1250HC

Volume 1:
Betriebsanleitung
Instruction manual
Manuel d'instruction
Unfallverhütungsvorschriften für Turmdrehkrane
Crane accident prevention regulations
Règlement de prévention des accidents pour les grues
HV-Schraubverbindungen
High-tensile bolt connections
Assemblages par boulons à h.r.
Stromlaufpläne
Wiring diagrams
Schémas électriques
Anleitung zum Klettern
Climbing instruction
Instruction de télescopage
Bedienungsanleitung für den Kranführer
Operating manual for the crane operator
Manuel de conduite pour le grutier
Volume 2:
Ersatzteilliste
Spare parts list
Liste des pièces de rechange
Handbuch für - Turmdrehkrane
Manual for tower cranes
Manuel pour grues à tour
ABB Schalt- und Steuerungstechnik
Advant Controller 31
Intelligent Decentralized Automation System
Danfoss
VLT®AutomationDrive FC 302
en Instruction Manual
Tower crane
1250 HC 40
1250 HC tower standard
Serial No.: 49516

Manufacturer
Liebherr-Werk Biberach GmbH
88400 Biberach
Republic of Germany
Product identification
Product group: Tower crane
Type: 1250 HC 40
Variant: -
Serial No.: 49516
Year of construction: 2011
Conformity:
Document identfication
Issued: 07.11 en
Compiled by: TB-KT/Dokumentation
LBC/en/01/Issued: 07.11
1250 HC 40/49516
en Instruction Manual
Tower Crane
1250 HC 40
1250 HC tower system
Werk-Nr.: 49516
Manufacturer
88400 Biberach
Republic of Germany
Product identification
Product group: Tower Crane
Type: 1250 HC 40
Variant: -
Serial No.: 49516
Year of construction:
Conformity:
Document identfication
Issued: 07.11 en
Compiled by: TB-KT/Dokumentation
1250 HC 40/49516
Fundamental Notes
Observing the operating instructions

These operating instructions have been compiled to enable the operator to operate the crane safely
and to benefit fully from the application possibilities available.
– Read the operating instructions thoroughly, paying particular attention to the notes on safety.
– It is the responsibility of the crane operator to ensure that all personnel involved with the crane
have read and fully understood these operating instructions.
– Ensure that the operating instructions are always stored safely at the application site of the crane.
They must be accessible at all times to personnel involved with the crane.
– Ensure that the operating instructions are maintained in a legible condition.
– Always pass on the operating instructions to each subsequent owner of the crane.
Additional documentation and instruction

The operating instructions are a part of the overall documentation. Observe all enclosed documenta-
tion and instructions, in particular the Corner pressures, foundation loadings, ballast data.
Note also the valid rules and regulations for accident-prevention and environmental protection for the
respective application site. If you should receive any other information from us regarding the crane,
for example in the form of technical information letters, these notes are also to be observed and ad-
ded to the operating instructions.
Contact
Should further information be required regarding this crane, please contact:
Postfach 1663
D-88396 Biberach
Our After-Sales-Service can be contacted as follows:
Tel.: +49 (0) 7351 41 20 00
Fax.: +49 (0) 7351 41 27 27
Technical After-Sales-Service: tkd.service@liebherr.com
Spare-parts sales: evk.service@liebherr.com
Liebherr on the internet: http://www.liebherr.com
For any queries regarding stability, please apply directly to the Statical Data Department:
Tel: +49 (0) 7351 41 29 07
Fax: +49 (0) 7351 41 28 79

e-mail: statik.lbc@liebherr.com
For any queries regarding the documentation, please apply directly to the Technical Documentation
Department:
Tel: +49 (0) 7351 41 22 28
Fax: +49 (0) 7351 41 22 49
e-Mail: doku.lbc@liebherr.com
1250 HC 40 / 49516 1-1

Instruction Manual
Copyright
Passing on or copying of these operating instructions is prohibited, unless expressly authorised. Con-
travention of these stipulations places you under obligation of damage compensation. All rights in ac-
cordance with copyright laws remain reserved.
Symbols in the operating instructions

Danger!
This symbol indicates the threat of immediate danger. Negligence of the notes on danger can result
in serious physical injury or fatalities
Warning!
This symbol indicates a possibly dangerous situation. Negligence of the warnings can result in se-
rious physical injury or fatalities
Caution!
This symbol indicates the possible occurrence of damage. Negligence of these notes can result in
damage to surrounding buildings or harm to the environment.
Note
The symbol indicates user tips and particularly useful information.
– This symbol indicates a listing.
X This symbol means: „Carry out this task“.
This symbol means: „Prerequisite must be fulfilled“.
ª This symbol means: „Subsequent to task“.
Symbols in the pictures
Danger symbols
General danger symbol Danger resulting from electrical energy
Tab. 0-1 Danger symbols
1-2 1250 HC 40 / 49516

Instruction Manual
Danger symbols
Danger of crushing within slewing range of the Danger of crushing
crane
Danger resulting from swinging loads Danger resulting from battery acid
Danger resulting from spur gear running when Danger of falling

exposed
Danger resulting from instability Danger resulting from hydraulics becoming rup-
tured
Tab. 0-1 Danger symbols
Regulatory signs
Wear protective gloves! Wear a safety helmet!
Put on a safety harness! Close trapdoors!
Keep environment clean! Observe the wind conditions!

Tab. 0-2 Regulatory signs
1250 HC 40 / 49516 1-3

Instruction Manual
Further symbols
Direction of manual Correct!
turning
Direction of move- Incorrect!

ment for crane part
Movement stops! Check!
Order of operational Order of individual

stages task stages
Clean! Fill in oil!
Location of grease Check oil level!

nipple
Carry out lubrication! Do not use any lubri-

cant. Keep free of
grease and oil!
Tightening torque Observe the weight

details!
Tab. 0-3 Further symbols

1-4 1250 HC 40 / 49516

Instruction Manual
Table of contents
1 Notes on Safety .................................................................................................................... 1-1

