Liebherr-Werk Ehingen GMBH Service Information Messages As At: December - 2006

LIEBHERR-WERK EHINGEN GMBH
Service Information Messages

as at: December - 2006
Chapter: U06 / ZF ASTronic 2302 / 2602
Crane
Contents (page 1 of 1) type Info No.
ZF-AStronic: Indications for travel mode (Crane with 1-stage transfer case) * 03 U060101e
ZF-ASTronic: Indications for checking abrasion of clutch dirk * 03 U060301e
Preventive measures for gear repair on gear replacement * 03 U060401e
Replacement indications for gear box ZF-TCTronic 2602 * 03 U060501e
ZF-ASTronic: Replace of temperature sensor in the transmission actuator * 03 U060601e
ZF-ASTronic: Indications for travel mode (Crane with 2-stage transfer case) * 03 U060602e
Remarks:
*03 re: LTM 1045/1, 1055/1, 1090/3, 1100/2 and LTM 1200/1.
LTM 1045-3.1, 1055-3.1 1090-4.1, 1095-5.1, 1100-4.1, 1100-5.1 and LTM 1100-5.2
LTM 1130-5.1, 1150-5.2, 1160-5.1, 1200-5.1, 1220-5.1 and LTM 1220-5.2.
07.11.2001 VMS/ju U060101e
ZF ASTronic gear box

Indications on clutch actuation and displacement mode
Technical description
The control system „ZF-ASTRONIC“ is the combination of an electronic-pneumatic controlled claw
gear with an automated dry clutch.
Due to the automated clutch, the clutch actuation by the driver is no longer required (no clutch pedal).
The driver has the choice of driving the crane vehicle in „All-automatic mode“ but also in „Semi-
automatic mode“ (manual displacement mode).
In order to enable a jerkless and smooth displacement of the crane, the gear control can be switched
to a special displacement program = „Manoeuvring mode“!
The handling of the 3 displacement modes is specified in the crane’s operating instructions!
Short indications on the function and operation of the 3 displacement modes:

1. All-automatic mode (automatic displacement mode)
After the start of the Diesel engine, the automatic displacement program becomes effective
by the activation of the forward displacement range . The pilot light is shining!
After the release of the parking brake and the actuation of the gas pedal, the vehicle starts moving.
The starting speed is calculated fully automatically and activated according to the start conditions.
The all-automatic displacement program determines the time and control of the respective speed.
2. Semi-automatic mode (manual displacement mode)

Should critical displacement situations require the prevention of the automatic speed change (to maintain
the speed), or to control the speeds manually, it is possible to switch over to manual displacement mode
(FP2) by pressing the displacement program key. The pilot light is shining! This intervention can be
performed at any time even during the displacement.
Also at manual displacement mode, the automatic starting speed selection remains effective.
3. Manoeuvring mode (special displacement program)

For the slow-jerkless displacement, it is possible to switch over to manoeuvring mode by pressing
the displacement mode key . The pilot light is shining!
• further indications on the manoeuvring mode, see overleaf

Keyboard unit (section) Display unit
clutch function
display (when
pilot light - ON
= clutch released)
engine speed
gear function
display
(e.g.: warning
signalCL)
-1-
Indications on clutch actuation and displacement mode U060101e
3. Manoeuvring mode (special displacement mode)

In the manoeuvring mode, the clutch does not engage entirely within a defined delay - as in the displacement
mode „FP1 and FP2“- but only after a gas pedal position of > 50%.
As within the gas pedal range from 0 % to approx.. 50 % overheating of the clutch is possible due to the permanent
slipping of the clutch, the engine speed is limited automatically to 700 1/min.
At a gas pedal position of >50 %, the engine speed is increased proportionally up to max. 1400 1/min.
Warning: • If due to excessive manoeuvring, the clutch attains its load capacity, it will
be signalized on the gear display by „CL“ (flashing)!
• If the warning signal „CL“ is active, interrupt the manoeuvring mode without
delay until the warning signal „CL“ has disappeared.
• If at active warning signal (CL), the manoeuvring mode is not interrupted,
the clutch can get damaged!
Indications on the manoeuvring mode

