General

General instruction

Table of contents

Introduction ...................................................................................................................................... 2
Rules for prevention of accidents (UVV) during repair work .............................................................. 3
Important safety indications ............................................................................................................... 3
General safety indications .................................................................................................................. 3
Indications on waste disposal ............................................................................................................ 5
Maintenance indications on exchange components ............................................................................. 5
Tightening torques, general ................................................................................................................ 6
Tightening torques for screwed plugs - ERMETO ............................................................................ 10
Tightening torques for swivelling screw-fitting - SWV ....................................................................... 12
Liquid sealing and locking adhesives ................................................................................................ 13
General graphical symbols - hydraulic .............................................................................................. 14
General graphical symbols - electric ................................................................................................ 17

-1-
General
LIEBHERR-WERK EHINGEN GMBH

Introduction
The present service manual contains technical documentations which give information about the
set-up of the crane as well as outline of components, pneumatic/hydraulic circuit diagrams with
functional descriptions and electric circuit diagrams.

This documentation refers to a Liebherr standard-type product according to the state of design
of the date of issue.

The contents of the service manual are also available as a PDF file of the LWE network LiSSy. The
service manual is also available on CD-ROM.

The service manual is subdivided into general, carrier, superstructure, telescopic boom and Liccon
test system.
For certain units (such as "Diesel engine/automatic transmission", etc.), please refer to the technical
manuals of the respective sub-suppliers.

The present documentation is intended for qualified personnel who have had a special trainig in
respect to the unit or assembly concerned!

Liebherr-Werk Ehingen GmbH do not assume responsibility for damages caused by work carried
out in an unqualified manner by non Liebherr personnel!

The same applies to replacement parts which do not comply with the attribute "Original - Lieb-
herr - Spare Part" and consequently are not included in the Liebherr guarantee.

Respect the national regulations during any maintenance and repair work!
• For Germany: prevention of accidents (UVV), see the following pages
• For other countries: country-specific regulations
• In den USA: national regulations, especially
1. OSHA (Occupational Safety and Health Administration) Regulation 1910.180 (for crawler
locomotive and truck cranes)
2. OSHA Regulation 1926.550 (for cranes and derricks)
3. ASME (American Society of Mechanical Engineers) Regulation B30.5-1994

Indications on maintenance and maintenance intervals are stipulated in the operating instructions
of the respective Liebherr mobile crane.

The present service manual is not subject to any updating service.

Issued by LIEBHERR-WERK EHINGEN GMBH

Department: After-sales service - Training (KD/VMS).

No part of this manual may be reproduced or transmitted in any form or by any means without the
prior written consent of Liebherr.

Subject to technical modifications !

-2-
General
Rules for prevention of accidents (UVV) during repair work
Important safety indications

As a matter of principle, the maintenance and repair personnel of Liebherr cranes is responsible for
their safety during work.

The observation of all applicable safety rules and legal regulations is a preriquisite for the prevention of
injuries to persons and damages to the product during maintenance and repair work.

Repair mechanics are responsible to become familiar with those rules prior to the start of work.

The appropriate repair of Liebherr products requires adequately trained specialists:

The repair mechanic is responsible for his adequate instruction.

The following safety indications are employed in the present manual:

INDICATION: Serves to indicate special working procedures, methods, information,

use of special devices, etc.

WARNING: Is employed if deviating and unqualified working manner can cause

damages to the product.

DANGER Is employed if a lack of care can lead to personal injury or mortal

danger.

Tyre-change on crane vehicles must be carried out only by authorized specialists, the same
applies to the dismounting from and mounting of the tyres on the rim.

All statically effective elements on the carrier and superstructure must be welded only by the
MANUFACTURER or by authorized specialists.

General safety indications

• Prior to the start of tests and repair work, the actual instructions must be read through exactly.

• Shown pictures, drawings and parts are not always illustrated in their original version; they are
intended for the demonstration of the working procedure.

