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Unlimited Español 2020 PDF
Unlimited Español 2020 PDF
Type:
LRB 255
Serial number:
111 622
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:
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.
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:
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]
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.
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]
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.
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
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: 2.60 3.10 1.80 1.96 2.97 3.58
Max. permitted load on Kelly winch: 2.99 3.30 1.97 2.02 3.45 3.79
Max. permitted load on crowd winch: 4.14 3.75 2.36 2.16 4.70 4.27
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
Max. permitted load on auxiliary winch: 36.0 42.8 25.2 27.3 41.1 49.4
Max. permitted load on Kelly winch: 34.4 40.5 24.3 26.5 39.0 46.8
Max. permitted load on crowd winch: 65.3 58.2 35.3 32.0 73.3 65.6
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
Max. permitted load on auxiliary winch: 37.0 44.1 25.6 27.9 42.2 50.9
Max. permitted load on Kelly winch: 42.5 46.9 28.0 28.7 49.1 53.9
Max. permitted load on crowd winch: 58.9 53.3 33.6 30.7 66.8 60.7
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]
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.
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]
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.
Type:
LRB 255
Serial number:
111 622
OPERATION .......................................................5
CHAPTER INDEX
MAINTENANCE ..................................................7
REPAIR ...............................................................8
OPTIONS ............................................................9
LRB255_V001 (mf) LWN - TD4/2/2010
APPENDIX ....................................................... 10
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INDEX
INDEX
1. INTRODUCTION 1-1
1.1 Foreword 1-1
1.2 Handling of documentation 1-2
1.2.1 How are the Operating instructions set up? 1-3
1.2.2 System requirements of the computer for use of CD-ROMs 1-3
1.2.3 Storage of documentation 1-3
1.2.4 Current status of documentation 1-4
1.3 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
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INDEX
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INDEX
0-7
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INDEX
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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INDEX
0-9
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INDEX
0 - 10
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INDEX
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
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0 - 11
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INDEX
0 - 12
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INDEX
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
0 - 13
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INDEX
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
9.18.1 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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INDEX
9.21.2 Mounting 9 - 66
10. APPENDIX 10 - 1
10.1 General 10 - 1
0 - 16
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0 - 17
INDEX
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1
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ï
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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:
1-1
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1. INTRODUCTION
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.
Technical information
Here you find information about the hydraulic and electric system of your ma-
chine.
1-2
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1. INTRODUCTION
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.
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1. INTRODUCTION
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
© 08/2008 Copyright by
Liebherr-Werk Nenzing GmbH
A-6710 Nenzing/AUSTRIA
All rights reserved.
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1. INTRODUCTION
1.4.1 Length
1-5
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1. INTRODUCTION
1.4.4 Volume
1.4.5 Pressure
1-6
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1. INTRODUCTION
1.4.6 Temperature
1.4.7 Speed
1.4.8 Force
1.4.9 Torque
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1. INTRODUCTION
1.4.10 Performance
1-8
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1. INTRODUCTION
1-9
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1. INTRODUCTION
NOTES:
1 - 10
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1. INTRODUCTION
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2
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2
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2. PRODUCT DESCRIPTION
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.
2-1
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2. PRODUCT DESCRIPTION
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. PRODUCT DESCRIPTION
These main components of the LRB 255 are described in detailed order over the following pages.
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2. PRODUCT DESCRIPTION
* Option
not represented: Leader ladder, hose package
2-4
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2. PRODUCT DESCRIPTION
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
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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2. PRODUCT DESCRIPTION
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.
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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2. PRODUCT DESCRIPTION
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.
6
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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)
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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,
- is mounted on the universal carriage,
- features two upper and lower rubber buffers respec-
tively (2),
- can be configured to the specifics of the customer,
independent of the hammer.
A fixture has been installed with the diaphragm on the
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),
- is mounted on the universal carriage,
- can be configured to the specifics of the customer,
independent of the drilling drive.
A fixture has been installed with the diaphragm on the
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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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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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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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.
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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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 *.
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.
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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.
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2.5 Uppercarriage
25
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Diesel engine
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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2.6 Undercarriage
30
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2.7 Counterweight
2.7.1 Rear counterweight
The rear counterweight is prerequisite for stability of the machine.
31
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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5 Leader height adjusting cylinder (Z5) 11 Leader lateral inclination cylinder (Z6)
6 Leader foot cylinder ** 12 Upper leader rotary cylinder (Z3)
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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
35
Transport weight piling rig and drilling equipment (fully fuelled and ready for operation),
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Max. payload second piling rig including cover and pile . . . . . . . . . . . . . . . . . . . . . . . . 30 t [66100 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']
Permissible max. windspeed when operating the machine . . . . . . . . 20 m/s [44.7 mph] (wind force 8)
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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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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]
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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.
The following auxiliary equipment has been provided:
- Hoist limit switch on the leader head
- 3-coil-limit switch
- Rope length measuring
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.
The following auxiliary equipment has been provided:
- Hoist limit switch on the Kelly jib
- 3-coil-limit switch
- Rope length measuring
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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.
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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!
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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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DANGER!
WARNING!
CAUTION!
NOTE!
