charger
irregular
is interrupted Conveyor start injection pump out of step Adjust conveyor start
or does not have
maximum output Injection pump, flow rate out of step or Have injection pump checked in a special-
control rod sticking ist workshop
Throttle linkage not on full load stop Check throttle linkage or adjust
Engine compression too low Check valves pistons and cylinders and
replace if necessary
4) Exhaust is Air filter contaminated Clean air filter

black
Leaks in the induction system Check or replace hoses and lines
Conveyor start injection pump out of step Adjust conveyor start and replace if neces-
sary
Flow rate of injection pump too great Have injection pump checked in a special-
ist workshop
5) Exhaust is Lubricating oil level in engine too high Correct oil level
blue
Lubricating oil is channelled into the Repair or replace cylinder heads, change
combustion chamber and is ignited. Clear- pistons and liners
ance between valve rod and valve guides
too great, piston rings worn, broken or
seized, signs of corrosion on pistons and
cylinder liners.
Seal on exhaust turbo charger on com- Check exhaust turbo charger and replace
pressor side faulty if necessary
6) Exhaust is white Cylinder head seals faulty and cooling Replace cylinder head seal
water is channelled into the combustion
chamber
Cylinder head cracked or is leaking Replace cylinder head
7) Engine rattling Injection nozzles leaking or vaporisation Check injection nozzles and replace if nec-
not complete essary
Conveyor start of the injection pumps out Check conveyor start and readjust if nec-
of step essary
8) Engine knock- Injection nozzles damaged or carbonised Check and adjust injection nozzles and
ing replace if necessary
Piston rings worn or broken, pistons cor- Check pistons and cylinder liners and re-
roded place if necessary
Main or connecting rod bearing faulty Reposition engine or replace
Diesel engine fault chart, continuation chart 8-02
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8. REPAIR WORK
Fault Cause Remedy
9) Cooling water Too little cooling water in the cooling sys- Refill cooling water
temperature tem
too high
Air in the cooling system Bleed cooling system
Cooler externally contaminated Clean cooling system
Cooler internally contaminated or calcified Decalcify cooler
Thermostat faulty Check thermostat and replace if necessary
Cooling water pump faulty Check cooling water pump and repair or
replace if necessary
Ventilator faulty Check ventilator and replace if necessary
10) Lack of Oil level in oil pan too low Refill oil up to prescribed filling mark
lubricating oil
pressure
low
Lubricating oil too thin Drain oil, refill prescribed oil
Oil pressure gauge or pressure transducer Check oil level and replace damaged oil
faulty pressure transducer or gauge
Lubricating oil pressure pump faulty Replace lubricating oil pressure pump
Lubricating oil pressure pump blocked in Check control valve in the lubricating oil
the open position pressure pump
Bearing clearance too great due to wear or Reposition engine or replace

damage to bearings
11) Lubricating oil Oil cooler or oil cooler plate leaking Pressure test, replace if leaking
in cooling system
Cylinder head seal leaking Replace cylinder head seal
12) Cooling water Cylinder head seal leaking Replace cylinder head seal
in lubricating oil
O-rings on the cylinder liners leak Replace O-rings
Diesel engine fault chart, continuation Chart 8-03

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8. REPAIR WORK
6
8.8 Fire extinguishers
Two fire extinguishers (fig. 6) type GS6 are located in
the uppercarriage. They are arranged on the left and
right of the door on the respective first doors. (fig. 7,
digits 1+2)
The fire extinguishers can be used in temperatures rang-
ing from -20 °C to +60 °C . The fire extinguishers are
filled with foam (Totalit G CEN) and are therefore suit-
able for fighting fires of classifications A, B and C.
The fire extinguishers should be checked by a specialist
in accordance with the prescribed inspection intervals
(see test badge). It is imperative that all further informa-
tion given by the specialist is adhered to. Fire extinguish-
7 ers must be replaced in accordance with the intervals
prescribed (see test badge).
8.9 Personal protective equipment