Examples for the displacement (manoeuvring) at manoeuvring mode „ON“ :
1. Slow „manoeuvring“ within restricted areas
2. Slow approach to and leave from parking position

3. Slow start on slopes - of up to approx. 20 %
Note: only if absolutely required!
4. Displacement at steep boom

(admissible only on even ground!)
Warning: Manoeuvring at stuck crane

vehicle is inadmissible!
-2-
Functional diagram for clutch actuation on the ZF ASTronic gear
E/A-module 2 CAN - communication
E/A-module 5 SPI
compressed-
air supply
SCI
(hand brake)
engine electronics ABV electronics
parking brake E/A-module 1
control module with
gear electronics
Diesel
engine
-3-
displ. controller
keys with function
indications ZF gear
forward (AS-Tronic)
neutral
reverse
manually: higher speed

FP 1-autom. (lamp OFF) dry clutch path
FP 2-man. (lamp ON) sensor
foot brake pedal manually:lower speed
(service brake)
keyboard unit OFF ON
Indications on clutch actuation and displacement mode
manoeuvring mode ON/OFF

0% (On = lamp ON)
valves
↑
Indication: clutch clutch
←
displ. programs actuator „off“
0 1/min At manoeuvring, the
50% = 70 - automatic clutch is not entirely operating
←
↑ 1400 1/min - manual engaged within a gas piston valves
↑ 100% range between clutch
accelerator - manoeuvring mode pedal
0% and 50%. compressed
max. engine speed „on“
(gas pedal) SPI air supply
U060101e
control electronics
13.06.2003 VMS/ju U060301e
LTM cranes with automated power-shift gear ZF-ASTronic

Checking abrasion of clutch disk
• On dismounted clutch (e.g.: during gear box repair)
Clutch disk X→ ← Measure rivet depth

- Dimension „X“ = . . . mm
Test value at new clutch disk:

= 1,5 mm (LTM 1100/1 & 1200/1)
= 1,6 mm (LTM 1045/1 & 1055/1)
= 1,7 mm (LTM 1090/3 & MK100)
Test value for worn out

Y clutch disk
= min. 0,3 mm
Fitting instruction:
During the fitting of a new clutch X→ ← Warning:
disk, slightly lubricate the hub At a rivet depth (X) of
profile (Y) with high-duty grease less than 0,2 mm, replace the
LWE - No. 861305708 or clutch disk!
Sachs - No. 4200080050!
Indication on service life (example):

• If an abrasion of approx. 50 % (0,8 mm) has been determined on a clutch disk upon
approx. 30000 km operation, it can be assumed that the clutch disk will remain operative
for another 25000 km approximately.
• Evidently, the kilometric performance stated above is no reference abrasion value for all
aforementioned crane types, as the abrasion is differing in accordance with the specific
job conditions!
Liebherr-Werk Ehingen GmbH, Kundendienst

22.09.2004 VMS/ju U060401e
LTM cranes with gear oil cooler (heat exchanger)

Preventive measures for gear repair or gear replacement
If at a gear failure (transfer case or power shift gear) metal particles or impurities are
noticeable in the gear oil, absolutely replace also the respective oil cooler!
Important indication:
At the ocasion of a gear replacement, also replace the respective oil cooler as a
matter of principle!
Equally important is the flushing of the hydr. conduits from the gear to the oil cooler
and from the oil cooler to the gear!
At a replacement of automatic or power shift gears, we again draw your attention to the
other control measures - see Service Information „U069702e“!
Fitting example - LTM 1080/1:
Pos. 1: 2
Power shift gear ZF 6WG260
Pos. 2:
Oil cooler for power shift gear
Further fitting examples:

- see page 2
Liebherr-Werk Ehingen GmbH, Kundendienst -1-

Preventive measures for gear repair or gear replacement U060401e
Fitting example - LTM 1050-70:
Pos. 1: Pos. 2:
Power shift gear ZF 6WG201 Oil cooler for power shift gear
Fitting example - LTM 1090/2:

Pos. 1: Pos. 2:
Automatic transmission Allison 4560 WTEC Oil cooler for automatic transmission
1
2 4
Pos. 3:
Drop box - gear
3 Pos. 4:
Oil cooler for drop box
Fitting example - LTM 1055/1: 2 4

Pos. 1: Pos. 2:
ZF Astronic gear Oil cooler for Astronic gear.
Pos. 3: Pos. 4:
Transfer case Oil cooler for transf. case
1

LTM 1100-5.1 (1100/2) with ZF gear box - ASTronic 2602
Replacement - gear box, complete (without Diesel engine)
18.07.2005 VMS/ju U060501e
LTM 1100-5.1(1100/2) with ZF gear box - ASTronic 2602

Replacement - gear box, complete (without dismantling of the Diesel engine)
A B
ZF 16 AS-Tronic
2602 with Intarder
tightening torque 85 Nm
clutch disk 1
tightening torque 55 Nm
clutch disk 2
pressure plate
pilot bearing load ring attachment
uncoupling bearing
uncoupling fork
clutch tappet
Important:
The following new sealings are required. clutch actuator
• pump fitting-steering (A) = O-ring (513115008)
• pump fitting-suspension (B) = O-ring (513502708)

LTM 1100-5.1 (1100/2) with ZF gear box - ASTronic 2602 U060501e
Dismantling of gear box
1. Reduce airpressure by actuating the
brake pedal several times. 1
2. Dismantle engine - gear box

cleading
3. Dismantle suction and exhaust 2

pipes 2
4. Drain coolant at pos. A into

appropriate recipient.
5. Dismantle hydr. pumps-steering (3)

and suspension (4). 3
6. Dismantle electr. cable harnesses

(carrier electrics) C
from gear box (pos. B, C and D).
B D

7. Dismantle air duct (5) and cardan
shaft (6)
.
6
5
8. Dismantle cardan shaft (6) equally

from transfer gear (7) and pull it to
the rear after dismantling of the
upper gear holders (8). 7
9. Dismantle coolant hoses (9).
10. Dismantle coolant pipes (10) incl.

holding plate (11).
11
9
10

11. Dismantle air duct (12) and clutch

actuator (13).
12. Release uncoupling lock!
- Turn engine manually until load

load ring ends (14) become
visible!
- Dismantle clutch tappet (15)!
- Release uncoupling bearing (17)

by pulling of uncoupling lever 13 12
(16), into direction direction
engine (X), press and unhook
load ring ends (14)!
14
14
17
16 15
16
13. Suspend gear box by appropriate

lifting tackle to standby crane.
Pay attention:
Attach gripping chains to the rear
of the lifting rope.

14. Unscrew bolts (18) of the engine

flywheel housing fixation
.
18 (12x)
15. Pull away gear box to the rear of

the engine until the gear drive shaft
has been pulled out of the clutch.
16. Lift gear precautiously and

simultaneously put it into oblique
position by gripping chains.

Fitting indications
Fitting of gear box in reversed order.
Important:
N
• When the clutch is replaced, equally
replace the mechan. actuation parts
(uncoupling bearing, uncoupling lever
and bearings)!
Equally replace the pilot bearing S
(in the engine flywheel)!
• Lubricate newly greasing points „S“ with

special grease
„Optimol Olista Longtime 3 EP“
(LWE Id.no. 861305708)!
Pay attention:
Do not grease sliding surface of
uncoupling bearing!
• Remove grease on hub profile of clutch

disks and only slightly lubricate with
special grease!
• Insert vis crosswise changing and then

tighten them, crosswise changing, by
(55 Nm)!
• Check whether the load ring ends (14)

are hooked onto the clutch pressure
plate!
• When gear box is fixed to the engine by 14

2 bolts, lock the load ring by fitting lever
to uncoupling bearing by pulling the un-
coupling ever (by rope loop or V-belt).
Check again whether load ring is locked
correctly!
• Fit clutch tappet (15) and clutch actuator!
• Place gear fixing bolts to the flywheel

housing and tighten them by tightening
torque (85 Nm)!
• Check oil level of gear box! 15
• Fill up coolant (only employ new mixture

of coolant)!