1.1 Avoiding dangers ......................................................................................................... 1-1
1.2 Intended use ................................................................................................................ 1-1
1.3 Personnel qualification ................................................................................................. 1-2
1.4 Particular dangers ........................................................................................................ 1-2
1.4.1 Risk of instability .............................................................................................. 1-2
1.4.2 Danger of crushing........................................................................................... 1-2
1.4.3 Danger resulting from damaged ropes ............................................................ 1-2
1.4.4 Dangers resulting from copied Liebherr crane parts........................................ 1-2
1.4.5 Dangers resulting from electrical energy ......................................................... 1-3
1.4.6 Dangers resulting from hydraulic energy ......................................................... 1-3
1.4.7 Danger of harming the environment ................................................................ 1-3
2 Technical description .......................................................................................................... 2-1

2.1 General assembly arrangement................................................................................... 2-2
2.1.1 Special features of the 1250 HC series ........................................................... 2-2
2.1.2 Counter-jib short for 53,1 m and 41,5 m jib...................................................... 2-3
2.1.3 Counter-jib long for 82,1 m, 76,3 m and 64,7 m jib.......................................... 2-4
2.1.4 Slewing platform with tower head .................................................................... 2-5
2.1.5 Jib .................................................................................................................... 2-6
2.1.6 Tower system................................................................................................... 2-8
2.2 Components............................................................................................................... 2-11
2.2.1 Undercarriage 1250 HC ................................................................................. 2-11
2.2.2 Foundation anchors 630 EC-H ...................................................................... 2-12
2.2.3 Foundation anchors 1250 HC ........................................................................ 2-12
2.2.4 Foundation anchors 500 HC .......................................................................... 2-12
2.2.5 Base tower section 1250 HC ......................................................................... 2-12
2.2.6 Tower section 1250 HC ................................................................................. 2-13
2.2.7 Tower section 1250 HC ................................................................................. 2-13
2.2.8 Erection platform for the 1250 HC tower........................................................ 2-13
2.2.9 Climbing equipment for the 1250 HC tower ................................................... 2-13
2.2.10 Ball slewing ring support for the 1250 HC tower............................................ 2-14
2.2.11 Upper part of crane ........................................................................................ 2-14
2.2.12 Control system 1250 HC................................................................................ 2-15
2.2.13 Rope list ......................................................................................................... 2-16
2.2.14 Hoist gear....................................................................................................... 2-18
2.2.15 Slewing gear .................................................................................................. 2-19
2.2.16 Trolley travel gear .......................................................................................... 2-20
2.2.17 Cabin.............................................................................................................. 2-21
2.2.18 Electrical equipment....................................................................................... 2-23
LBC/en/Issued: 07.11
3 Specifications ....................................................................................................................... 3-1

3.1 Complete crane ............................................................................................................ 3-2
3.1.1 Lifting capacity ................................................................................................. 3-2
3.2 Components................................................................................................................. 3-8
3.2.1 Hoist gear......................................................................................................... 3-8
3.2.2 Slewing gear .................................................................................................. 3-11
3.2.3 Trolley travel gear .......................................................................................... 3-12
1250 HC 40 / 49516 I
Table of contents Instruction Manual
3.2.4 Electrical connection data .............................................................................. 3-13

3.2.5 Current data ................................................................................................... 3-14
3.2.6 Power set / autotransformer........................................................................... 3-14
3.3 Ambience / Climatisation ............................................................................................ 3-15
3.3.1 Mains power supply, ambient and storage conditions for top-slewing cranes 3-15
3.3.2 Climate control for switch cabinets................................................................. 3-16
3.4 Criteria for the auxiliary crane .................................................................................... 3-18
3.4.1 Crane configuration 1250 HC on 1250HC tower............................................ 3-18
3.4.2 Crane configuration 1250 HC on 1250HC tower and 630EC-H foundation anchors
3-24
4 Corner pressures, foundation loadings and ballast data ................................................. 4-1

4.1 Foundation reaction forces........................................................................................... 4-2
4.1.1 General notes on safety for foundation loading tables..................................... 4-2
4.1.2 Initial use of the crane ...................................................................................... 4-4
4.1.3 Foundation reaction forces according DIN15019/DIN1055-4:1986 ................. 4-5
4.1.4 Counterballast ................................................................................................ 4-41
4.1.5 Counter-ballast arrangement ...................................................................... 4-42
4.1.6 Counterballast block „A“ with steel ballast frame ........................................... 4-44
4.1.7 Counterballast block „A“ with steel ballast frame ........................................... 4-45
5 Preparing for application of the crane................................................................................ 5-1

5.1 Safe distances.............................................................................................................. 5-2
5.1.1 Safe distance to high-voltage power cables..................................................... 5-2
5.1.2 Safe distance to parts in the immediate vicinity ............................................... 5-3
5.1.3 Safe distance between tower cranes ............................................................... 5-4
5.2 Preparing the foundation .............................................................................................. 5-5
5.2.1 Foundation pit for foundation anchors.............................................................. 5-5
5.2.2 Foundation slabs for the undercarriage ........................................................... 5-6
5.3 Foundation ................................................................................................................... 5-8
5.4 Rail tracks for rail-going cranes .................................................................................... 5-9
5.4.1 Prerequisites for laying rail tracks .................................................................... 5-9
5.4.2 Rail recommendation ....................................................................................... 5-9
5.4.3 Rails on concrete sleepers............................................................................. 5-10
5.4.4 Rails on concrete strip foundation.................................................................. 5-11
5.4.5 Rails on steel supports................................................................................... 5-12
5.4.6 SRS-crane rail track system........................................................................... 5-13
5.4.7 Track end protection ...................................................................................... 5-14
5.4.8 Rail for travel limit switch................................................................................ 5-14
5.4.9 Installation tolerances for crane rail tracks in accordance with VDI 3576 ...... 5-15
5.4.10 Laying rail tracks in curve............................................................................... 5-18
5.5 Lightning protection / protection against electrostatic charge .................................... 5-19
5.5.1 Fundamental notes ........................................................................................ 5-19
5.5.2 Earthing measures for rail-going cranes ........................................................ 5-19
5.5.3 Earthing measures for stationary cranes ....................................................... 5-20
5.6 Electrical connection .................................................................................................. 5-21
5.6.1 Regulations .................................................................................................... 5-21
5.6.2 Protective measures on the construction site ................................................ 5-21
5.6.3 Electrical connection to the site junction box ................................................. 5-22
6 Erection ................................................................................................................................. 6-1