All personal protective equipment should be cleaned reg-
ularly, maintained and replaced if necessary.
You yourself are responsible for wearing the personal
protective equipment. Tight-fitting protective work clothes
should be worn when working on the machine, as well
as the personal protective equipment designed for each
respective duty.(see also chapter 3, "Personal protective
equipment").
8.10 Preservation guidelines

If the machine is to be out of service for an extended
period, the boom/the piling and drilling system should be
laid down and the hydraulic cylinders should be re-
tracted. The batteries main switches are to be switched
off.
Depending on external influences (temperature devi-
ations, seaside areas) accordingly suitable positioning of
the machine should be noted.
8.11 Resale - taking out of service

LIEBHERR AFTER SALES SERVICE should be notified
immediately if the machine is to be resold or taken out
of service.
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8. REPAIR WORK
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8. REPAIR WORK
NOTES:
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8. REPAIR WORK
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9. OPTIONS
9. OPTIONS
9.1 General
This chapter
- gives a summary as to which retrofit kits and special attachments are available for the machine,
- contains important information and notes on safety, completing the standard operating manual.
IMPORTANT !
The options actually installed are quoted under point 1.3 in the machine pass.
The standard operating manual remains valid following the mounting of options and must be adhered
to!
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9. OPTIONS
9.2 Heating and air conditioning system

9.2.1 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
9.2.2 Air conditioning system units
1 Condenser 3 Air conditioning box with heating and evap-

orator
2 Compressor 4 Coolant collector
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9. OPTIONS
9.2.3 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.
LRB255_V001 (mf) LWN - TD4/2/2010
Left control panel (X11) Fig. 9-01
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9. OPTIONS
2
Heating mode
The rotary switch (Fig 2, 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. 2, 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. 2, 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. 2, 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. 2, 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.
9.2.4 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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9. OPTIONS
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. OPTIONS
3
9.3 3-coil-limit switch
9.3.1 General
The optional 3-coil-limit switch (fig. 3, no. 1) can be
mounted for both hoist winches and serves as a safety
device against unintentional reeling out of the complete
hoist cable from winch 1 to winch 2. The 3-coil-limit
switch is set so that at least three so-called safety
windings remain on the winch.
9.3.2 Adjusting 3-coil-limit switch

Adjustment of the 3-coil-limit switch is necessary with every cable change or if the entire hoist cable
has been wound onto the winch for transport and the winch was then moved (actuated) in this
condition.
Procedure
• The machine is in assembly operation .
• Reel out hoist cable from the winch until only three windings remain on the winch. Then remove
cover of 3-coil-limit switch and adjust 3-coil-limit switch until it switches.
• Wind up hoist cable for several windings and then it is absolutely imperative that functioning of
the 3-coil-limit switch be checked again .
IMPORTANT!
When changing the cable lower the winch until the 3-coil-limit switch switches. Then actuate
pre-selection key "Bridging limit switch " on the right- hand control panel, lower winch further and
change the hoist cable.
DANGER !
• The 3-coil-limit switch is adjusted if the winch is "turning empty" (no hoist cable on the
winch or hoist cable for transport wound completely onto winch).
Correct adjustment should be checked during start-up via slow actuation of the 3-coil-limit
switch.
• Should the winch be in optional free-fall operation, functioning of the 3-coil-limit switch is
bridged. The hoist cable can be unintentionally, completely reeled out from the winch.
• 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
• The length of hoisting rope required for this purpose depends on the boom configuration,
the reeving of the load hook and the type of application.
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9. OPTIONS
9.4 Cold weather kit

9.4.1 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. OPTIONS
9.4.2 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.
4
Components of the auxiliary heating system (Figure 4)
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
5
Right control panel (Figure 5)
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
9.4.3 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
9.5 GSM Service Modem

A GSM telephone modem is connected to the Litronic system. The modem is located in the
machine's switch cabinet and operates with an antenna on the roof of the cab. The actual operating
data and the stored machine data can thus be transferred to Liebherr Service Point. This data can
then determine causes of faults, organise mechanics accordingly and arrange the supply of spare-
parts quickly and efficiently via a diagnosis system. The SIM card is not included in the delivery
scope and must be ordered separately by the user.
9.6 Function lock