The word NOTE
- indicates a potentially damaging situation,
- relates to operating and maintenance procedures,
- 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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Physical requirements:
• Adequate vision with unimpaired peripheral vision
• Satisfactory spatial perception
• No colour blindness
• Adequate hearing
• Adequate physical aptitude
• Quick reaction times
• Manual dexterity
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
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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.).
NOTE!
You are responsible for making sure that you
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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.
IMPORTANT!
Hit the window around the edges only. Protect your eyes
and other parts of your body from flying glass.
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Not displayed:
- Internal and external rear-view mirror
NOTE !
The boom equipment for the machine is optional.
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WARNING !
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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Prohibition signs
These symbols
- are circular and of a bold red colour,
- are located wherever a potentially dangerous action is prohibited.
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.
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Fire extinguishers
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WARNING!
There are numerous hazards and situations involving the machine that can cause injuries.
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.
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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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WARNING!
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WARNING!
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WARNING!
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.
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WARNING!
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.
• 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:
NOTE!
Fire extinguishers are subject to national regulations and must therefore be replaced by the operator
if necessary.
• 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
13
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• 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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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.
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WARNING!
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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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.
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WARNING!
14
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15
Front half of the machine: Length of the piledriving element (pile) + 1.0 m
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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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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.
The maximum permissible wind speed is dependent upon the length of the leader:
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The maximum permissible wind speed is dependent upon the setting-up stage of the machine:
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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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)
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Danger!
Danger due to soft foundation! Insufficient load-bearing capability of foundations will result in
the machine tipping over.
Countermeasures:
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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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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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!
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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.
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
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For example, in Germany the following safe distances from overhead power lines are to be
maintained when operating the machine:
In the United States of America the following safe distances from overhead power lines are to be
maintained when operating the machine:
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:
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How do you find out the nominal supply voltage of an overhead power line?
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.
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.
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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
Voltage [kV]
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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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.
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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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.
NOTE!
Instead of hopping, you can also leave the danger zone by pressing your knees together and taking
small steps.
Your shoes must
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- always rub against each other to remain in contact with each other,
- never leave the ground completely.
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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.
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!
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.
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!
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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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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.
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.
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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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.
• 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.
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?
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CAUTION!
• 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.
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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The same procedures apply as described in section 3.8.5 "Overhead power lines":
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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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.
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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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3.11.1 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.
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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.
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19
20
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21
22
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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23
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
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Hand signals for lifting operations in accordance with ASME/ANSI B30.5, continued
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
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Hand signals for lifting operations in accordance with ASME/ANSI B30.5, continued
29
30
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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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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NOTES:
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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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4.4 Cab
4.4.1 Cab overview
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4. CONTROL AND OPERATING ELEMENTS
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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• 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!
• 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 * /
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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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Description of keys
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NOTE !
The keys of control panel (X12) remain active as long as the indicator lamp below the key is lit.
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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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2
LRB255_V001 (mf) LWN - TD4/2/2010
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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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
Potentiometer 2
NOTE !
Adjustment of the potentiometer always applies to the activated pre-selection.
(LED in the pre-selection display lights up.)
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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
LRB255_V001 (mf) LWN - TD4/2/2010
display.
The potentiometer is set from minimum to maximum value in a clockwise direction.
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Potentiometer 1
Potentiometer 2
Potentiometer 3
Potentiometer 4
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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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The auxiliary panel(X26) * is used for controlling the 4-time press (Push&Pull variant X26).
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4. CONTROL AND OPERATING ELEMENTS
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
Potentiometer 2
Potentiometer 3
Potentiometer 4
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Description of keys
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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.
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.).
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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.
There are two variants of the LCD screen possible. The function is the same on both variants,
operation slightly varies.
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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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.
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Page "Adjustments"
This display screen page serves for entering the necessary
values depending on the operating mode.
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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.
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Symbol "Eccentric" *
The eccentric is preselected and can be adjusted via the rocker switch on the
right-hand switch lever. See chapter 5 "Vibrator".
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 display field-kelly drilling is overlayed on the LCD-display screen if kelly drilling has been
pre-selected.
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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.
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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].
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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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The display field CFA drilling is overlayed on the LCD-display screen if CFA drilling has been
pre-selected.
The other elements have already been described in the display field-kelly drilling.
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The display field double rotary drilling is overlayed on the LCD-display screen if double rotary drilling
has been pre-selected.
NOTE !
The other elements have already been described in the display field-kelly drilling or CFA drilling.
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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.
Suspension quantity
Shows the total suspension quantity in m³ [yd³].
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.
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.
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.
Cylinder ram 1
Cylinder ram 2
Cylinder ram 3
Cylinder ram 4
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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.
NOTE !
The other elements have already been described in the display field-kelly drilling or CFA drilling
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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 "Adjustments"
Upon actuation of function key F6 , page "Adjustments" is switched over to.
This symbol is displayed only in assembling operation.
NOTE !
Upon actuation of this function key, no error acknowledgement or error remedying is resulted!
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The following function key symbols only appear upon actuation of function key F7.
The following function key symbols only appear upon re-actuation of function key F7 .
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NOTE!
The currently selected operating mode is surrounded by a darker frame on the display.
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NOTE !
The further function key symbols are described in chapter 4 under "Operation diagram".
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This display screen page gives information concerning the operating condition of all main compo-
nents.
Symbol "Caution"
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Symbol "Stop"
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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.
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.
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Display field-Component
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NOTE !