6.1 Notes on safety for erection ......................................................................................... 6-2
6.1.1 Who is permitted to erect the crane? ............................................................... 6-2
6.1.2 Under which conditions may erection be carried out? ..................................... 6-2
6.1.3 Which personal protective equipment must be worn? ..................................... 6-2
6.1.4 Which additional guidelines must be observed? .............................................. 6-2
6.1.5 Which dangers are resulted from the crane? ................................................... 6-3
II 1250 HC 40 / 49516
Instruction Manual Table of contents
6.2 Fundamental notes on erection.................................................................................... 6-4

6.2.1 Tower connecting material............................................................................... 6-4
6.2.2 Slewing ring connecting material ..................................................................... 6-9
6.3 Preparing for erection................................................................................................. 6-12
6.4 Mounting the guardails............................................................................................... 6-13
6.4.1 Handrail system (variable) ............................................................................. 6-13
6.4.2 Handrail system (welded) .............................................................................. 6-19
6.5 Installing the crane base ............................................................................................ 6-22
6.5.1 Installing the reinforced base tower section................................................... 6-22
6.5.2 Preparing the base tower section for installation ........................................... 6-35
6.5.3 Preparing the tower section for installation .................................................... 6-39
6.5.4 Preparing the tower section for installation .................................................... 6-41
6.5.5 Foundation anchor ......................................................................................... 6-53
6.6 Mounting the tower sections without climbing equipment .......................................... 6-72
6.6.1 Installing the erection platforms (optional ) ................................................... 6-72
6.6.2 Installing the base tower section.................................................................... 6-73
6.6.3 Installing the tower section............................................................................. 6-76
6.6.4 Installing the pin connections on tower sections............................................ 6-81
6.6.5 Dismantling the erection platform .................................................................. 6-82
6.6.6 Installing additional tower sections ................................................................ 6-83
6.6.7 Hooking the power supply cable onto the tower ............................................ 6-84
6.7 Mounting the slewing platform and tower head.......................................................... 6-86
6.7.1 Installing the slewing assembly with roller slewing ring support .................... 6-86
6.7.2 Installing the pre-assembled cabin on the slewing platform .......................... 6-90
6.7.3 Installing the slewing assembly with roller slewing ring support .................... 6-91
6.7.4 Preparing the tower head for installation ....................................................... 6-92
6.7.5 Installing the tower head .............................................................................. 6-100
6.8 Mounting the counter-jib........................................................................................... 6-104
6.8.1 Counter-jib guying........................................................................................ 6-104
6.8.2 Preparing the counter-jib for installation ...................................................... 6-117
6.8.3 Installing the counter-jib ............................................................................... 6-126
6.8.4 Mounting the jib............................................................................................ 6-133
6.8.5 Jib assembly ................................................................................................ 6-133
6.8.6 Preassembling jib......................................................................................... 6-140
6.8.7 Mounting jib section 1 to the slewing platform ............................................. 6-161
6.8.8 Hooking jib section 1 into the guying ........................................................... 6-163
6.8.9 Installing the A-ballast slab .......................................................................... 6-166
6.8.10 Mounting the tie rod and hooking jib section 1 into the guying .................... 6-170
6.8.11 Installing the counterweight ......................................................................... 6-171
6.8.12 IMounting the trolley travel ropes................................................................. 6-172
6.8.13 Rope reeving on the trolley travel gear ........................................................ 6-173
6.8.14 Rope reeving trolley travel rope 2 „long“...................................................... 6-174
6.8.15 Rope reeving trolley travel rope 1 „short“..................................................... 6-178
6.8.16 Applying tension to the trolley travel ropes .................................................. 6-181
6.8.17 Securing the trolley ...................................................................................... 6-182
6.9 Mounting the hoist rope............................................................................................ 6-183
6.9.1 Reeving the hoist rope in the tower head .................................................... 6-185
6.9.2 Reeving the hoist rope in the jib heel piece ................................................. 6-186
6.9.3 Reeving the hoist rope in the trolley............................................................. 6-187
6.9.4 Mounting the hoist rope at the twist compensator ....................................... 6-191
6.10 Preparing crane for 4-fall / 2-fall operation ............................................................... 6-193

6.10.1 4-fall operation ............................................................................................. 6-194
6.10.2 2-fall operation ............................................................................................. 6-198
6.10.3 Converting from 4-fall to 2-fall operation / from 2-fall to 4-fall operation ...... 6-201
6.11 Installing the aircraft warning system and wind measuring system (optional) ........ 6-202
6.11.1 Installing the aircraft-warning system........................................................... 6-202
6.11.2 Dismantling the anemometer ....................................................................... 6-203
6.11.3 Setting the sensors (potentiometer)............................................................. 6-204
1250 HC 40 / 49516 III

6.11.4 Setting the overload protection system ........................................................ 6-208

6.11.5 Preparing for initial start-up .......................................................................... 6-210
6.12 Climbing the crane ................................................................................................... 6-211
7 Climbing the crane ............................................................................................................... 7-1
8 Operation............................................................................................................................... 8-1
8.1 Notes on operational safety.......................................................................................... 8-2
8.1.1 Who is permitted to operate the crane? ........................................................... 8-2
8.1.2 Under which conditions may the crane be operated? ...................................... 8-2
8.1.3 For the contractor:............................................................................................ 8-2
8.1.4 For the crane operator: .................................................................................... 8-3
8.1.5 Operating instructions ...................................................................................... 8-4
8.1.6 Safe distance to obstacles in the immediate vicinity ........................................ 8-6
8.1.7 Safe distance between tower cranes ............................................................... 8-7
8.1.8 Safe distance to overhead electric lines........................................................... 8-7
8.1.9 Measures to be taken if contact is made with live overhead electric lines ....... 8-8
8.1.10 Weathervaning ................................................................................................. 8-9
8.1.11 Safety plates .................................................................................................. 8-10
8.1.12 Information plates........................................................................................... 8-12
8.2 Control and operating elements ................................................................................. 8-13
8.2.1 A summary of all operating elements............................................................. 8-13
8.2.2 Radio remote-control desk (optional) ............................................................. 8-14
8.2.3 Control stand in the cabin (optional) .............................................................. 8-16
8.2.4 Electrical free jib slewing / Emergency-Stop control box ............................... 8-21
8.2.5 Slewing........................................................................................................... 8-25
8.2.6 Manoeuvring the trolley.................................................................................. 8-26
8.2.7 Lifting and lowering the hook ......................................................................... 8-27
8.2.8 Travelling with the crane ................................................................................ 8-28
8.3 Operation.................................................................................................................... 8-29
8.3.1 Pre-start checks ............................................................................................. 8-29
8.3.2 Starting up the crane...................................................................................... 8-30
8.3.3 Shutting down the crane ................................................................................ 8-34
8.3.4 Setting down the load in the event of power failure ....................................... 8-39
8.4 4-fall / 2-fall operation................................................................................................. 8-40
8.4.1 Converting from 4-fall to 2-fall operation ........................................................ 8-40
8.4.2 Converting from 2-fall to 4-fall operation ........................................................ 8-45
8.5 Operational faults ....................................................................................................... 8-50
9 Maintenance and inspection ............................................................................................... 9-1