For safety reasons all functions of the machine are locked below an outside temperature of - 25 °C [-
13°F].
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9. OPTIONS
9.7 Refuelling pump

6
Refuelling pump
1 Hydraulic tank 7 Emergency-Off-Switch

2 Refuelling pump 8 Switch, red "Pump off"
3 Auxiliary switch "Pump on / off" 9 Switch, green "Pump on"
4 Supply line to fuel tank 10 Operating panel
5 Connection for suction hose 11 Suction hose
6 Cover lid
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9. OPTIONS
9.7.1 General
The refuelling pump is
- located on the right-hand side of the uppercarriage, directly alongside the fuel tank,
- accessible upon opening of the rear side doors.
Technical data
Suction height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 4 m [13 ft]
Flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 l/min [13.2 gal/min]
Duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 15 min
9.7.2 Refuelling
WARNING !
Safety guidelines under point 3.7.5 "Danger of fire and explosion" when refuelling must be
strictly adhered to.
CAUTION !
Only use refuelling tanks

- for the conveyance of diesel fuel,
- with the suction hose and fuel sieve included in delivery.
Notes on quality of the diesel fuel should be referred to under point 7.17. In the event of
danger, refuelling procedure can be interrupted via pressing of the Emergency-Off-Switch on
the operating panel.
The Emergency-Off-Switch on the operating panel does not only serve for emergency shut-down of
the refuelling pump, but can also be actuated on the machine during other danger situations.
Do not allow the refuelling pumps to completely empty. If the fuel tanks are empty, shut down
the refuelling pumps immediately via the red switch on the control panel.
Procedure:
• Shut down diesel engine subsequently switching the ignition back on.
• Prepare fuel container and open right, rear side doors.
• Remove cover cap from refuelling pump.
• Secure suction hose to refuelling pump connection.
• Submerge the other end of the hose with the fuel filter in the diesel fuel completely.
• Press green switch on the operating panel - the pump starts up.
A level monitor controls the level in the fuel tank. As soon as the maximum level has been reached,
the refuelling pump stops automatically.
• After refuelling, disconnect suction hose from refuelling pump and raise in the air, ensuring that the
rest of the diesel fuel flows back into the fuel container.
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9. OPTIONS
• Allow fuel sieve to drip dry before wiping.

• Roll up suction hose and stow away under the refuelling pump.
• Close refuelling pump with cover cap.
CAUTION !
Wipe up any spattered diesel fuel, particularly in the tin trough under the refuelling pump.
Keep fuel filter on the suction hose clean.
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9. OPTIONS
9.8 Process data acquisition (PDE)

9.8.1 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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9. OPTIONS
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. OPTIONS
9.8.2 PDE monitor

The PDE monitor is split into four main areas. These main areas apply to all screen pages, unless
stated otherwise.
Home screen
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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9. OPTIONS
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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9. OPTIONS
"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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9. OPTIONS
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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9. OPTIONS
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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9. OPTIONS
Alphanumeric keypad
(upper case including special characters)
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9. OPTIONS
"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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9. OPTIONS
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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9. OPTIONS
PDE settings page
10
"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. OPTIONS
9.8.3 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)
9.8.4 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
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- 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. OPTIONS
9.8.5 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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9. OPTIONS
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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9. OPTIONS
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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9. OPTIONS
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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9. OPTIONS
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. OPTIONS
9.8.6 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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9. OPTIONS
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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9. OPTIONS
Real time pile display
The real-time pile display is used as a graphic support to the double rotary drilling and CFA drilling
modes.
11
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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9. OPTIONS
12
Correctly set-up pile
If the pile is withdrawn correctly, the corresponding area is displayed in gray.
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13
Incorrectly set-up pile
If the pile is pulled too quickly, the corresponding area is displayed as yellow if the deviation is minor
(Figure 13, item 1) or as red if it is severe (Figure 13, item 2). The concrete pressure scaling is
displayed logarithmically (Figure 13, item 3).
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9. OPTIONS
14
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 14, item 1). The concrete pressure scaling is displayed on a linear basis
(Figure 14, item 2). Switching the concrete pressure scaling is done with the "Horizontal increase"
button (Figure 14, item 3).
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9. OPTIONS
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. OPTIONS
9.8.7 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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9. OPTIONS
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 *).
15
HEAD.TXT
Interrupting recording
Operating mode
9.8.8 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. OPTIONS
9.8.9 Protocol style