All further monitoring displays are already described in chapter 4 under "Operation diagram".
NOTE !
The further function key symbols are described in chapter 4 under "Operation diagram".
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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.
As a result of the fault message, the speeds of these functions and movements are reduced to 50%:
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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.
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.
The following measures should be taken immediately with the appearance of an error mes-
sage:
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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"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.
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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Page "Adjustments"
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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NOTE !
The further function key symbols are described in chapter 4 under "Operation diagram".
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14
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.
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
Adjusts the volume of the warning buzzer.
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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
With this button the LCD screen can be
- set to three different levels of brightness,
- switched to inverse display mode (for use at night).
16
4.18.2 Keyboard menu
CAUTION
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
With this button the LCD screen can be
- set to three different levels of brightness,
- switched to inverse display mode (for use at night).
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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4. CONTROL AND OPERATING ELEMENTS
NOTES:
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4. CONTROL AND OPERATING ELEMENTS
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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.
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".
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.
IMPORTANT !
All Emergency-Off-switches must be unlocked, in order to restart the diesel engine.
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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 !
CAUTION !
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5. OPERATION
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".
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).
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5.4 Start-up 2
DANGER!
Prerequisites:
• Sufficient battery capacity for starting the machine.
• All checks before start-up have been carried out.
• All Emergency-Off switches are unlocked.
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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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".
NOTE !
Do not remove filling sieve for refuelling.
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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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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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
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".
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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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:
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
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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WARNING!
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5. 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
WARNING !
IMPORTANT !
With every travel movement the warning light flashes on the cab roof and as an option, a warning
signal sounds.
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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.
15
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16
Foot pedal control
The crawler is actuated proportionally via both foot ped-
als in the operator's cab:
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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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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18
Turning on one crawler
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
IMPORTANT !
Preserve the crawler: Avoid turning on the spot as far as
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possible.
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5. OPERATION
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.
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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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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20
Rotate uppercarriage
WARNING !
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).
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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 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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22
Rotating uppercarriage in swing gear free-
swing
WARNING !
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.
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.
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23
The optional swing gear limitation limits the swing range of the upper carriage.
CAUTION!
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24
CAUTION!
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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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5.6.1 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.
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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• 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 !
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While the Litronic® test system is in operation, fault messages from the Litronic® control do
not display!
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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.
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This enables you to load a saved select list from the memory card.
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This menu can be used to enter the Litronic® code to reach Supervisor level. Supervisor level is
required to set the time, for example.
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This menu displays all the CAN modules installed, together with their application status.
This menu displays all the CAN lines installed, together with their settings.
This menu can be used to set the options for how the INPUT/OUTPUT menu displays.
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.
• USE DEFAULT loads english as the new system language, and goes back to the SPECIAL
FUNCTIONS menu.
• MENU 1/2 switches between the two menu bars.
• BACK aborts the procedure and switches back to the SPECIAL FUNCTIONS menu.
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"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.
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This menu displays the current system status (running, stopped etc.) and the timing for the PLC
tasks (programmable logic controller).
MDE/PDE menu
This menu displays the status of the MDE (machine data entry), the PDE (process data entry) and of
the data logger.
Clients menu
This menu displays the status of the individual communications interfaces (clients).
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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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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.
Weight adjustment
28
Horizontal adjustment whole seat
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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.
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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".
IMPORTANT !
Commercially available windshield cleaning liquid can
also be used.
For safety reasons, however, it should not be flammable!
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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.
• 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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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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31
Inclining the leader (forward/backward)
WARNING !
The leader is inclined via actuation of the support arm brace-support cylinder (Z2) in the Y-direction
(forward/backward).
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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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.
This direction is always authorised.
Key "lower/left"
Retract basic arm-adjusting cylinder. Reach is reduced.
This direction is only authorised if the following limit switches are not activated:
- 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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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 !
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5. OPERATION
Key "lift/right"
Extend leader height adjusting cylinders. The leader or the leader height adjust-
ment carriage are adjusted upwards.
This direction is only authorised if the following limit switches are not activated:
- 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 *
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 !
Key "lift/right"
The leader is adjusted to the right.
This direction is always authorised.
Key "lower/left"
The leader is adjusted to the left.
This direction is always authorised.
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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
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°).
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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.
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.
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.
This direction is always authorised.
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5. OPERATION
40
Adjusting the leader foot *
The lead foot plate can be adjusted by operating the
lead foot cylinder.
Key "lift/open"
Retracting the leader foot cylinder. This direction is always authorised.
Key "lower/close"
Extending the leader foot cylinder.
This direction is always authorised.
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
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)
Upon actuation of the key (fig. 42, no. 1) on the left-hand
switch lever and actuation of the left-hand switch levers
forwards/backwards, the leader height adjusting cylinder
is extended or retracted.
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
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
Upon actuation of the key (fig. 44, no. 1) on the left-hand
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:
• Switch lever in zero position = Leader remains in position
• 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) *
Upon actuation of the key (fig. 45, no. 1) on the left-hand
switch lever and actuation of the left-hand switch lever
left/right, the leader foot cylinder is extended or retract-
ed.
Prerequisites:
- No other cylinder adjustment via switch lever active,
- 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.
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).
Procedure:
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 other cylinder adjustment via switch lever active,
- 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.
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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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51
WARNING !