9.1 Notes on safety for maintenance.................................................................................. 9-2
9.1.1 Safety via regular maintenance........................................................................ 9-2
9.1.2 Who is permitted to carry out maintenance and inspection? ........................... 9-2
9.1.3 Safety measures .............................................................................................. 9-2
9.1.4 Which personal protective equipment must be worn? ..................................... 9-2
9.1.5 Which additional guidelines must be observed? .............................................. 9-2
9.1.6 Which dangers are resulted from the crane? ................................................... 9-2
9.1.7 Notes on safety for maintenance tasks on the brakes ..................................... 9-3
9.1.8 Fundamental notes on maintenance for brakes............................................... 9-5
9.1.9 Essential maintenance instructions for hydraulic braking systems .................. 9-7
9.2 Maintenance and inspection chart................................................................................ 9-8
9.3 Inspection tasks.......................................................................................................... 9-10
9.4 Hoist gear ................................................................................................................... 9-11
9.4.1 Checking correct functioning of the hoist gear brake ..................................... 9-11
9.4.2 Inspection tasks on the hoist gear.................................................................. 9-11
9.4.3 Lubrication tasks at the hoist gear ................................................................. 9-11
9.4.4 Inspecting the telescope power supply lines for wear.................................... 9-12
IV 1250 HC 40 / 49516
Instruction Manual Table of contents
9.4.5 Analysing / changing gear oil ......................................................................... 9-13

9.4.6 Checking the brake callipers.......................................................................... 9-16
9.4.7 Analysing / replacing the hydraulic oil............................................................ 9-18
9.4.8 Cleaning tasks ............................................................................................... 9-21
9.5 Slewing gear .............................................................................................................. 9-22
9.5.1 Check functioning of the slewing gear brake ................................................. 9-22
9.5.2 Inspection tasks at the slewing gear .............................................................. 9-22
9.5.3 Lubrication tasks on the slewing gear............................................................ 9-23
9.5.5 Cleaning tasks ............................................................................................... 9-25
9.6 Trolley travel gear ...................................................................................................... 9-26
9.6.1 Checking functioning of the trolley travel gear brake ..................................... 9-26
9.6.2 Inspection tasks at the trolley travel gear....................................................... 9-26
9.6.3 Lubrication tasks on the trolley travel gear motor .......................................... 9-26
9.6.5 Cleaning tasks ............................................................................................... 9-29
9.7 Roller slewing ring ...................................................................................................... 9-30
9.7.1 Lubrication tasks on the roller track ............................................................... 9-30
9.7.2 Lubrication tasks on the gear teeth................................................................ 9-31
9.7.3 Inspection tasks at the roller slewing ring ...................................................... 9-32
9.8 Electrical system ........................................................................................................ 9-34
9.8.1 Check the switchgear cabinet ........................................................................ 9-34
9.8.2 Checking the limit switches............................................................................ 9-35
9.9 Upper and bottom hook block and load hook............................................................. 9-36
9.9.1 Inspecting the upper hook block, bottom hook block and load hook ............. 9-36
9.9.2 Check the load hook to cross-head connection ............................................. 9-38
9.9.3 Inspecting the load hook ................................................................................ 9-40
9.10 Ropes, rope pulleys and rope end fittings.................................................................. 9-43
9.10.1 Lubrication tasks on the ropes ....................................................................... 9-43
9.10.2 Rope inspections on the hoist rope drum ...................................................... 9-44
9.10.3 Inspections on the ropes................................................................................ 9-47
9.10.4 Inspections at the rope pulleys ...................................................................... 9-51
9.10.5 Inspections at the rope end fittings ................................................................ 9-53
9.10.6 Cleaning the ropes......................................................................................... 9-58
9.10.7 Cleaning the rope pulleys .............................................................................. 9-59
9.11 Operator’s cab............................................................................................................ 9-60
9.11.1 Lubrication tasks at the front windshield ........................................................ 9-60
9.11.2 Lubrication tasks at the roof hatch ................................................................. 9-61
9.12 Analysing hydraulic oil / gear oil................................................................................. 9-64
9.12.1 Analysis kit ..................................................................................................... 9-65
9.12.2 Filling out the sample form............................................................................. 9-65
9.12.3 Taking a sample with the hand pump ............................................................ 9-66
9.12.4 Evaluating the laboratory report..................................................................... 9-68
9.13 Lubricant chart for Liebherr cranes ............................................................................ 9-69
9.13.1 Notes in general............................................................................................. 9-69
9.13.2 Lubricant requirements .................................................................................. 9-69
9.14 Lubricants, fluid capacities ......................................................................................... 9-72
10 Repair .................................................................................................................................. 10-1

10.1 Notes on safety for repair........................................................................................... 10-2

10.1.1 Who may carry out repair tasks? ................................................................... 10-2
10.1.2 Safety measures ............................................................................................ 10-2
10.1.3 Which personal protective equipment must be worn? ................................... 10-2
10.1.4 Which additional guidelines must also be noted? .......................................... 10-2
10.1.5 Which dangers can be resulted from the crane? ........................................... 10-2
10.1.6 Restarting the crane following repairs and modification work........................ 10-2
10.2 Hoist gear brake......................................................................................................... 10-3
10.2.1 Preparing for repair tasks............................................................................... 10-3
1250 HC 40 / 49516 V
10.2.2 Components of the hydraulic brake ............................................................... 10-4