At present the following protocol styles can be selected:
16
Soil Mixing, 1
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9. OPTIONS
17
Vibrator, 0
18
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Vibrator, 1
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9. OPTIONS
19
Vibrator, 2
20
CFA, 0
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21
CFA, 1
22
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CFA, 2
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9. OPTIONS
23
Double rotary drilling 0
24
Double rotary drilling, 1
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25
Double rotary drilling, 2

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9. OPTIONS
9.9 Pile/pipe guide

9.9.1 General
The optional pipe guide guides and stabilises the pile or the pipe on the lower part of the leader.
NOTE !
The technical data, special safety guidelines, the operation and maintenance of the attachments can
be obtained from the operating instructions of the respective manufacturer.
9.9.2 Mounting/dismounting pipe guide
26
Pipe guide from the left Pipe guide from the front
• Dismantle locking pins (fig. 26, no. 7) and connecting pins (1).
• Position the pipe guide (fig. 27, no. 3) under the leader. The leader rear wall (3) is flush with the
guide claws of the pipe guide.
• Thread the leader, insert connecting pins (1) and secure via the locking pin (7). Pin the pipe guide
as low as possible on the leader.
• Connect hydraulic hoses for the cylinder (4) on the front right-hand side of the bulkhead plate (via
quick-release couplings).
Disassembly is resulted accordingly in reverse order.
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9. OPTIONS
27
Pipe guide from above
9.9.3 Operating the pipe guide

The pipe guide is actuated via the following keys on the auxiliary panel (X25).
Pre-selection key "Pile guidance" *

For pre-selection of the pile/pipe guide.
Key "lift/open"
The pipe guide is opened. The guide arms (6) are actuated away from each
other and the boring tube (5) is authorised.
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Key "lower/close"
The pipe guide is closed.
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9. OPTIONS
28
9.10 Counterweight mounting device
9.10.1 General
The counterweight mounting device allows the mounting
and dismounting of the counterweight without using an
auxiliary crane.
Assembly or disassembly is carried out during mounting
or setting down of the piling rig and drilling system.
9.10.2 Mounting/dismounting the counterweight
DANGER !
Risk of injury when mounting the counterweight!

- Carry out movements slowly and conscientiously.
- Remaining between counterweight and basic machine
and below the counterweight is prohibited.
29
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9. OPTIONS
Mounting the counterweight

• Piling rig and drilling system has been lain down, the leader is turned to the front
• Secure tackle (fig. 29, no. 1) via shackle (2) and the upper butt straps on the support arm brace
• Mount piling rig and drilling system (see chapter 6 "Assembly and disassembly")
• Position counterweight immediately behind the machine
• Secure lower tackle via turnbuckle (3) and shackle to the eyebolts of the counterweight
• Tension tackle slightly, and as vertically as possible, adjust the piling rig and drilling system
accordingly
• Always guide the leader to the front as close to the ground as possible and if possible reposition
to the front /down
DANGER !
Danger of tipping !
Adjust universal carriage all the way down.
Lift or set down counterweight immediately behind the machine, position transporter ac-
cordingly.
Always guide the leader to the front as close to the ground as possible and if possible
reposition to the front /down.
The uppercarriage is positioned parallel to the undercarriage. Do not rotate the uppercar-
riage. Do not actuate crawler.
• Lift counterweight carefully and position on the rear of the uppercarriage

• Pin counterweight
Install tensioning bolts on the and lower side
fix it at the sides
see chapter 6 under "Mounting the rear counterweight"
• Relieve tackle and loosen from lower counterweight
• Set down piling rig and drilling system again and remove tackle on the support arm brace support
Dismounting the counterweight