The adjustment range of the auxiliary is fixed by the hoist limit switch and 3-coil-limit switch.
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),
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.
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.
This symbol appears in the display field on the LCD-display screen, as soon as
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).
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).
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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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.
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59
5.8.8 Actuating the kelly winch *
DANGER!
WARNING !
The adjustment range of the kelly winch is limited via the hoist limit switch and 3-coil-limit switch.
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.
LRB255_V001 (mf) LWN - TD4/2/2010
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
11.5 m Display "Cable length measurement kelly winch" (in the display field-kelly
drilling)
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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NOTE !
For a precise display of the cable length, a layer-change and reeving of the kelly winch must be
programmed.
• Programming reeving
As the kelly rope can be reeved, the reeving must be defined when calculating the cable length.
Procedure
Symbol "Adjustments"
Upon actuation of function key F6 , page "Adjustments" is switched over to.
9 number of pumps
Page "Adjustments"
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5. OPERATION
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.
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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.
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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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
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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:
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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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.
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.
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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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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When the mooring has been selected, the following symbol appears on the LCD screen:
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
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WARNING!
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5. OPERATION
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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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
DANGER !
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!
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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.)
DANGER!
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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
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.
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.
This symbol appears in the display field on the LCD-display screen, as soon as
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.
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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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
Kelly drilling is often carried out in connection with the optional casing oscillator . The casing
oscillator is auxiliary equipment for fitting the exterior piping.
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5. OPERATION
Symbol "Adjustments"
Upon actuation of function key F6 , page "Adjustments" is switched over to.
9 number of pumps
999 flow rate case oscillator [l/min]
999 max. pressure [bar]
Page "Adjustments"
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5. OPERATION
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"
The entered values are only accepted by the control following actuation of the
"Enter" key.
NOTE!
With incorrect entry, the old values are maintained.
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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.
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5. OPERATION
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5. OPERATION
Symbol "Adjustments"
Upon actuation of function key F6 , page "Adjustments" is switched over to.
9 number of pumps
Page "Adjustments"
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5. OPERATION
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"
The entered values are only accepted by the control following actuation of the
"Enter" key.
NOTE!
With incorrect entry, the old values are maintained.
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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):
• 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
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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:
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5. OPERATION
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.
The display field double rotary drilling is overlayed on the LCD-display screen.
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5. OPERATION
Symbol "Adjustments"
Upon actuation of function key F6 , page "Adjustments" is switched over to.
Page "Adjustments"
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5. OPERATION
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"
The entered values are only accepted by the control following actuation of the
"Enter" key.
NOTE!
With incorrect entry, the old values are maintained.
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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):
• 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
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
• Switch lever in zero position = Drilling drive remains in
position
• Switch lever forwards = Drilling drive turns to the left
82
Switching over torque drilling drive 2
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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.
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
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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)
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5. OPERATION
Symbol "Adjustments"
Upon actuation of function key F6 , page "Adjustments" is switched over to.
9 number of augers
9 number of pumps
Page "Adjustments"
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5. OPERATION
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"
The entered values are only accepted by the control following actuation of the
"Enter" key.
NOTE!
With incorrect entry, the old values are maintained.
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
units can be found in the manufacturer's operating manual.
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
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5. OPERATION
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5. OPERATION
Symbol "Adjustments"
Upon actuation of function key F6 , page "Adjustments" is switched over to.
Page "Adjustments"
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5. OPERATION
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"
The entered values are only accepted by the control following actuation of the
"Enter" key.
NOTE!
With incorrect entry, the old values are maintained.
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5. OPERATION
88
Starting the clamping tongs system
Closing the clamping tongs
Right joystick:
• Press button (Figure 88, item 1)
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5. OPERATION
89
Right joystick:
• Press button (Figure 89, item 1):
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5. OPERATION
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.
Possibility "1":
90
Possibility "2":
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5. OPERATION
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 .
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.
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5. OPERATION
Prerequisite: The vibratory hammer is at rest, the pile is lowered to the floor and prevented from
tipping over.
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5. OPERATION
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.
This is resulted as follows:
- Pick up sheet pile and mount hammer
- Activate hammer
- Insert sheet pile in the ground
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5. OPERATION
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5. OPERATION
Symbol "Adjustments"
Upon actuation of function key F6 , page "Adjustments" is switched over to.
Page "Adjustments"
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5. OPERATION
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"
The entered values are only accepted by the control following actuation of the
"Enter" key.
NOTE!
With incorrect entry, the old values are maintained.
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:
The LED in the pre-selection display "Flow rate auxiliary hydraulics" lights up on
the right-hand control panel (X23).
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
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.
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.
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5. OPERATION
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5. OPERATION
92
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5. OPERATION
Symbol "Adjustments"
Upon actuation of function key F6 , page "Adjustments" is switched over to.
9 number of pumps
999 flow rate case oscillator [l/min]
999 max. pressure [bar]
9 number of pumps
Page "Adjustments"
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5. OPERATION
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"
The entered values are only accepted by the control following actuation of the
"Enter" key.
NOTE!
With incorrect entry, the old values are maintained.
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5. OPERATION
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.
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5. OPERATION
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.
NOTE !
The casing oscillator is controlled externally.
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5. OPERATION
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
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.
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5. OPERATION
93
5.15.3 Switch off diesel engine
CAUTION!