• The figures, drawings and parts are not drawn to scale. Consequently it would be inappropriate to
draw conclusions from those concerning size and weight (even not for parts within a representation).

• The work must be carried out in accordance with the specifications.

• On completion of the repair work and tests, the specialists must satisfy themselves of the
unobjectionable functioning of the product.

-3-
General
Rules for prevention of accidents (UVV) during repair work

General safety indications

• Switch off the Diesel engine and make sure that it will not be switched on again without permission
(remove the batteries or the battery main switch).

• Do wear safe work clothes during maintenance or repair work. Besides safety helmets and
protective shoes, safety goggles and protective gloves are required for certain work.

• Do not modify the specified setting values for the pressure relief and safety valves.

• All maintenance and repair work on the travel gear, brake, steering and hydraulic systems must be
carried out by trained specialists.

• Pay attention to absolute cleanness during the replacement of fuel and oil filters:
- Remove accurately any spilled Diesel fuel or oil..
- Check the tightness of the systems by a test run.

• Check the V-chamber of the Diesel engine in respect to spilled oil and fuel, especially on completion
of repair and maintenance work, but also within regular intervals. Spilled fuel within the V-chamber
can spread within the engine compartment and catch fire at hot spots during displacement.

• Panel absorbers are installed within the engine zone of the carrier (carrier engine lining) for the
reduction of noise emissions. Those panel absorbers, on the base of glass fibre with incorporated
sound absorbing material, are not inflammable in clean condition, i.e. they are combustion impeding.
.
If the engine compartments are not regularly cleaned, spilled oil or fuel can accumulate, especially
during maintenance and repair work.
Effected panel absorbers must absolutely be removed as they have become burnable or
inflammable.The same applies to the panel absorbers within the entire zone of the exhaust gas
system. Consequently, the engine compartments must only be cleaned with non-inflammable
detergents, non aggressive to hoses and cables.

• Moreover it is pointed out that even fuel and oil hoses can embrittle or become porous over the
years due to ageing.
Hoses with a porous outside appearance must be replaced without delay.

• Do not step, under no circumstances, on pipes and hoses installed within the engine compartment
during repair and maintenance work.
This applies also to injection pipes in particular.
If stepping on the engine is unavoidable during mounting, protect the engine with a covering plate
(e.g. with a timber board).

-4-
General
Rules for prevention of accidents (UVV) during repair work

General safety indications

• For safety reasons, do employ only original spare parts for the replacement of hoses and pipes.

• Particular attention is drawn to the fact that all electric cables must be installed according to
specification and fixed by their retaining clamps.
Impaired cables must be replaced appropriately without delay.

• Be cautious when handling hydraulic oil!

• Do not leave tools or other objects behind on the carrier or superstructure.

• Set the carrier or superstructure into operation only on completion of the repair and maintenance
work when,
- the work is properly completed,

- the carrier or superstructure has been reset into safe working condition and all persons, who did
parcitipate in the work, have left the mobile crane.

• Moreover, pay attention to the following measures:

- Annual crane inspection in accordance with the regulations of the respective

countries (in Germany: Inspection according to UVV cranes „VBG9“).

- Annual crane carrier inspection (in Germany: Inspection acc. to STVZO) (motor vehicle safety
standards).

Waste disposal indications

• Engine-, transmission and hydraulic oils, lubricating greases, fuels and coolants:
- Those substances must not get into the soil, waters, sewerage, drains or ground water!

- The local regulations of the respective authorities must be observed for the disposal!

Maintenance indications on exchange components

• Pay attention to the following indications for the exchange of drive components such as Diesel
engine, transmission, axles, etc.:

- Prior to setting into operation, fill the correct oil type up to the max. mark.
(for oil type, see type plate and table of lubricants in the operating instructions)

- Perform the first maintenance according to chapter MAINTENANCE INTERVALS (in the crane
operating instructions), subsequently, the regular maintenance intervals are applicable.