Dismounting of the counterweight is resulted accordingly in reverse order.
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9. OPTIONS
30
9.11 Air compressor
9.11.1 General
The machine features its own air compressor, providing
the power for pneumatic tools.
The air compressor (fig 30, no. 2)
- is located right-hand side in the uppercarriage,
- is driven hydraulically.
The quick-release coupling for the connection of the air
hose is located in the bulkhead plate on the front right-
hand side of the uppercarriage (fig. 30, no. 1).
Compressor type: LE-40B
Connection: 1/2 '
max. pressure: 10 bar [145 psi]
NOTE !
The describtion of the compressor is enclosed in volume 4. Technical data, safety guidelines and
maintenance guidelines can be found there.
Maintenance and repair work of the air compressor must only be done by authorised and qualified
personnel.
9.11.2 Start-up
• Bring the air compressor in operation according to the information supplied by the manufacturer in
volume 4 (check oil level, etc.).
The air compressor functions only with the diesel engine running.
9.11.3 Operating the air compressor

The air compressor is switched on and off on the left hand control panel (X11).
Key "Air compressor On / Off"

Switching the air compressor on and off.
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9. OPTIONS
9.12 Cooler for vibrator gearbox oil

The cooler for the vibrator gearbox oil (Figure 31, item 2)
- is located on the base arm (1),
- cools the gearbox oil in the vibrator,
- is switched on and off automatically when required.
As an option two separate cooling circuits for the operation of a belt vibrator are provided (as shown
here).
31
NOTE!
On commissioning check oil level or after changing the vibrator gearbox oil
- fill up the system with gearbox oil,
- switch the vibrator on for a short time,
- check the gearbox oil again and top up if necessary
Specification and interval: see the vibrator manufacturer's operating manual
Initial filling in factory: Mobil SHC-632
32
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Drain plugs (Figure 32, item 2) are provided for draining off the gearbox oil.
Each circuit includes an oil filter (3) * and a ball valve (1) *. The oil cooler can be detached from the
vibrator with the ball valve. When changing the filter, always close the ball valve.
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9. OPTIONS
9.13 Optional floodlights on the superstructure

9.13.1 Location
This additional equipment comprises three Xenon floodlights, which are mounted
- on the front right of the superstructure (Figure 33, item 1 and,
- on the left of the superstructure (2).
The standard floodlights on the front of the cab have been replaced by Xenon floodlights
33
The floodlight on the left of the superstructure (2) can also be mounted in another corner on the
sound protection shield.
9.13.2 Operational controls

The optional floodlights are switched on and off with the "Work floodlights on / off" button on the
left-hand control panel (X11).
Switches the optional floodlights and the work floodlights on and off.
NOTE!
To be noted, particularly at low temperatures:
The batteries run down when the diesel engine is not running and the work floodlights and optional
floodlights are left on for extended periods.
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9. OPTIONS
34
9.14 Central lubrication for the kinematics
and roller slewing ring
9.14.1 General
The central lubricating system lubricates the kinematics,
the bearings of the roller slewing ring and the teeth
profile.
The central lubricating system works when

- the diesel engine is running and
- the safety lever of the control system is in the down
position.
The lubrication procedure is resulted automatically in
accordance with the programmed lubrication and break
time.
The grease pump (Figure 34, item 3) is located at the
right hand side in the rear of the superstructure.
When the grease pump is switched on, grease is carried
from the grease container to the various lubrication
points on the kinematics (Figure 34, item 1) and on the
slewing ring (2).
35
The time intervals for the lubrication and break times can
be adjusted via the switch unit (fig. 35, no. 5).
CAUTION !
The pressure relief valve (fig. 35, no. 2) has been

set by the manufacturer and may not be adjusted! It
serves as an overpressure safety and not for work-
ing pressure adjustment!
1 Grease container
2 Pressure relief valve
3 Grease nipple for refilling
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4 Push button for intermediate lubrication