Shut-down stages :
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 :
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5. OPERATION
96
5.16 Catch belt and fall protection runner
DANGER !
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.
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
• 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.
CAUTION !
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5. OPERATION
NOTES:
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5. OPERATION
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6. ASSEMBLY AND DISASSEMBLY
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6. ASSEMBLY AND DISASSEMBLY
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:
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6. 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.)
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.
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6. ASSEMBLY AND DISASSEMBLY
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.
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. ASSEMBLY AND DISASSEMBLY
1
6.4.3 Prepare basic machine
check: shunting plug and connecting cable inserted
CAUTION !
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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6. ASSEMBLY AND DISASSEMBLY
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
DANGER!
5
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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 !
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. ASSEMBLY AND DISASSEMBLY
CAUTION !
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.
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6. ASSEMBLY AND DISASSEMBLY
CAUTION!
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
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6. ASSEMBLY AND DISASSEMBLY
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).
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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6. ASSEMBLY AND DISASSEMBLY
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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6. ASSEMBLY AND DISASSEMBLY
15
Folding down the platforms on the undercarriage
• Lift up and fold down platforms on the undercarriage
(fig. 15)
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6. ASSEMBLY AND DISASSEMBLY
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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6. ASSEMBLY AND DISASSEMBLY
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
• 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. ASSEMBLY AND DISASSEMBLY
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".
* Option
** Should the piling rig and drilling system has been dismantled for transport.
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6. ASSEMBLY AND DISASSEMBLY
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.
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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6. ASSEMBLY AND DISASSEMBLY
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!
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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6. ASSEMBLY AND DISASSEMBLY
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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6. ASSEMBLY AND DISASSEMBLY
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!
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6. ASSEMBLY AND DISASSEMBLY
DANGER !
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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6. ASSEMBLY AND DISASSEMBLY
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.
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.
• 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
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6. ASSEMBLY AND DISASSEMBLY
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.
Key "lift/right"
The leader is turned to the right or upwards.
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6. ASSEMBLY AND DISASSEMBLY
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.
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
WARNING!
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6. ASSEMBLY AND DISASSEMBLY
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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6. ASSEMBLY AND DISASSEMBLY
28
Position lateral adjustment kit central; the leader is
positioned parallel to the uppercarriage
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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6. ASSEMBLY AND DISASSEMBLY
29
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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6. ASSEMBLY AND DISASSEMBLY
NOTE !
See chapter 5 under "Adjusting leader height".
Key "lift/right"
Extend leader height adjusting cylinder.
Key "lower/left"
Retract leader height adjusting cylinder.
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6. ASSEMBLY AND DISASSEMBLY
30
Key "lift/open"
Extend support arm brace-support cylinder.
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6. ASSEMBLY AND DISASSEMBLY
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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6. ASSEMBLY AND DISASSEMBLY
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!
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6. ASSEMBLY AND DISASSEMBLY
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.
IMPORTANT !
Depending on the piling rig or drilling device, a cor-
responding adapter or drilling gear carriage must be
mounted.
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6. ASSEMBLY AND DISASSEMBLY
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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6. ASSEMBLY AND DISASSEMBLY
38
6 - 35
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6. ASSEMBLY AND DISASSEMBLY
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.
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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6. ASSEMBLY AND DISASSEMBLY
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.
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.
CAUTION !
Inclination of the leader with mounted torque stay rod causes damage to the machine !
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6. ASSEMBLY AND DISASSEMBLY
* 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. ASSEMBLY AND DISASSEMBLY
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 !
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6. ASSEMBLY AND DISASSEMBLY
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.
NOTE!
Operation can be resulted via the auxiliary panel or via the switch lever.
• 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
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6. ASSEMBLY AND DISASSEMBLY
Procedure
41
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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6. ASSEMBLY AND DISASSEMBLY
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
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6. ASSEMBLY AND DISASSEMBLY
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.
"Lower/close" key
Retracting the supporting arm support cylinder.
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6. ASSEMBLY AND DISASSEMBLY
NOTE !
See chapter 5 under "Adjusting leader height".
"Lift/right" key
Extend leader height adjusting cylinder.
"Lower/left" key
Retract leader height adjusting cylinder.
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6. ASSEMBLY AND DISASSEMBLY
43
"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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6. ASSEMBLY AND DISASSEMBLY
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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6. ASSEMBLY AND DISASSEMBLY
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").
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.
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6. ASSEMBLY AND DISASSEMBLY
48
Checking:
The holding arm support cylinder is fully retracted!
WARNING!
6 - 49
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6. ASSEMBLY AND DISASSEMBLY
"Lift/right" key
Extend the basic arm adjusting cylinder completely. The piling rig and drilling
device are set down on the uppercarriage.
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.
WARNING !
Risk of collision !
When turning the leader, an assistant is necessary to monitor the procedure.
Key "lower/left"
The leader is turned to the left.
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6. ASSEMBLY AND DISASSEMBLY
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.
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.
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6. ASSEMBLY AND DISASSEMBLY
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.
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6. ASSEMBLY AND DISASSEMBLY
51
6.8.5 Mounting uppercarriage locking
DANGER !
CAUTION !
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 - 55
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6. ASSEMBLY AND DISASSEMBLY
DANGER!
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 !
52
6 - 56
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6. ASSEMBLY AND DISASSEMBLY
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.