ZF manual transmission - ASTronic 2302 / 2602 U060601e
Transmission actuator: Replace temperature and speed sensor
14.07.2006 KD-juh1 U060601e
Automatic transmission - ZF ASTronic 2302/2602

Replace temperature / speed sensor in the transmission actuator
Tips for replacement Transmission actuator
A) Brief instructions (KD-LWE)
- see page 2 to 3
B) ZF dismantling / assembly
instructions
- see page 5 to 16
Complete replacement set
Id.no. 964024108
Single replacement parts
1 Wiring harness (1) with temperature /
speed sensor, cable plug (1a) for
displacement sensors, 2 fastening
screw (1b), 1 profile seal (1c) and
Specialty assembly grease (1d)
Id.no. 10340298
2 Flat gasket ring
Id.no. 571802208
4b
3 Profile seals
Id.no. 10340300 2
4 Flat gasket ring
with profile seal (4a) 3
and 2 bolts (4b)
Id.no. 10340299
4
Additional seals:
For crane models with ZF 16 AS-
Tronic 2602 transmissions,
4a
the following is required for
mounting the hydraulic pumps
1 O-seal (Id.no. 513115008) and
1 O-seal (Id.no. 513502708)! 1c
1b 1 1d
1a
Liebherr-Werk Ehingen GmbH, Customer service -1-
A) Brief instructions for replacement
Important Instructions:
Safety measures, setting values and installation references must be derived from the ZF
dismantling and assembly instructions!
All seals that become visible when removing and dismantling from the transmission actuator
must be replaced prior to the assembly (see ZF assembly instructions)!
1. Transmission actuator - removal Complete transmission actuator
• Compressed air system on the crane’s
chassis must be completely bled.
(activate the brake pedal several times)
• Compressed air line at the pressure

limiting valve (a) of the transmission a
actuator must be carefully assembled.
Note:
A residual air pressure still exists in
the compressed air line!
4a
c
• Remove the cable plugs (b+c)
on the transmission actuator. d
b
• After unbolting the 15
screws M8 (d), remove the transmission
actuator from the transmission. Transmission actuator (view from the top)
• The transmission actuator is installed in

reverse sequence. e
2. Exchange cable harness (1) with the
sensor 1
• Remove the upper part of the f
transmission actuator after removing the
2 screws (4a) from the lower part.
Caution
Separate the plug connections (e) and
(f) previously.
• Remove the cable duct (g).

- Unscrew the rivet heads (5 mm drill)
- loosen with screw drive
Transmis. act., bottom part (view from the bottom)
k h
g
• Remove the plug on the displacement

sensor (h)
• Dismantle the selector cylinder (k)
A) Brief instructions for replacement
2. Exchange cable harness (1) with the
sensor m
• Remove plug on displacement sensors
(m) .
- carefully lift the cover plate
• Dismantle the temperature sensor (n)

and speed sensor (r).
- Unscrew the torque screw (p)
(torque bit = T25)
- Remove the sensor with the cable from
the bracket
(s)
n p
n r
s
Assembly instructions:
Temperature sensor (n) must first
plugged into the bracket (s)!
• Remove cable harness (1) with the 1

temperature sensor, speed sensor
and sensor plug from the lower part
of the transmission actuator.
• Screw rivet pins (t) with flat-nosed pliers

and possibly remove riveting residue or
drilling chips.
• Assembly of the cable harness (1) with

sensor and plug in reverse sequence.
- also refer to ZF instructions.
Note:
Lightly grease profile seals with
specialty grease (1d).
t
• Check transmission functions on
operation-ready crane vehicle.
After start-up:
- Select test routine „47“ , see page 4
- If possible, complete test with „ZF

Testmann pro“.

Brief description of the test program
Starting prerequisites
Before the test program can be started, the following conditions
must be fulfilled:
- operating mode chassis
- ignition „ON“ (engine OFF)
Activate test program

On the keyboard unit:
- activate all 4 buttons at the same time.
Switch over between the individual tests
Count down test status
Count up test status
Start and end individual tests
start the selected test
1x end current test

2x back to the 1st test
End test program

The test program is ended via ignition OFF.
Important:
After the repair on the manual transmission (ZF ASTtronic), erase the
inactive errors in the error memory of the transmission ECU.
- Select test routine „47“.