10.2.3 Setting values................................................................................................. 10-5
10.2.4 Checking brake lining and brake disc ............................................................ 10-6
10.2.5 Replacing the brake blocks ............................................................................ 10-7
10.3 Slewing gear brake................................................................................................... 10-13
10.3.1 Preparations prior to repair .......................................................................... 10-13
10.3.2 Adjusting data .............................................................................................. 10-14
10.3.3 Checking the air gap and the brake disc...................................................... 10-14
10.3.4 Adjusting the air gap .................................................................................... 10-15
10.3.5 Replacing the brake disc.............................................................................. 10-16
10.3.6 Adjusting the microswitch............................................................................. 10-18
10.3.7 Adjusting the braking moment...................................................................... 10-19
10.4 Trolley travel gear brake........................................................................................... 10-20
10.5 Free jib slewing ........................................................................................................ 10-24
10.5.2 Adjusting data .............................................................................................. 10-25
10.5.3 Checking the air gap .................................................................................... 10-25
10.5.4 Adjusting the air gap .................................................................................... 10-26
10.6 Ropes ....................................................................................................................... 10-28
10.6.1 Transporting ropes ....................................................................................... 10-28
10.6.2 Storing the ropes.......................................................................................... 10-29
10.6.3 Unwinding the rope from the reel ................................................................. 10-29
10.6.4 Rewinding the ropes from the reel onto the rope drum................................ 10-30
10.6.5 Preparations prior to reeving of the rope and reeving the rope.................... 10-31
10.6.6 Rectifying twists in the hook block ............................................................... 10-33
11 Optional equipment ............................................................................................................ 11-1

11.1 Centralised lubrication system (Display) .................................................................... 11-2
11.1.1 Laying diagram, hydraulic diagram ................................................................ 11-3
11.1.2 Wiring diagram ............................................................................................... 11-5
11.1.3 Operation ....................................................................................................... 11-5
11.1.4 Maintenance, inspection and repair ............................................................. 11-12
11.1.5 Faults and their causes ................................................................................ 11-16
VI 1250 HC 40 / 49516
1 Notes on Safety
1.1 Avoiding dangers
Liebherr cranes are designed to the current state of technology and all recognised safety-technical
regulations. Nevertheless, if utilisation is not carried out properly, danger to life and limb of the ope-
rator or to a third party, or impairment of the crane of other tangible assets could be resulted.
In order that danger may be avoided, Liebherr cranes may only be used:
– for its intended use.
– under the observation of the complete crane documentation
– under observation of the local, valid guidelines for accident-prevention.
– in a safety-technical sound condition.
1.2 Intended use
Liebherr cranes may only be used for the lifting and lowering, as well as horizontal transport, of loads
freely suspended from the load hook. Loads may only be lifted from firm ground. The crane may not
exceed the maximum load specified in the respective lod diagram. The crane may only be erected
and operated in accordance with the specifications in the operating instructions. Any other use, or
excessive use, is not considered intended use.
The following in particular are prohibited :
– Pulling off fixed loads.
– Pulling diagonally or dragging of loads.
– Transporting of persons with the load or the load carrying gear.
– Increasing the weight of loads which have already been lifted.
– The utilisation of unsuitable ropes which do not comply with the specifications in the operating in-
structions.
– Utilisation of parts other than original crane parts.
– Bridging and modifying the setting of limit switches.
– Modifying the crane configuration which is described in these operating instructions.
– The mounting of advertising surfaces, accessories or modifications without express authorisation
of the manufacturer.
– Non-adherence to guidelines specific to the respective crane type. See chapter Operation: „Ope-
rating instructions“.
Liability of the manufacturer becomes null and void for damage which occurs as a result of any of the
aforementioned points being neglected.

Adherence of the maintenance and inspection requirements is also considered use as directed.
1250 HC 40 / 49516 1-1

Notes on Safety Instruction Manual
Personnel qualification
1.3 Personnel qualification
Operation, maintenance and inspection may only be carried out by a trained crane operator.
Erection, dismantling and repair tasks may only be carried out by qualified, specialist personnel.
Tasks to the electrical equipment of the crane may only be carried out by an electrical specialist in
accordance with the electrotechnical regulations.
Only personnel with special knowledge and experience of hydraulics may carry out tasks to the hy-
draulic devices.
1.4 Particular dangers
1.4.1 Risk of instability

Depending on the configuration of the crane, very different prerequisites for stability may be required.
The documentation „Corner pressures, foundation loadings, ballast data“ or chapter 2 „Stability“ is
only valid for the configuration specified. If the configurations are not specified, the operator can ob-
tain the structural data from the Liebherr-Werk Biberach.
1.4.2 Danger of crushing

Danger of crushing can be resulted:
– in the immediate supporting vicinity of the crane.
– from the open running gears.
– in the area of the slewing platform.
– in the entire vicinity of the crane when being erected.
– in the area of the climbing equipment.
All areas which pose a danger of crushing should be accordingly safetguarded or cordoned off.
Should operating, erection or maintenance tasks be necessary within an area of the crane which has
not been safeguarded, a second person must be called in who can shut down the respective move-
ment immediately should a dangerous situation arise.
1.4.3 Danger resulting from damaged ropes

The utilisation of unsuitable ropes can lead to serious accidents. In order to ensure safe operation,
– only use ropes which comply with the Liebherr-guidelines.
– pay particular attention to sections of ropes which run over rope pulleys and rope drums and whe-
re the rope end fittings are located.