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. ASSEMBLY AND DISASSEMBLY
53
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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6. ASSEMBLY AND DISASSEMBLY
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
LRB255_V001 (mf) LWN - TD4/2/2010
CAUTION !
Remove the hydraulic hoses following application of the pin retraction device.
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6. ASSEMBLY AND DISASSEMBLY
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. ASSEMBLY AND DISASSEMBLY
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.
• 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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6. ASSEMBLY AND DISASSEMBLY
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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6. ASSEMBLY AND DISASSEMBLY
55
Lash and secure basic machine to flat bed trailer
56
Lashing flaps on the undercarriage (Figure 56, optional)
Observe the angle of the chains!
CAUTION !
WARNING !
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6. ASSEMBLY AND DISASSEMBLY
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. ASSEMBLY AND DISASSEMBLY
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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6. ASSEMBLY AND DISASSEMBLY
57
58
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6. ASSEMBLY AND DISASSEMBLY
CAUTION!
The basic machine and attachment components can be exposed to salt- water 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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6. ASSEMBLY AND DISASSEMBLY
NOTES:
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6. ASSEMBLY AND DISASSEMBLY
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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.
LRB255_V001 (mf) LWN - TD4/2/2010
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
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.
DANGER!
IMPORTANT!
More information can be found in Chapter 7 "Welding repairs".
7.1.3 Cylinder
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7. MAINTENANCE
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
6000 hrs / every 3 years
1000 hrs / half-yearly
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
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
6000 hrs / every 3 years
1000 hrs / half-yearly
every year at the start of the cold season every year at the start of the cold season
* *
8 hrs / daily
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7. MAINTENANCE
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
Special intervals
40 hrs / weekly
every year at the start of the cold season every year at the start of the cold season
* *
8 hrs / daily
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
See the lubricant table for the grease type
o Lubricate all rope pulleys in the lifting system and feed system
See the lubricant table for the grease type
o Check rope deflection pulley for tight fit
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7. MAINTENANCE
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
6000 hrs / every 3 years
1000 hrs / half-yearly
every year at the start of the cold season every year at the start of the cold season
* *
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
See the lubricant table for the grease type
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.
See the lubricant table for the grease type
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
according to WORK TO BE CARRIED OUT
operating hours
by maintenance personnel by authorized qualified personnel
x one-off task x one-off task
Special intervals
40 hrs / weekly
every year at the start of the cold season every year at the start of the cold season
* *
8 hrs / daily
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7. MAINTENANCE
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
6000 hrs / every 3 years
1000 hrs / half-yearly
every year at the start of the cold season every year at the start of the cold season
* *
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
according to WORK TO BE CARRIED OUT
operating hours
by maintenance personnel by authorized qualified personnel
x one-off task x one-off task
Special intervals
40 hrs / weekly
every year at the start of the cold season every year at the start of the cold season
* *
8 hrs / daily
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
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
6000 hrs / every 3 years
1000 hrs / half-yearly
every year at the start of the cold season every year at the start of the cold season
* *
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
according to WORK TO BE CARRIED OUT
operating hours
by maintenance personnel by authorized qualified personnel
x one-off task x one-off task
Special intervals
40 hrs / weekly
every year at the start of the cold season every year at the start of the cold season
* *
8 hrs / daily
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7. MAINTENANCE
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
6000 hrs / every 3 years
1000 hrs / half-yearly
every year at the start of the cold season every year at the start of the cold season
* *
8 hrs / daily
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7. MAINTENANCE
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
Special intervals
40 hrs / weekly
every year at the start of the cold season every year at the start of the cold season
* *
8 hrs / daily
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 pre- tension the re-tensioning is done
using the travel gear
o Check tensioning cylinders for leaks
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7. MAINTENANCE
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
6000 hrs / every 3 years
1000 hrs / half-yearly
every year at the start of the cold season every year at the start of the cold season
* *
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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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
Special intervals
40 hrs / weekly
every year at the start of the cold season every year at the start of the cold season
* *
8 hrs / daily
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7. MAINTENANCE
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
6000 hrs / every 3 years
1000 hrs / half-yearly
every year at the start of the cold season every year at the start of the cold season
* *
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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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".
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7. MAINTENANCE
WARNING!
Avoid direct contact with the fuel and/or the condensate/diesel mixture.
Risk of chemical burns and eye injuries.
DANGER!
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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.
- 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!
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7. MAINTENANCE
1 Drain plug
- Position the acid-resistant container underneath the drain opening (Figure 4, item 1).
- Open the drain plug.
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7. MAINTENANCE
NOTE
Note the maximum fill level in the container.
- Leave the drain plug open until only pure fuel runs out of the drain opening.
- Retighten the drain plug.
CAUTION!
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7. MAINTENANCE
1 Drain plug
- Position the acid-resistant container underneath the drain opening (Figure 5, item 1).
- Open the drain plug.
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7. MAINTENANCE
NOTE
Note the maximum fill level in the container.
- Unscrew the drain plug.
- Drain off the condensate/diesel mixture.
- Leave the drain plug open until only pure fuel runs out of the drain opening.
- Retighten the drain plug.
CAUTION!
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7. MAINTENANCE
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7. MAINTENANCE
CAUTION!
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7. MAINTENANCE
DANGER!