• Observe the running-in specifications.

-5-
General
General tightening torques

Friction coefficient µ tot = 0,14 not lubricated

bolts and nuts without additional treatment

Shank bolts with standard metric thread to DIN 13, sheet 12

Standard strength rating 8.8 Tigthening torque

thread when using lock
Tightening torque whashers

-6-
General
General tightening torques

Friction coefficient µ tot = 0,14 not lubricated

bolts and nuts without additional treatment

Shank bolts with standard metric thread to DIN 13, sheet 12

Fine strength rating 8.8 Tigthening torque

thread when using lock
Tightening torque whashers

-7-
General
General tightening torques

Friction coefficient µ tot = 0,14 not lubricated

bolts and nuts without additional treatment

Shank bolts with standard metric thread to DIN 13, sheet 12

Standard strength rating 10.9 Tigthening torque

thread when using lock
Tightening torque whashers

-8-
General
General tightening torques

Friction coefficient µ tot = 0,14 not lubricated

bolts and nuts without additional treatment

Shank bolts with standard metric thread to DIN 13, sheet 12

Fine strength rating 10.9 Tigthening torque

thread when using lock
Tightening torque whashers

-9-
General
Tightening torques for screw-in ,unions (Ermeto)

Straight threaded unions = GE (R = inch / M = metric)

Type with edge seal Type with EOLASTIC sealing ring

Type Thread Tightening torque Type Thread Tightening tor-
M or R kpm Nm M or R que kpm Nm

- 10 -
General
Tightening torques for screw-in ,unions (ermeto)

Non-restricted swivel threaded unions = DSVW (R = inch / M = metric)

Type Shouldered screw Screw plug

Thread Torque (app.) Thread Torque (app.)

- 11 -
General
Tightening torques for swivel threaded ,unions

swivel threaded unions = SWV (R = inch / M = metric)

Type Thread Tightening torque

M or R

- 12 -
General
Liquid sealing and locking adhesives

Summary of Products
Supplier Code Colour Quantity Id.Nr.-LWE or Supplier Code Colour Quant. Id.Nr.-LWE

Loctite 243/*1 blue 50 ml 8112 057 08 or Epple 3150 50 gr

(242)

Loctite 262/*2 red 200 ml 8112 011 08 or Omnifit 100 H 200 gr

Loctite 270/*3 green 50 ml 8112 017 08 or Omnifit 200 M 50 gr

or Omnifit 200 H
Loctite 510/*4 orang 50 ml 8700 021 08 or Dirko D gray 100 gr 8700 018 08
or Hylomar SQ 32H 100 gr 8700 028 08

Loctite 572/*5 white 250 ml 8700 019 08 or Omnifit FD 10

Loctite 574/*6 green 50 ml 8112 058 08

Loctite 603/*7 green 50 ml 8112 018 08 or Epple 4150 50 gr

(601)
Loctite 638/*8 green 50 ml 8112 055 08

Loctite 640/*9 green 50 ml 8112 059 08

Loctite 648/*0 250 ml 8655 023 23

Loctite 5366*x 350 ml 8112 060 08 or Omnivisc 1050 90 gr 8627 609 23

Loctite 7063*y 400 ml 8112 061 08

Explanation:
*1 = Locking - slight to medium strength
*2 = Locking - medium strength
*3 = Locking - high strength
*4 = Surface sealing - slow hardening time
*5 = Special sealing (pipe thread)
*6 = Surface sealing - quick hardening time
*7 = Bonding - high strength/play < 0,1/slow hardening time
*8 = Bonding - high strength/play > 0,1/quick hardening time
*9 = Bonding - medium strength/play < 0,1/slow hard. time
*0 = Bonding - high strength/play < 0,1/quick hardening time
*x = Adhesive. transparent silicone compound
*y = Cleaner for clarification / degreese

Indication for the repair of Liebherr engines:

The following instructions have been modified in the workshop manual!
a) Instead of Loctite „242“, Loctite „243“ must be employed now.
b) Instead of Loctite „640“, Loctite „648“ must be employed now.
c) Instead of Loctite „601“, Loctite „5366“ or Omnivisc „1050“ must be employed now.
Furthermore, for the fitting of all sealing covers acc. to DIN 443, Loctite „648“ must be
employed now instead of Loctite „270“.