(for engine „Off)

B) ZF dismantling / and assembly instructions
Excerpts from the ZF repair instructions 1327 751

003
Replace the transmission actuator and the cable harness with

the temperature / speed sensor and the displacement sensor
plug
dismantle transmission actuator .................................................... 6-7

attach transmission actuator .......................................................... 8-9
dismantle / attach transmission actuator top ................................ 10
dismantle / attach selector cylinder................................................ 11
dismantle cable harness with temperature / speed sensor .... 12-13

attach cable harness with temperature / speed sensor ........... 14-15

B) ZF dismantling / assembly instructions, transmission actuator removal
CAUTION
If the transmission actuator or the top of the
transmission actuator is replaced, the following
must be observed.
• Reprogram transmission actuator
• Take over vehicle parameters of the removed
transmission actuator or re-
enter.
Remove transmission actuator

________________________________________________
DANGER
Only work on the transmission actuator
when the ignition is off.
1 Switch ignition off
CAUTION
If dismantling vehicle-specific parts
(such as the fuel pump, coolant pipe,
exhaust pipe or steering pump),
contact the vehicle
manufacturer.
2 Remove the electrical connections

on the transmission actuator
_________________________________________________
DANGER
Wear safety glasses when dismantling the
compressed air line on the transmission
actuator.
Compressed air will escape!
Risk of injuries due to contaminant particles.
3 Dismantle compressed air line on the pressure

limiting valve of the transmission actuator.
4 remove 15 hex bolts M8 (74.09; 74.07) on the

transmission actuator (74.03).

B) ZF dismantling / assembly instructions, transmission actuator removal
Remove transmission actuator
CAUTION
The profile seals (/170) and pressure springs
(06.05;34.14 and 12.09) can fall into the
transmission housing.
NOTE
Both profile seals (/170) are included in sealing
set 10340300.
5 remove the transmission actuator (74.03)from

the transmission housing and note the
dimensions „a“ and „b“ for later installation.
6 Remove the pressure springs (06.05;34.14 and

12.09).
NOTE
Cover the transmission opening, otherwise, dirt may
fall into the transmission.
7 Remove seal (74.01) and clean sealing

surfaces on the transmission housing and on
the transmission actuator.
8 If sealing residue or dirt fell into the

holes of the guide bolt (06.04;34.13
and 12.08), they must be removed
and cleaned.
.
9 Remove ball pin (06.08), if
damaged.

B) ZF dismantling / assembly instructions, transmission actuator installation
Install the transmission actuator
1 If the ball pin is replaced,

moisten the thread of the ball pin (06:08) with
Loctite No. 262.
Tighten ball pin at 23 Nm.
2 Switch the piston rods (4) on the transmission

actuator in center position (neutral). The correct
position has been reached when a light
resistance is noticeable when pulling out the
piston rod (4).
3 Transmit the dimensions „a“ and „b“ of the

removed transmission actuator to the piston
rods (3 and 5).
4 Selector panel (6) and piston rod (4) must be

on top of each other (flush). Verify that the
profile seals (/170) are inserted on the
transmission actuator.
Legend
Piston rod (3) = switches the split group (GV)
Piston rod (4) = switches the basic transmission
Piston rod (5) = switches the section group (GP)
Selector panel (6) = selects the transmission gases
NOTE
Do not push the center shift rail
(06:01) too far into the transmission of the 12 gear version
otherwise the shift finger can fall
into the transmission.
Legend
12:01 Shift rail (GV)
06:01 Shift rail Basic transmission
34.01 Shift rail GP
06:08 ball pin