7
LRB255_V001 (mf) LWN - TD4/2/2010
1 Filter cartridge
- Loosen the fuel filter cover and unscrew together with the filter cartridge.
7 - 27
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7. MAINTENANCE
CAUTION!
WARNING!
CAUTION!
7 - 28
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LIEBHERR
7. MAINTENANCE
CAUTION!
NOTE
The system can only be bled when the ignition is turned on.
8
LRB255_V001 (mf) LWN - TD4/2/2010
7 - 29
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7. MAINTENANCE
1 Vent screws
2 Hand pump tappet
WARNING!
CAUTION!
7 - 30
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7. MAINTENANCE
CAUTION !
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!
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.
11
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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.
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7. MAINTENANCE
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
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7. MAINTENANCE
14
7.8.3 Releasing tension in the chain
WARNING !
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.
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7. MAINTENANCE
16
7.9 Swing gear / Rotary connection
NOTE !
When checking the oil level, the machine must be posi-
tioned horizontally.
17
7.9.3 Lubricating the rotary connection, ball tracks
CAUTION !
• 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
• 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.
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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.
22
7.12 Feed winch *
7.12.1 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.
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7. MAINTENANCE
23
7.13 Kelly winch *
7.13.1 Check oil level
NOTE !
To check the oil level, adjust the lead to maximum
outreach (dipstick stands vertical).
• Take out the dipstick again and check the oil level.
• The oil level must be between the MIN. and MAX.
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"
and "Lubricant requirements".
24
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7. MAINTENANCE
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!
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.
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
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.
LRB255_V001 (mf) LWN - TD4/2/2010
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7. MAINTENANCE
27
28
29
7 - 42
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7. MAINTENANCE
30
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.
31
32
LRB255_V001 (mf) LWN - TD4/2/2010
7 - 43
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7. MAINTENANCE
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.
33
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.
34
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7. MAINTENANCE
35
Troubleshooting:
..
Is there evidence of external heat damage, such as recrystallization, localized melting of steel, etc.?
Stop using the machine and if possible determine the cause of the damage.
Change the rope or pair of ropes immediately.
.
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
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?
Stop using the machine and if possible determine the cause of the damage.
Change the rope or pair of ropes immediately.
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!
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.
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).
• 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
37
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7. MAINTENANCE
Low-twist ropes
.
NOTE!
Ropes described as "low twist" vary considerably with regard to the turning moment or twist when
under stress.
WARNING!
..
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.
LRB255_V001 (mf) LWN - TD4/2/2010
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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.
Under these conditions non-twist-free ropes achieve a higher fatigue life compared with low-twist
ropes.
WARNING!
..
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
.
NOTE!
Ensure that rope drums and ropes are not damaged during storage.
CAUTION!
• 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
38
Figure 38 shows a rope drum being transported correctly (left) and incorrectly (right) on a forklift
truck.
.
NOTE!
Test templates are available in many different shapes. The best are round templates manufactured
on a lathe.
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7. MAINTENANCE
39
1 Test template
2 Winch drum
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:
7 - 53
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7. MAINTENANCE
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.
• 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.
.
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.
..
Troubleshooting:
Is the rope groove base worn by less than the rope diameter?
Replace the rope pulley.
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7. MAINTENANCE
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.
.
NOTE!
The grease must not leak from between the rope pulleys.
The position of the bearing and circlip must be correct to ensure optimum rope drive.
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7. MAINTENANCE
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.
• Clean plastic rope pulleys using a cleaning cloth and suitable cleaning agents.
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!
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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.
.
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
Troubleshooting:
.
Does the rope show signs of damage, deformation, wear, etc.?
Withdraw the rope from service and replace it with an intact one.
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.
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.
LRB255_V001 (mf) LWN - TD4/2/2010
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7. MAINTENANCE
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.
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.
.
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!
• 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:
.
Does the rope show signs of damage, deformation, wear, etc.?
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:
.
Does the rope show signs of damage, deformation, wear, etc.?
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.
WARNING!
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
Rope lock
45
1 Rope lock
2 Rope fixation
3 Intermediate connector
4 Hoisting rope
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
1 Wire clamp
2 Ferrule
3 Rope thimble
Troubleshooting:
.
Is the ferrule split or cracked?
Remove the rope immediately.
Troubleshooting:
.
Does the rope thimble show any signs of corrosion, cracks or wire breaks?
Replace the rope thimble.
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7. MAINTENANCE
47
7.15 Load hooks
The load hooks should undergo a visual inspection be-
fore beginning operation.
48
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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
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7. MAINTENANCE
CAUTION !
7 - 66
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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.
LRB255_V001 (mf) LWN - TD4/2/2010
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7. MAINTENANCE
55
7.17.2 Check oil level
• 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.
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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).
CAUTION!
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58
7.17.6 Clean the magnet plug
CAUTION!
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7. MAINTENANCE
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.
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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!
7.18.3 Batteries
CAUTION !
General
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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 .
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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61
DANGER !
Risk of accident !
Before beginning operation, check functioning of all limit
switches via careful actuation.
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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64
7.20.1 Limit switch feed
Functional inspection
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 .
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7. MAINTENANCE
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
NOTE!
For authorisation to use oils from other manufacturers, please contact:
Liebherr-Lubricant-Hotline: +49 (0) 7354/80-6060 or lubricants@liebherr.com
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)
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. MAINTENANCE
NOTE!