- 13 -
General
Hydraulic symbols (general)

Description Symbols Description Symbols

Pumps Valve control

Constant pump 4/2 way-valve with solenoid

1 direction of flow control and retracting spring

2 directions of flow 4/3 way-valve with hand-

control and spring centred

Variable displacement pump

1 direction of flow

2 directions of flow Parts are shown by

capital letters

example: Cutoff-valve
Motors Z - control line
P - pressure line
Constant motor R - backflow line
1 direction of flow L - leckage line

2 directions of flow

Variable motor Way valves

1 direction of flow
Possible flow into two
2 directions of flow directions

Control by hand

Cylinder Control by pressure against

reduction spring
Single action cylinder
Retraction over external force
4/2 way- valve with one air
Retraction over return spring releasing

Assembled with pre-control

valve with solenoid control
against contraction spring,
Double action cylinder detailed symbol
one sided piston rod
Simple symbol
Two sided piston rod

- 14 -
General
Hydraulic symbols (general)
Description
Pressure valves
Pressure relief valve
Valve to limit the pressure on
the input by opening on the
output against counter force
Pressure relief valve
Yet with remote control affec-
ting the counter force.
The remote control neutralizes
the counter force.
*The remote control amplifies
the counter force.
Pressure sequence valve
The input pressure is limited
the value proportional to the
control pressure.
Changeover valve
Against the spring force be-
vomes the output open to give
the way free to other devices.
Pressure regulating valve
The output pressure is kept con-
stant independent from a higher
input pressure dependent from
a higher input pressure:
without leggage
(over controls are not
equalized)
with leggage
(over controls becomes
equalized)
Symbols Description Symbols
Lock valves
Non-return valve
Locking, if output pressure is
higher as input pressure.
With counter pressure, by ex.;
spring locking if output pressure
is higher as or equal input
pressure
Remote controlled non-return
valve
locking if output pressure is
higher as input pressure, but
remote control may cancel the
locking.
locking if output pressure is
higher as or equal input pressure,
but remote control may cancel
the flow.
Flow valve
Throttle valve
Flow valve with internal re-
striction flow and pressure falls
are according to the viscosity.
Shutter valve
Valve with constant short re-
striction, flow and pressure falls
are nearly independent from the
viscosity.
Filter
Device to separate from dirt
particulars.
- 15 -
General
Hydraulic symbols (general)

Description Symbols Description Symbols

Throttle non-return valve Mechanical operation

with push button

Throttle non-return valve with
flow in one direction and throt- with spring
teling.
with a roller
P.e.; throttle adjustable

via roller with one way operat-

Heat exchanger ion (switching)

for example: unit is mechani-

cally operated via roller
Pre-heater
Device to heat the hydro-liquid for example: unit is mechani-
or air. The pointers indicate the cally operated via roller with
input of heat. one way operation (switching)

Cooler Combined operation

Device to cool the hydro-liquid.
The pointers indicate the out- with solenoid and pre-control
put of the heat. valve

without lines for cooling fluid with solenoid or pre-control

valve
with lines for cooling fluid

Quick-fitting pipe unions

- connected without return
check valves
Pressure switch - connected with open return
check valves
Device with electrical contacts.
- disconnected, with open end
They get closed or opened by
pressure. - disconnected by return check
valves (locked end)