5 Switch unit
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9. OPTIONS
9.14.2 Filling the grease container

The grease container (Figure 35, 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.
9.14.3 Function
After switching on the diesel engine, the yellow indicator lamp lights up (fig. 36, no. 4) for approx.
1.5 seconds, signaling that operation can begin.
To check the functioning , push the red push button (fig. 35, no. 4) on the side of the pump
housing. Intermediate lubrication is thus resulted with the programmed lubrication time. When this
lubrication time is spent, the lubricating procedure is switched off and the programmed break time
begins. All further lubrication procedures are initiated automatically via the pre-set times.
The lubrication procedure is stopped when the diesel engine is switched off.
Upon reactivation, the lubrication procedure is continued automatically via the control.
Intermediate lubrication of the roller slewing ring can be carried out at any time via push button
(fig. 35, no. 4) as long as the diesel engine is running.
CAUTION!
If the central lubricating 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.
The grease container must always be sufficiently filled.
Rotate the superstructure several times or change position of the undercarriage.
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36
9.14.4 Programming time intervals
The switch unit (fig. 36, no. 1) is mounted directly on
the grease pump. For time adjustment, the protective
frame must first be removed. Then remove the protective
cover.
Adjusting lubrication time

• The lubrication time can be programmed in minutes
via the switch (2) using a screwdriver.
Adjustment range: 1 - 16 min.
Set at the factory: 6 min.
Setting the break time

• The break time can be programmed in hours via the
switch (3) using a screwdriver.
Adjustment range: 0,5 - 8 h
Set at the factory: 8 h
CAUTION !
An incorrectly programmed central lubrication system leads to insufficient lubrication and

damage to the machine!
NOTE !
Upon completion of adjustment, replace and secure protective cover again, in order that no water
can penetrate the switch unit.
9.14.5 Maintenance of the central lubricating system

The central lubricating 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 kinematics, the pinion and the slewing roller (a collar of
grease must be visible from outside). See also Chapter 7 "Maintenance of the piling and drilling
equipment"
• 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 lubricating system.

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9. OPTIONS
37
9.15 Central lubrication for the lead slide
9.15.1 General
The central lubricating system lubricates the guides of
the lead in front and the rope pulleys in the universal
slide.
The central lubricating system works when

- the diesel engine is running,
- the safety lever of the control system is in the down
position and
- the key "Slide greasing" is activated.
The lubrication process starts when the feed is actuated.
The grease pump (Figure 37, item 3) is located at the
rear right of the superstructure .
When the grease pump is switched on, grease is carried
from the grease container to the various lubrication
points on the universal slide (Figure 37, item 1 and 2).
38
CAUTION!
The overpressure valve (Figure 38, 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. OPTIONS
9.15.2 Filling the grease container

The grease container (Figure 38, 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.
9.15.3 Function
"Slide greasing on / off" preselect key

Preselects the slide greasing.
When the feed is actuated, the lubrication process starts automatically.

The lubrication process continues as long as the feed is actuated.
CAUTION!
If the central lubricating system does not work properly, the machine will be insufficiently
lubricated and may be damaged!
9.15.4 Maintenance of the central lubricating system

The central lubricating 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 lead guides. See also Chapter 7 "Maintenance of the piling
and drilling equipment"
• Check the lubrication pipes for leaks
• Check the level of the grease container and top up if necessary
LRB255_V001 (mf) LWN - TD4/2/2010
A steam cleaner can be used to clean the central lubricating system.
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9. OPTIONS
39
9.16 Additional ballast 1.4 t
General
If required, an additional 1.4 t [3090 lbs] ballast plate
(Figure 39, item 1) can be bolted onto the bottom of the
rear counterweight.
DANGER!
Danger of toppling!
Mount and dismount the additional ballast only with
the lead in upright position.
Pay attention to the increased ground pressure due
to the additional ballast.
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9. OPTIONS
40
DANGER!
Danger of toppling!
The additional ballast reduces the support surface
area. The rear counterweight will topple over or sink
into the ground more easily!
Support the entire ballast along its sides with
squared timbers.
Adding the additional ballast