Any additives should be added by the fuel supplier.
Take advice from your fuel supplier or LIEBHERR Customer Services.
CAUTION!
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7. MAINTENANCE
CH-4 E4
Cl-4 E5
E6
E7
Normal climate
to -10° C up to 0.5% 250 OH 500 OH
up to [17° F] over 0.5% 125 OH 250 OH
OH...operating hours
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7. MAINTENANCE
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.
Do not use more than 60% anti-corrosive agent/anti-freeze, as the cooling effect rapidly de-
creases with higher proportions.
NOTE!
A list of manufacturers of approved anti-corrosive/anti-freeze agents is obtainable from Liebherr
Customer Services.
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7. MAINTENANCE
NOTE !
Data of all installed components, see under "Technical data" in chapter 2 of this operating manual.
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7. MAINTENANCE
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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NOTES:
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8. REPAIR WORK
8. REPAIR WORK
8.1 General
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8. REPAIR WORK
NOTE!
When changing ropes, the regulations for handling wire ropes must generally be observed (see
"Ropes" in Chapter 7).
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8. REPAIR WORK
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
8.3.2 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.
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8. REPAIR WORK
DANGER!
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.
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8. REPAIR WORK
Work distribution
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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.
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
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.
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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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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
NOTE !
Ignition start system with Liebherr engines only !
1) Engine will not Fuel tank empty Refill fuel tank and bleed fuel system
start
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
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
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
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8. REPAIR WORK
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
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
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
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8. REPAIR WORK
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
Cooling water pump faulty Check cooling water pump and repair or
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
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
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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).
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NOTES:
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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
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
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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).
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9. OPTIONS
2
Heating mode
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!
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.
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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.
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
remaining on the winch.
• 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
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.
NOTE!
The hydraulic oil heating only works if the safety lever is lowered.
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9. OPTIONS
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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While the hydraulic oil heating is active, the "Hydraulic oil temperature too low"
symbol appears in the status display of the LCD screen.
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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Refuelling pump
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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 !
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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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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External sensors
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Home screen
Kelly drilling
Job site 12.49/4
Pile number 5
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9. OPTIONS
"PDE" symbol
Tap on this symbol to go to the PDE home page.
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"Hourglass" symbol
The system is at full capacity.
"Protocol" symbol
The protocol is generated.
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Kelly drilling
Job site Nenzing
Kelly drilling
Pile number
A12.43/3
Alphanumeric keypad
(lower case including digits)
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Alphanumeric keypad
(upper case including special characters)
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9. OPTIONS
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.
Enter
Confirm input(s) from the keypad.
Shift lock
For switching the keypad between upper and lower case.
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10
"Print-out" symbol
Tap on this symbol to create the record as a print-out.
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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.
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
LRB255_V001 (mf) LWN - TD4/2/2010
- 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
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]
4. Feed speed in m/min [ft/min]
5. Amplitude * in mm [inch/100]
6. Interruption ¹
7. Concrete volume * in m³ [yd³]
8. Concrete pressure * in bar [bar]
9. Time (per PDE trigger)
Style ²
Pile diameter* cm [ft]
Total concrete volume* in m³ [yd³]
Number of pulses* (concrete pump)
Liters/pulse* (concrete pump)
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
8. Time (per PDE trigger)
Drop weight in kg [lbs]
Total blows
Total energy in kNm [ft.lbs]
Depth step in mm [ft]
The data are recorded when lowering.
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Push&Pull mode
The following data are recorded when in Push&Pull mode:
1. Depth in cm [ft]
2. Ram pressure. in bar [bar]
3. Vibrator unit [EIN/AUS]
4. Interruption ¹
5. Time (per PDE trigger)
Data are recorded while lifting and lowering.
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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.
Kelly drilling
Job site Nenzing
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9. OPTIONS
Kelly drilling
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
The real-time pile display is used as a graphic support to the double rotary drilling and CFA drilling
modes.
11
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13
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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14
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
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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16
Soil Mixing, 1
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17
Vibrator, 0
18
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Vibrator, 1
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19
Vibrator, 2
20
CFA, 0
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21
CFA, 1
22
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CFA, 2
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24
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25
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9. OPTIONS
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.
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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27
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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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.
DANGER !
29
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9. OPTIONS
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.
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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.
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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
LRB255_V001 (mf) LWN - TD4/2/2010
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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33
The floodlight on the left of the superstructure (2) can also be mounted in another corner on the
sound protection shield.
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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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.
35
The time intervals for the lubrication and break times can
be adjusted via the switch unit (fig. 35, no. 5).
CAUTION !
1 Grease container
2 Pressure relief valve
3 Grease nipple for refilling
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CAUTION!
Ensure maximum cleanliness when filling the container! Otherwise the system can easily
become blocked by dirt.
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.
CAUTION !
NOTE !
Upon completion of adjustment, replace and secure protective cover again, in order that no water
can penetrate the switch unit.
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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.
38
CAUTION!
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CAUTION!
Ensure maximum cleanliness when filling the container! Otherwise the system can easily
become blocked by dirt.
9.15.3 Function
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.
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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.
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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!
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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!
Procedure
CAUTION!
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9. OPTIONS
"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
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44
DANGER!
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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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9.21.1 General
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
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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
NOTES:
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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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NOTES:
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