Hydroreservoir
Flow dividing valve Storing of liquid volumes
under pressure

Slewing connection
Stop valve Pipe through-connection
for slewing

- 16 -
General
General elektrical symbols

General circuit elements

GERMAN BRITISH US/CANADIAN INTERNATIONAL
DESCRIPTION
SYMBOLS SYMBOLS SYMBOLS SYMBOLS

Resistor
or or or

with tappings

Winding, inductor or

with tappings or

Capacitor
or

with tappings

Polarized electrolytic
capacitor

Permanent magnet
Accumulator cell, battery
(long line = positive pole)
Earth (ground)

Frame or chassis

Variable in operating
state

/ = continous
- = stepwise
Variable for test

Variable under the in-

fluence of a physical
quantity linear non-linear

Spark gap

Surge diverter general

or

- 17 -
General
General elektrical symbols

General circuit elements

GERMAN BRITISH US/CANADIAN INTERNATIONAL
DESCRIPTION
SYMBOLS SYMBOLS SYMBOLS SYMBOLS

Symbol for arc-over or point

of insulation breakdown

Thermocouple

Clock

Converter, transmitter

Amplifier, general symbol

Single-phase
bridge-connected
rectifier

Fuse or or or or or or

Plug and socket device

or

Filament lamp

Discharge lamp

- 18 -
General
General elektrical symbols

Operating mechanism
GERMAN BRITISH US/CANADIAN INTERNATIONAL
DESCRIPTION
SYMBOLS SYMBOLS SYMBOLS SYMBOLS
Manual operating
mechanism new new

Foot operated
mechanism

Cam operated annotated with

mechanism C0

Pneumatic operating
mechanism new

Power operating
mechanism

new

Motor operated
mechanism

Switching
mechanism
Operating element with
automatic return on dis-
continuation of actuating
force for contactors,
relays trips
Operating coil enegized
(the arrow denotes the
oprating state, if this de-
viates from the standard
representation)

Relay with coils

acting unidirectionally

- 19 -
General
General elektrical symbols

Operating mechanism
GERMAN BRITISH US/CANADIAN INTERNATIONAL
DESCRIPTION
SYMBOLS SYMBOLS SYMBOLS SYMBOLS

Time delay for electro-

mechanic operating
elements or
or or
magnetic
drop-out delay or

delayed
pick-up or or
or

delayed
pick-up and or
drop-out

Polarized relay or or

Remanence relay or

Resonance relay or

Latching device
latched unlatched

old
Notch new
Device for time delayed old TC or T0C
operation following new T0 or T00
actuating force to right
Device for cyclic old
actuation new
with annotation
x

- 20 -
General
General elektrical symbols

Switchgear
GERMAN BRITISH US/CANADIAN INTERNATIONAL
DESCRIPTION
SYMBOLS SYMBOLS SYMBOLS SYMBOLS

Make contakt (NO) or or or or or or

old new

Break contakt (NC) or or or or or or

old new

Change-over contact or or or
or or
old new
or

Change-over contact
make-before-break or or or
old new
TC or
Time-delayed contacts: T0C
make, delayed make old new T0 or
T00
break, delayed break old new
T0 or
T00
make, delayed break old new TC or
T0C
break, delayed make old new

Contactor

old new

Triple-pole circuit
breaker. e.g. air circuit
breaker fitted with
3 thermal overcurrent old
relays and 3 electro-
magnetic overcurrent
releases

new

- 21 -
General
General elektrical symbols

Switchgear
GERMAN BRITISH US/CANADIAN INTERNATIONAL
DESCRIPTION
SYMBOLS SYMBOLS SYMBOLS SYMBOLS

Triple-pole
isolator old

new

Triple-pole old
load-break switch

new

Circuit breaker
or
or or or

Isolating
Circuit breaker

Isolating fuse

Triple-pole
fused isolator

isolating link.
change-over type

Single throw switch

manually operated

- 22 -
General
General elektrical symbols

Switchgear
GERMAN BRITISH US/CANADIAN INTERNATIONAL
DESCRIPTION
SYMBOLS SYMBOLS SYMBOLS SYMBOLS
Momentary or spring
return switches
(manualy operated)
with 1 NO contact old new

with 1 NC contact
old new

foot operated
old new

cam operated
old new

flow speed actuated

old new
pressure actuated

old new

temperature actuated
old new

liquid level actuated

old new

over/under flow speed

over/under pressure P P
over/under temperature T T
over/under liquid level Q Q L L
over/under speed n n SP SP
Examples:
Momentary switch SP
opens at overspeed
old new
Momentary switch
closes at under temper- T
ature
old new