• Position the rear counterweight on the additional bal-
last plate
• Bolt the rear counterweight at the rear (Figure 40, item
1) and at the front (2,3); fit washers
• Mount the entire counterweight on the rear of the
superstructure as described in Chapter 6 "Mounting
the rear counterweight"
• Insert both straining screws (6)
• Fit bolts (4) and secure using washer (8) and cotter
pin (7)
• Tighten nuts (5)
Removing the additional ballast

• Undo nuts (5)
• Remove cotter pin (7) and bolt (4)
• Remove bolt (4)
• Dismantle the entire counterweight as described in
Chapter 6 "Dismantling the counterweight" and place
on the ground
• Remove screws at rear (Figure 40, item 1) and at front
(3)
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9. OPTIONS
41
9.17 Additional ballast 7.3 t
General
As an option an additional counterweight (Fig. 41, no.1)
of 7.3 t [16094 lbs] is bolted onto the back of the rear
counterweight.
This additional ballast is only provided for double rotary
operation or for special operations approved from the
manufacturer. Pay attention to the corresponding load
charts in Volume 2.
DANGER!
Danger of toppling!
Mount and dismount the additional ballast only with
the lead in upright position.
Pay attention to the increased ground pressure due
to the additional ballast.
ATTENTION!
Danger of crushing!
When mounting or dismantling the ballast do not
remain underneath and between the additional bal-
last and the rear counterweight.
IMPORTANT!
Use a suitable auxiliary crane!
Mount additional ballast

• Fasten additional ballast to the eyebolts (Fig. 41, no.
2)
• Position additional ballast on the rear of the coun-
terweight
• Bolt the additional ballast with the three bolts (Fig. 41,
no. 3, 4) to the counterweight; install washers
one bolt: M30x450 (Fig. 41, no. 3)
two bolts: M30x420 (Fig. 41, no. 4)
Tightening torque: 1250 Nm
Dismantle additional ballast

• Fasten additional ballast to the eyebolts (Fig. 41, no.
2)
• Tension the chains or belts
• Dismantle bolts (3, 4)
• Dismantle additional ballast
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9. OPTIONS
42
9.18 Sheet pile feeder
9.18.1 General
The optional sheet pile feeder (Figure 42, item 1) is used
to raise the pile into the clamps (5) of the vibrator.
DANGER!
The pile can become detached, fall over or start to

swing as it is being raised.
Keep a safe distance away!
Procedure
• Fully retract the cylinder (2)

• Attach the slinging equipment (3) to the pile (4)
• Raise the universal tool carriage with the attached
vibrator until the pile hangs freely
• Open the clamps (5)
• Extend the cylinder until the pile sits in the clamps
• Close the clamps (5) (check that the pile is held
securely in the clamps)
• Fully retract cylinder (2) (slinging equipment no longer
under strain)
CAUTION!
The sheet pile feeder will be damaged if the vibrator

is switched on when the slinging equipment (chains)
is taut.
• Shake down the pile.

• Take the slinging equipment (3) off the pile.
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9. OPTIONS
9.18.2 Operating the sheet pile feeder

The sheet pile feeder is controlled by the following keys on the additional desk (X25) or the left-hand
joystick.
"Relative movement/sheet pile feeder" preselect key

To select the sheet pile feeder.
"Lift/Open" key
The cylinder on the vibrator is extended, (slinging equipment becomes taut).
"Lower/Close" key
The cylinder on the vibrator is retracted, (slinging equipment goes slack).
43
Controlling the sheet pile feeder using the left-hand
joystick
When the latch button (Figure 43, item 1) on the left-

hand joystick is operated, the cylinder on the vibrator
moves in a certain direction and continues moving while
the button remains pressed.
If the button is pressed again, the direction of movement
changes.
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9. OPTIONS
9.19 Line pull limitation

9.19.1 General
With the help of the line pull limitations the maximum
line pull of the winches can be limited to a certain value.
Line pull limitations are used to
- reach national standards and
- if with certain applications no higher line pull is allowed
44
9.19.2 Line pull limitation winch 2 to 10 t
DANGER!
Switching over must only be done if

- no load is lifted,
- ignition is turned off.
Switch line pull limitation on or off