– pay close attention to the ropes as soon as changes are noticed.
1.4.4 Dangers resulting from copied Liebherr crane parts

The utilisation of copied crane parts (plagiarisms) could cause the tower crane to topple, and thusse-
rious injury to persons or material damage to property.
1-2 1250 HC 40 / 49516

Instruction Manual Notes on Safety
Particular dangers
To prevent hazardous situations,

– use original-Liebherr-crane parts only.
1.4.5 Dangers resulting from electrical energy

Always keep the switchgear cabinets locked. Access is only permitted to authorised personnel with
key or tools.
– If tasks to voltage-carrying parts are necessary, a second person should be called upon to switch
off the main switch wherever necessary.
1.4.6 Dangers resulting from hydraulic energy

Always release pressure in sections of the system and pressure lines before commencing with repair
tasks.
– Replace hydraulic hose lines in appropriate time intervals, even if no safety-relevant faults are evi-
dent
1.4.7 Danger of harming the environment

The environment could be harmed if care is not taken when handling fuels and lubricants.
– Afford the utmost of care when replacing or refilling fuels and lubricants. Fuels or lubricants should
not be allowed to permeate the soil or enter bodies of water.
1250 HC 40 / 49516 1-3

Notes on Safety Instruction Manual
Particular dangers
1-4 1250 HC 40 / 49516

2 Technical description
The product will be presented to you in this chapter. A summary of erection and all functions is pro-
vided. Innovations with which you are possibly not yet familiar are indicated in particular.
Liebherr tower cranes are constructed around the modular design principle. This instruction
manual only applies to the crane configurations specified in the chapter Technical descrip-
tion.
All subsequent chapters refer to the configuration specified therein.
1250 HC 40 / 49516 2-1

Technical description Instruction Manual
General assembly arrangement
2.1 General assembly arrangement
2.1.1 Special features of the 1250 HC series

– All drives are regulated via frequency converters
– SPS-control
– High-performance hoist gear with frequency converter control with positioning mode
– FC-slewing gear with load swing attenuation, positioning mode
– Slewing gear brake with electrical free-jib slewing
– Trolley travel gear with frequency converter control
– 2/4-fall hook block for all output ranges
Fig. 2-1 Overview of configuration, crane type 1250 HC (jib length 53,3 m)
(a) Counterweight (j) Trolley
(b) Counter-jib (For further information, see: Chap. 2.1.2 (k) Guying, jib
Counter-jib short for 53,1 m and 41,5 m jib oder For further
information, see: Chap. 2.1.3 Counter-jib long for 82,1 m,
76,3 m and 64,7 m jib)
(c) Switching station (l) Support
(d) Slewing platform (For further information, see: Chap. 2.1.4 (m) Trolley travel rope
Slewing platform with tower head)
(e) Tower (For further information, see: Chap. 2.1.6 Tower sys- (n) Tower head)
tem)
(f) Crane base (foundation anchor or undercarriage) (o) Guying, counter-jib
(g) Trolley travel gear (p) Mounting the hoist rope
(h) Jib (For further information, see: Chap. 2.1.5 Jib) (q) Auxiliary crane
2-2 1250 HC 40 / 49516

Instruction Manual Technical description
Fig. 2-1 Overview of configuration, crane type 1250 HC (jib length 53,3 m)
(i) Lifting beam with hook block (For further information, see: (r) Hoist gear
Chap. Hook block)
2.1.2 Counter-jib short for 53,1 m and 41,5 m jib
EXAMPLE
EXAMPLE
Fig. 2-2 Arrangement of short counter-jib (1250 HC shown with counterweight as an example)
(a) Hoist gear with hoist rope (f) Counter-jib end section
(b) Guying, counter-jib (g) Counterweight slab B
(c) Slewing platform with tower head (For further infor- (h) Counterweight slab A
mation, see: Chap. 2.1.4 Slewing platform with
tower head)
(d) Switching station (i) Auxiliary crane
(e) Counter-jib heel piece
1250 HC 40 / 49516 2-3

2.1.3 Counter-jib long for 82,1 m, 76,3 m and 64,7 m jib
EXAMPLE
Fig. 2-3 Arrangement of long counter-jib (1250 HC shown with counterweight as an example)
(a) Hoist gear with hoist rope (f) Counter-jib end section
(b) Guying, counter-jib (g) Counterweight slab B

(c) Slewing platform with tower head (For further infor- (h) Counterweight slab A
mation, see: Chap. 2.1.4 Slewing platform with
tower head)
(d) Switching station (i) Auxiliary crane
(e) Counter-jib heel piece (j) Counter-jib intermediate section
2-4 1250 HC 40 / 49516

2.1.4 Slewing platform with tower head
Fig. 2-4 Arrangement of slewing platform with tower head (illustration shows the detail without
counter-jib, jib and tower)
(a) Slewing platform (g) Guying, jib
(b) Counter-jib (h) Jib (For further information, see: Chap. 2.1.5
(for further information see: Jib)

Chap. ›Counter-jib short and long‹
(c) Guying, counter-jib (i) Cabin with platform
(d) Switching station (j) Slewing gear
(e) Tower head (k) Roller slewing ring support
(f) Overload protection (l) Tower section 1250HC (For further information,
see: Chap. 2.1.6 Tower system)
1250 HC 40 / 49516 2-5

2.1.5 Jib
Fig. 2-5 Jib arrangement (81 m jib shown as an example)

(a) Jib pivot section (C036.020-611.111) (h) Jib head section (C036.020-641.111)
(b) Intermediate jib section (C036.020-621.111) (i) Guying, jib
(c) Intermediate jib section (C036.020-631.111) (j) Guy frame
(d) Intermediate jib section (C036.020-632.111) (k) Trolley 1
(e) Intermediate jib section (C036.020-635.111) (l) Trolley 2
(f) Intermediate jib section (C036.020-633.111) (m) Trolley travel gear
(g) Intermediate jib section (C036.020-634.111) (n) Lifting beam with hook block (For further
information, see: Chap. Hook block)
2-6 1250 HC 40 / 49516

Hook block
Fig. 2-6 Hook block

(a) Hook block (converted for 4-fall operation) (b) Hook block (converted for 2-fall operation)
1250 HC 40 / 49516 2-7

2.1.6 Tower system
Tower section with optional erection devicea)
Fig. 2-7 Tower section 1250 HC
(a) Erecting devicea (b) Tower section 1250 HC (c) Assembly aid for tower sec-
tion
a. The erecting device is not included in the standard delivery and must be ordered separately.
2-8 1250 HC 40 / 49516

Foundation anchors
Fig. 2-8 Foundation anchors 1250 HC (drawing no. C 036.020-372.100 shown as an example)
(a) Foundation anchors 1250 (b) Tower section 1250 HC (c) Tower pin connections
HC
1250 HC 40 / 49516 2-9