B) ZF dismantling / assembly instructions, transmission actuator installation
Install transmission actuator
Alternative: If the dimensions „a“ and „b“ cannot

be determined, the transmission actuator can be
assembled with the adjusting aid (34) 1x56 138 244.
In-house manufacture according to the drawing, see
specialty tools. Upon request, the tool
1x56 138 244 can also be delivered by ZF.
The piston rods (3, 4 and 5) of the transmission
actuator must be adjusted so that they contact the
adjusting aid (34). Switch the GV and GP shift rails
in the transmission in the direction of the power
take-off. Bring the center shift rail into neutral
position. Selector panel (6) and piston rod (4) must
be on top of each other (flush). Verify that the profile
seals are activated on the transmission actuator.
5 Place new seal (74.01) onto the transmission

housing.
6 Insert the guide bolts (06:04;34.13 and 12:08)

- if not yet assembled - and pressure springs
(06:05; 34.14and 12:09).
NOTE
Remove the pressure springs (06:05;34.14 and
12:09) must be equally long (approx. 50 mm).
In the event of deviations, replace pressure springs.
7 attach the transmission actuator (74.03),

the piston rods of the transmission actuator
must intermesh with the shift rails of the
transmission.The vertical ball pin (06:08) grips
into the selector panel.
CAUTION
The transmission actuator must be manually
pressed to the contact surface of the transmission.
Forceful pulling down with screws leads to damages.
8 Hex bolts M8 (74.09 and 74.07)

must be tightened at 23 Nm.
9 Connect the air line on the pressure limiting

valve of the transmission actuator.
Torque MA = 34 Nm
10 Reconnect the cable harness on the

transmission and vehicle otherwise, a function
test is not possible.
NOTE
Verify that the plugs are locked in and without
stress from tension.

B) ZF dismantling / assembly instructions, transmission actuator top removal and
attachment
Dismantle top part
NOTE
Seal set 10340299 contains the two
screws (/150-1), the flat seat (/150-2) and
the profile seal (/150-3).
Caution
Record the data on the model tag, they
are needed for replacement parts orders and
correspondence.
1 Remove both screws (/150-1).
2 Lift the top (/110) on the pressure limiting valve

(/180) and carefully place with both
cover plates (1) sideways into the grooves* (2).
Unplug the plug connections (7 and 8).
3 Remove the profile seals (/150-3).
4 Remove seal (/150-2) and clean sealing

surfaces.
Assemble top part
1 Insert the profile seals (/150-3).
2 Place seal (/150-2) onto the bottom part

(/130).
3 Reproduce plug connections (7 and 8).

. Also verify solid and correct seating of the
plug connections.
4 Place top part (/110) onto bottom part (/130).

Verify that the flat seal
(/150-2) does not shift, stabilize, if necessary.
Thetwo screws (/150-1) must be tightened at
9.5 Nm.
Liebherr-Werk Ehingen GmbH, Customer service - 10 -

B) ZF dismantling / assembly instructions, transmission actuator selector cylinder
removal and attachment
NOTE
The repair set 10340298 contains
a profile seal (29) for the selector cylinder (28).
Dismantling
1 Carefully life the cover plate and remove the

plug (26) from the sensor contact.
2 Remove three hex bolts (27).
3 Remove selector cylinder (28) and remove

profile seal (29).
4 Inspect parts and replace, if necessary.
Attachment
NOTE
Grease sealing and friction surfaces with
Uni-Silicon GLK 112.
1 Insert profile seal (29) on the bottom part

of the transmission actuator (/130).
2 Place complete selector cylinder (28) on the

transmission actuator’s bottom part (/130)
and tighten the three hex bolts (27) at 23 Nm.
3 Place plug (26) on the sensor contacts.

B) ZF Dismantling / assembly instructions, replace cable harness with temperature
and speed sensor
Dismantale cable harness (speed sensor
and temperature sensor)
In repair kit 10340208, cable harness

(temperature and speed sensor) and two self-
cutting screws with washers are
included.
1 Dismantle top part

(refer to page 11)
2 Carefully lift the cover plate and remove

the plug (26) from the sensor contact (34).
3 Remove the torque bolts (48).
NOTE
Remove the screw head (48) T25
4 transmission speed sensor (50) with spacer

and temperature sensor (51) from the holder
of the cylinder cover (58).
5 Remove the cable from the hinge socket (52).