- set the load down or let the rope loose
- turn ignition off
- actuate key (fig. 44)
• key activated= line pull winch 2: 10 t
• key not activated = line pull winch 2: nominal load
IMPORTANT!
The line pull limitation remains active as long as the
indicator lamp below the key is lit.
Operating of the winch is done like described in chapter
5 "Operation".
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9. OPTIONS
45
9.20 Concrete feed line
The optional concrete feed line (Bild 45, Nr. 1) is moun-
ted on the left side of lead.
The lines are not part of the standard equipment sup-
plied with the machine.
46
ATTENTION!
Collision hazard!
The concrete feed line collides with the holding arm,
if the lead is rotated all the way to the left side.
With the concrete feed line mounted, he lead must
not be rotated all the way to the left side!
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9. OPTIONS
9.21 Roof railing
9.21.1 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.
47
LRB255_V001 (mf) LWN - TD4/2/2010
1 Roof railing 2 Cotter pin
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9. OPTIONS
9.21.2 Mounting
The roof railing consists of segments. They are placed on the superstructure on special retainers,
subsequently secured via cotter pins (fig. 47, 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. OPTIONS
NOTES:
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9. OPTIONS
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10. APPENDIX
10. APPENDIX
10.1 General
All documents and information concerning purchase parts and sub contractors can be found in the
appendix.
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10. APPENDIX
NOTES:
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10. APPENDIX
LRB255_V001 (mf) LWN - TD4/2/2010
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Load capacity chart book EN

001 - 04.02.2010 / lwnfim2

Load Capacity Charts

The load capacities have been calculated according to:

Operating mode Maximum permissible wind speed in m/s [mph]

Liebherr -Werk Nenzing GMBH 12.01.2004

When moving with a load, higher stability factors apply.

- LRB 255 carrier with 12.3t [27100lbs] counterweight

Liebherr -Werk Nenzing GMBH 12.01.2004

Max. ground pressure [kg/cm 2] with 900mm grousers:

23.04.2010 LIEBHERR - Werk Nenzing A. Koller

Max. ground pressure [PSI] with 2.95ft grousers:

23.04.2010 LIEBHERR - Werk Nenzing A. Koller

This stability calculation applies to:

21m vertical leader: Drilling gear Drilling gear Drilling gear

24m vertical leader: Drilling gear Drilling gear Drilling gear

The machine may only be moved under the following conditions:

This stability calculation applies to:

70ft vertical leader: Drilling gear Drilling gear Drilling gear

80ft vertical leader: Drilling gear Drilling gear Drilling gear

The machine may only be moved under the following conditions:

Max. ground pressure [kg/cm2] with 900mm grousers:

17.06.2013 LIEBHERR - Werk Nenzing A. Koller

Max. ground pressure [PSI] with 2.95ft grousers:

17.06.2013 LIEBHERR - Werk Nenzing A. Koller

ORIGINAL 001 - 04.02.2010 / lwnfim2

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

SAFETY GUIDELINES .......................................3

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

ASSEMBLY AND DISASSEMBLY .....................6

2. PRODUCT DESCRIPTION 2-1

2.4.6 Feed system * 2-9

2.4.14 Supporting arm 2 - 13

3. SAFETY PRECAUTIONS 3-1

3.6 Safety signs on the machine 3 - 12

4. CONTROL AND OPERATING ELEMENTS 4-1

4.6 Left control panel (X11) 4 - 13

4.12 Page "Operation diagram" Leader 4 - 38

5.6.10 MESSAGES menu 5 - 38

5.11.2 Pre-selecting vibrator operation 5 - 116

5.13.4 Operating the hammer 5 - 128

6. ASSEMBLY AND DISASSEMBLY 6-1

6.6.2 Mounting/dismantling the piling rig or drilling device 6 - 33

7.3 Diesel engine 7 - 17

7.5 Cooling system 7 - 31

7.14.17 Check the rope fixation and rope thimble 7 - 62

8. REPAIR WORK 8-1

8.1 General 8-1

9.8.3 Compact flash card 9 - 25

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

1.3 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