Foundation anchors
Fig. 2-9 Foundation anchors 630 EC-H (drawing no. C 048.007-372.100 shown as an example)
(a) Foundation anchors rein- (b) Base tower section 1250 (c) Tower bolt connections
forced 630 EC-H HC reinforced
2 - 10 1250 HC 40 / 49516
Components
2.2 Components
2.2.1 Undercarriage 1250 HC
Undercarriage standard
Drawing No.:
Part No.:
Version
Designation
for straight track for curved track stationary
Track gauge
Travel gear Drawing No.
Part No.
Pivot Drawing No.
Part No.
Bogie support Drawing No.
Part No.
Cable drum Drawing No.
Part No.
Cable devia- Drawing No.
tion and guide Part No.
link chain
Anchor shoe Drawing No.
kit Part No.
Anchoring Drawing No.
plate kit Part No.
Central bal- Drawing No.
last block Part No.
Central bal- Drawing No.
last block B Part No.
Tab. 2-1 Undercarriage 1250 HC
Version
Designation
for straight track for curved track stationary
Access ladder Drawing No.
(not fitted as Part No.

standard)
Access ladder Drawing No.
(not fitted as Part No.
standard)
Tab. 2-2 Access ladder - Undercarriage 1250 HC
1250 HC 40 / 49516 2 - 11
Components
2.2.2 Foundation anchors 630 EC-H
630 EC-H Foundation anchor reinforced (4 pieces)

Drawing No.: C 048.007-372.100
Part No.: 9398 287 01
Fitting dimension for the 1250 HC tower 3,800 m x 3,800 m
system (Example)
Tab. 2-3
2.2.3 Foundation anchors 1250 HC
1250 HC Foundation anchor reinforced (4 pieces)

Drawing No.: C 036.020-372.100
Part No.: 9000 9693
Fitting dimension for the 1250 HC tower 3,800 m x 3,800 m
system (Beispiel)
Tab. 2-4
2.2.4 Foundation anchors 500 HC
Foundation anchor standard

Drawing No.: C 032.001-372.100
Part No.: 9535 275 01
Fitting dimension for the tower (Example) 2.200 m x 2.200 m
Fig. 2-10
2.2.5 Base tower section 1250 HC
Tower section 1250 HC reinforced
Length Drawing No. Part No.

11,6 m C 036.020-338.000 9002 1971
(C 036.020-338.100) (9002 1972)
Tab. 2-5
2 - 12 1250 HC 40 / 49516
Components
2.2.6 Tower section 1250 HC
Tower section 1250 HC

11,6 m C 036.020-337.000 9001 8232
(C 036.020-337.100) (9001 8227)
Tab. 2-6
2.2.7 Tower section 1250 HC
Tower section standard

5,8 m C 036.020-332.000 9000 7492
(C 036.020-332.100) (9000 7493)
Tab. 2-7
2.2.8 Erection platform for the 1250 HC tower
Erection platform standard
Drawing No. Part No.

C 036.020-966.000 ( x 2 ) 9001 3061
Tab. 2-8
2.2.9 Climbing equipment for the 1250 HC tower
Climbing equipment 1250 HC standard
Designation Length Drawing No. Part No.

Climbing equipment for 12,4 m C 036.001-321.000 9542 200 01
5,8 m tower sections
Hydraulic unit C 035.010-340.000 9543 025 01
Tab. 2-9
1250 HC 40 / 49516 2 - 13
Components
2.2.10 Ball slewing ring support for the 1250 HC tower
Roller slewing ring support 1250 HC
Designation Height Drawing No. Part No.

Roller slewing ring support 2,080 m C 036.020-333.000 9000 8743
Slewing ring connection
C 036.020-351.000 9001 0684
Roller slewing ring connec- 0,322 m
ROD 690 DA 001 9905 340 01
tion
Tab. 2-10
2.2.11 Upper part of crane
Top part of crane 1250 HC standard
Designation Drawing No. Part No.

Slewing platform C 036.020-411.000 9001 0264
Platform C 036.020-965.100 9001 0539
Platform for the cabin C 036.020-413.000 9001 0728
Cabin C 040.027-414.000 9332 945 01
Tower head C 036.020-541.000 9000 9345
Tab. 2-11
C 036.020-710.000 / 9000 9731 + C 036.020-712.000 / 9001 0490

Counter-jib cpl.
(without intermediate section) C 036.020-711.000 9000 9731
Counter-jib end section C 036.020-711.200 9000 9710
Counter-jib heel section C 036.020-711.100 9000 9585
Counter-jib intermediate section a C 036.020-712.000 9001 0490
Counter-jib tie bars 1) C 036.020-814.200 9001 0406
Counter-jib tie bars b C 036.020-814.100 9000 9966
Counter-ballast block A (7,10 t) C 036.020-718.310 9001 1228
Counter-ballast block B (4,50 t) C 036.020-718.320 9001 1312
Tab. 2-12 Counter-jib 1250 HC
a. for length of jib 64,7 m – 82,1 m
b. for length of jib 41,5 m – 53,1 m
2 - 14 1250 HC 40 / 49516
Components
Top part of crane 1250 HC standard

Jib 81,0 m / 79,6 m – 9343 627 01
Jib suspension C 036.012-812.600 9573 843 01
Jib 75,2 m / 73,8 m – –
Jib suspension C 036.012-812.400 9573 836 01
Jib 63,5 m / 62,1 m – –
Jib suspension C 036.012-812.400 9573 836 01
Jib 51,9 m / 50,5 m – 9343 260 01
Jib suspension C 036.012-812.300 9573 833 01
Jib 38,8 m / 40,2 m – 9343 280 01
Jib suspension C 036.012-812.200 9573 801 01
Trolley cpl. (50t Version) C 036.021-660.000 9000 9199
Trolley 1 C 036.021-661.000 9000 9150
Trolley 2 C 036.021-662.000 9000 9195
Trolley cpl. (40t Version) C 036.020-660.000 9000 7557
Trolley 1 C 036.020-661.000 9000 7558
Trolley 2 C 036.020-662.000 9000 7559
Hook block (50t Version) LAH 500 DM 026-000 9000 9920
Hook block (40t Version) LAH 400 DM 031-000 9001 0584
Tab. 2-13 Ausleger 1250 HC
2.2.12 Control system 1250 HC
Logic control PLC (400V, 50 Hz / 440 V, 60 Hz)
Additional
Designation Part No.
designation
Control stand SS 13542 AC31-S 1016 7292
Radio-control (not standard)
Electronic monitoring system 2 / AC31S 4017-5155-6155 9331 847 01
Circuit diagram 4005-22458
Switching station 9001 1565
Layout of equipment 4005-82315
Switchgear cabinet Circuit diagram 4005-21898
(Connecting compo- Layout of equipment 4005-81994
nentry decentralized 9317 292 01
PLC radio remote con-
trol)
Tab. 2-14 Hoist gear 110 KW
1250 HC 40 / 49516 2 - 15
Components
2.2.13 Rope list
Fig. 2-11 Ropes overview