and speed sensor
Dismantale cable harness (speed sensor
6 Unscrew the rivet heads (drill diameter

approx. 5 mm).
Remove the cable harness from
the transmission actuator’s
bottom part.
7 Unscrew the rivet shaft with

flat-nosed pliers.
8 Remove rivet residue and drilling chips.

and speed sensor
Attach cable harness (speed sensor and temperature
sensor)
1 Attach the cable harness (64) with two

self-cutting
Attach threaded screws (65) on the lower
part of the transmission actuator.
Torque MA = 2.2 Nm
64
2 Insert the spacer on the speed sensor (50)

into the groove on the temperature sensor
(51).
3 Insert these parts with the O-seal (49) in

the holder of the cylinder cover (58).
4 Tighten bolt (48) at 6 Nm.
5 Insert the sensor cable in the bracket (52).

and speed sensor
Attach cable harness (speed sensor
6 Install the cable free of kinks, abrasions

and jamming behind the rib (53).
7 Connect the plug (26) on the sensor

contacts (34).
8 Attach top part.

(refer to page 11)
9 Connect the plug (21) on the sensor

contacts (24).


18.12.2006 VKD-juh1 U060602e
ZF ASTronic transmission (for cranes with 2-stage transfer case)

Short notes for function and operation of the 3 travel modes:
(For operating instructions for the 3 travel modes, refer to crane operating instructions)
1. Full automatic operation (Automatic travel mode)
After starting the Diesel engine, with activation of the forward travel range , the
automatic travel program (FP1) becomes active. The indicator light lights up!
After releasing the parking brake and pressing down on the gas pedal, the vehicle starts to
move. The start out gear is calculated and placed fully automatically, depending on the start
out conditions (momentum regulation). The fully automatic travel program determines
at which point in time which gear is switched.
2. Semi automatic operation (manual travel mode)

If it is desired to prevent the automatic gear change in case a critical travel situation occurs,
(retain gear) or to switch the gears manually, press the travel program key to switch to
manual travel mode (FP2) .
The indicator light lights up!
This can also be done at any time during travel.
The automatic start out gear selection is retained, even in manual travel mode.
3. Maneuvering mode (special travel program)

Important:
Maneuvering mode is only possible if the off road gear is turned on!
- With the crane vehicle in parking position, change to off road gear by pressing the travel
program key . The indicator light lights up!
Add maneuvering mode
- Select travel direction (forward) by pressing the key . The indicator light lights up!
- With key switch down to 1st gear - maneuvering mode is turned on !
(Turn on check - see also display unit)
Turn the maneuvering mode off: With key shift up to 2nd gear.
• for additional important notes regarding maneuvering mode, see reverse page
Control unit (for example: Maneuvering mode) Display unit
Neutral Indicator light - On
Forward = Clutch not 100%
Reverse closed! (in
maneuvering mode,
FP 1-Automatic (light - off) light is always ON)
Manual: gear - shift up Engine RPM
FP 2-Manual (light - on)
Off road gear - On/Off Gear function
(On = light -On) display (Maneuvering
Manual: Gear- shift down mode in 1st gear -
(1st gear = maneuvering mode) added!)

Notes for using clutch and for travel operation U060602e
(for cranes with 2-stage transfer case)
3. Maneuvering mode (special travel program)
In maneuvering mode, the clutch does not close completely within a defined time period - as in
travel program „FP1 and FP2“!
The clutch is only fully (100%) closed at maximum travel pedal position (100%) !
Closing the clutch in maneuvering mode occurs in direct relationship to the travel pedal position.
With a slight movement of the travel pedal (for example approx. 10%) the clutch is only applied
slightly (approx. 20%) and transfers only a small drive momentum at slipping clutch. Depending
on the travel resistance of the vehicle, this drive momentum can already be sufficient to move the
vehicle. With increasing actuation of the travel pedal, the clutch is closed further and the
transferred drive momentum is therefore also increased.
For an unchanged travel resistance of the vehicle, this means:
• the difference RPM between engine and clutch (slipping of clutch) and therefore the heat
entry into the clutch becomes less, the load on the clutch is reduced !
• the travel speed increases.
For increased travel resistance (for example maneuvering at a slight incline, on gravel, etc.) the
travel pedal must be pressed down significantly further (approx. 30 – 40%) so that the drive
momentum is sufficient to move the vehicle, i.e. the heat input into the clutch is increased
quicker.
Important notes:
a) Slow maneuvering (travel pedal position at less than approx. 50% or at engine RPM
of approx. 700 RPM) should only be used if absolutely required!
b) Carry out maneuvering , if possible, only with a travel pedal position
of approx. 50% to approx. 100% or engine RPM of approx. 800 RPM to 1400 RPM!
Example: LTM 1045-3.1 / 1055-3.1
clutch in maneuvering (%)