- 23 -
General
General elektrical symbols

Valves (tubes), semiconductor elements

GERMAN BRITISH US/CANADIAN INTERNATIONAL
DESCRIPTION
SYMBOLS SYMBOLS SYMBOLS SYMBOLS

Electronics valve,
diode

Electronics valve,
triode
Single-anode
rectifier vessel
with mercury cathode
(ignitron)

Semiconductor diode
old new
Limiting diode old
new

Transistor
pnp npn
Thyristor,
general symbol
old new
Photo-resistor,
bidirectional
Photo-resistor,
unidirectional
Photo-elctronic ceil

Hall generator

- 24 -
General
General elektrical symbols

Voltage, current, frequency

GERMAN BRITISH US/CANADIAN INTERNATIONAL
DESCRIPTION
SYMBOLS SYMBOLS SYMBOLS SYMBOLS

Direct current DC

Alternating current AC

Direct or alternating
current (universal)
Undulating or rectified
current

Audio frequencies
Super audio, carrier
and radio frequncies

Supernigh frequencies
Square wave pulse
positive, negative
Single-phase A. C.
e.g. 16 2/3 Hz

3-phase A. C.
3-phase A. C.
with neutral
2-conductor D. C.

2-conductor D. C.
with neutral
Tripping devices
Thermal overload
or or
tripping device

Magnetic overcurrent
or
tripping device

Undervoltage
or UV
tripping device

Open-circuit shunt
or TC
trip coil

- 25 -
General
General elektrical symbols

Instruments and meters

GERMAN BRITISH US/CANADIAN INTERNATIONAL
DESCRIPTION
SYMBOLS SYMBOLS SYMBOLS SYMBOLS

Ammeter

Voltmeter

Douple Voltmeter

Single-phase
A. C. watthour meter

Single-phase
A. C. watthour recorder

Instrument shunt

Acoustic and visual signalling devices

Horn

Bell

Siren

Buzzer

Pilot light
indicating light

Semaphore indicator

Drop annunciator
make contact actuated
by the actuating system
make contact actuated
by the target

- 26 -
General
General elektrical symbols

Rotating machines
GERMAN BRITISH US/CANADIAN INTERNATIONAL
DESCRIPTION
SYMBOLS SYMBOLS SYMBOLS SYMBOLS

Three-phase
induction motor
with slipring rotor

Three-phase
induction motor with
squirrel cage rotor

Three-phase
induction motor with
squirrel cage rotor.
all six windings ends
brought out

Three-phase
induction motor with
squirrel cage rotor
and starting winding
in stator with capacitor

Three-phase
synchronous
generator

Three-phase
synchronous generator
with permanent magnet
excitation

Single-phase
synchronous generator
with permanent magnet
excitation

D. C. generator,
compensating and
interpole windings
arranged in symmetry
with the armature

- 27 -
General
General elektrical symbols

Rotating machines
GERMAN BRITISH US/CANADIAN INTERNATIONAL
DESCRIPTION
SYMBOLS SYMBOLS SYMBOLS SYMBOLS

D. C. series-wound
motor

D. C. generator with
permanent magnet
excitation

Three-phase
commutator motor with
shunt characteristics

Three-phase
commutator motor with
series characteristics

Repulsion motor

change-pole
squirrel-cage induction
motor with 2 separate
windings for pole
changing from 8 to 6
poles

Differential synchro
(transmitter or
receiver)

Synchro,
rotor single-phase
stator three-phase

- 28 -