engine RPM
travel pedal (%)

Caution: • If the clutch reaches its load limit during extended maneuvering, then
this is reported on the display on Gear display with „CL“ (blinking) !
• If the warning „CL“ is active, then maneuvering must be stopped
until the warning „CL“ has turned off again.
• If maneuvering is not stopped at active warning (CL),
then the clutch may be damaged!
Caution:
Select maneuvering mode only if
absolutely necessary!
Caution: Maneuvering is prohibited if
the crane vehicle is stuck!

Liebherr-Werk Ehingen GMBH Service Information Messages As At: December - 2006

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Liebherr-Werk Ehingen GMBH Service Information Messages As At: December - 2006

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Service Information Messages

ZF ASTronic gear box

Short indications on the function and operation of the 3 displacement modes:

2. Semi-automatic mode (manual displacement mode)

3. Manoeuvring mode (special displacement program)

• further indications on the manoeuvring mode, see overleaf

3. Manoeuvring mode (special displacement mode)

Indications on the manoeuvring mode

2. Slow approach to and leave from parking position

4. Displacement at steep boom

Warning: Manoeuvring at stuck crane

manually: higher speed

manoeuvring mode ON/OFF

LTM cranes with automated power-shift gear ZF-ASTronic

Clutch disk X→ ← Measure rivet depth

Test value at new clutch disk:

Test value for worn out

Indication on service life (example):

Liebherr-Werk Ehingen GmbH, Kundendienst

LTM cranes with gear oil cooler (heat exchanger)

Fitting example - LTM 1080/1:

Further fitting examples:

Liebherr-Werk Ehingen GmbH, Kundendienst -1-

Fitting example - LTM 1090/2:

Fitting example - LTM 1055/1: 2 4

Liebherr-Werk Ehingen GmbH, Kundendienst -2-

18.07.2005 VMS/ju U060501e

LTM 1100-5.1(1100/2) with ZF gear box - ASTronic 2602

pilot bearing load ring attachment

Liebherr-Werk Ehingen GmbH, Kundendienst -1-

2. Dismantle engine - gear box

3. Dismantle suction and exhaust 2

4. Drain coolant at pos. A into

5. Dismantle hydr. pumps-steering (3)

6. Dismantle electr. cable harnesses

Dismantling of gear box

8. Dismantle cardan shaft (6) equally

9. Dismantle coolant hoses (9).

10. Dismantle coolant pipes (10) incl.

Liebherr-Werk Ehingen GmbH, Kundendienst -3-

Dismantling of gear box

11. Dismantle air duct (12) and clutch

12. Release uncoupling lock!

- Turn engine manually until load

- Dismantle clutch tappet (15)!

- Release uncoupling bearing (17)

13. Suspend gear box by appropriate

Liebherr-Werk Ehingen GmbH, Kundendienst -4-

Dismantling of gear box

14. Unscrew bolts (18) of the engine

15. Pull away gear box to the rear of

16. Lift gear precautiously and

Liebherr-Werk Ehingen GmbH, Kundendienst -5-

• Lubricate newly greasing points „S“ with

• Remove grease on hub profile of clutch

• Insert vis crosswise changing and then

• Check whether the load ring ends (14)

• When gear box is fixed to the engine by 14

• Fit clutch tappet (15) and clutch actuator!

• Place gear fixing bolts to the flywheel

• Fill up coolant (only employ new mixture

Liebherr-Werk Ehingen GmbH, Kundendienst -6-