(a) Hoist rope (c) Trolley travel rope 2
(b) Trolley travel rope 1 (d) Erection ropes (x 2)
To increase life-expectancy of the hoist rope Liebherr recommends:

– Always use the hoist rope in its entire length.
– For more lenthy, consistent crane operation, use respectively adapted rope lengths.
Calculation of the optimum hoist rope length, 2-fall operation: Total hoist rope length = l0 + 2 · X
Calculation of the optimum hoist rope length, 4-fall operation: Total hoist rope length = l0 + 4 · X
Hoist rope length at X = 0 m hook height and 81 m: l0 = 145 m
Hook height: X
Ø Length
Utilisation Designation Rope end fitting Part No.
[mm] [m]
Hoist rope PC-EUROLIFT ZZ galvanized 27,0 525,0 1 thimble Ø 80 mm 9585 875 01

Nominal strenght 1960 N/mm2 +3,5% DIN 3090 BF / DIN 3093
C 056.001-020.200/101 1 end welded
Minimum rupture force Fmin = 650
kN
Tab. 2-15 Rope list for crane featuring 40t lifting capacity
2 - 16 1250 HC 40 / 49516
Components
Ø Length
Utilisation Designation Rope end fitting Part No.
[mm] [m]
Trolley travel PFEIFER SE PN 116 / 7 SZ galva- 16,0 97,0 1 thimble Ø 40 mm 1017 5479
rope 1 nized DIN 6899 BF / DIN 3093
Nominal strenght 1770 N/mm2 1 end welded
kN
Trolley travel PFEIFER SE PN 116 / 7 SZ galva- 16,0 170,0 2 ends welded 1017 5480
rope 2 nized
Nominal strenght 1770 N/mm2
kN
Ausleger- PC DUROLIFT SZ galvanized 22,0 19,0 1 thimble Ø 80 mm 1017 2994
Montageseil Nominal strenght 1960 N/mm2 DIN 6899 BF / 3093
(1 Stück) Minimum rupture force Fmin = 458 1 thimble Ø 45 mm
kN DIN 6899 BF / 3093
Ausleger- PC DUROLIFT SZ galvanized 22,0 13,6 1 thimble Ø 80 mm 1017 2993
Montageseil Nominal strenght 1960 N/mm2 DIN 6899 BF / 3093
(1 Stück) Minimum rupture force Fmin = 458 1 thimble Ø 45 mm
kN DIN 6899 BF / 3093
Montageseil PDS 506 SZ ZN 12,0 1,0 2 thimbles Ø 30 mm 7733 454 01
(4 Stück) Nominal strenght 1770 N/mm2 DIN 6899 / DIN 3093
kN
Montageseil PDS 506 SZ ZN 12,0 1,5 2 thimbles Ø 30 mm 1017 3392
(4 Stück) Nominal strenght 1770 N/mm2 DIN 6899 / DIN 3093
kN
Tab. 2-15 Rope list for crane featuring 40t lifting capacity
1250 HC 40 / 49516 2 - 17
Components
2.2.14 Hoist gear

Hoist gear type: WiW 300 VZ 427
Fig. 2-12 Hoist gear structural overview

(a) Motor (d) Telescopic current supply (g) Angular gear
bars
(b) Clutch (e) Hand-operated brake (h) Rope drum

release lever
(c) Change speed gear (f) Brake (i) Limit switch
Features:
– Squirrel-cage motor with forced ventilation
– Liebherr motor, regulated via frequency converter
– 3-speed Liebherr change speed gear
– Single-disc spring-loaded brake, holding function only (wear-free)
2 - 18 1250 HC 40 / 49516
Components
2.2.15 Slewing gear

Slewing gear type: 2 x DRW 200 AZ 403, 1 x DRW 200 AZ 404
Fig. 2-13 Slewing gear structural overview

(a) Spring-loaded brake (b) Motor (c) Planetary gear
Features:
– Squirrel-cage motor with forced ventilation
– Liebherr motor, regulated via frequency converter
– Electrical setting to weathervaning
– Limitation of the maximum permissible torque

– Spring-loaded brake, holding function only
– 3-stage Liebherr planetary gear
1250 HC 40 / 49516 2 - 19
Components
2.2.16 Trolley travel gear

Trolley travel gear type: KAW 200 KY 001
Fig. 2-14 Trolley travel gear structural overview

(a) Bevel and spur gear unit (c) Junction box (e) Rope drum
(b) Motor (d) Ventilation (f) Limit switch
The frequency-converter trolley travel gear allows a completely jolt- and jerk-free manoeuvring of the
trolley..
Features:
– Squirrel-cage motor with ventilation
– Motor, regulated via frequency converter
– Federkraftbremse
– 3-speed bevel gear
2 - 20 1250 HC 40 / 49516
Components
2.2.17 Cabin
Fig. 2-15 Cabin

(a) Cabin (b) Platform for the cabin
The crane is equipped with a cabin. This ergonomically designed working area for the crane operator
eases crane operation and reduces fatigue. The cabin also contributes toward safe crane operation,
as the crane operator can carry out all tasks comfortably, relaxed and totally stress-free over lengthy
periods of time.
Features:
– Sound-proofed and thermally insulated
– Outstanding visibility due to frameless windshield
– Cabin light
– Windshield wiper with windshield washing system
– Hinged windshield for ventilation
– Sliding windows at the side
– Glare protection
1250 HC 40 / 49516 2 - 21
Components
– Versatile adjustable crane operator's seat featuring control desk

– Heating and ventilation system in the crane operator's seat
– Heating regulation via thermostat and timer
– Air-conditioning (optional)
– Electronic monitoring system (EMS)
– Storage compartments for personal belongings
2 - 22 1250 HC 40 / 49516
Components
2.2.18 Electrical equipment
General
1 Connection data 1250 HC
The mains supply must always correspond with the connection values of the
crane!
For other mains voltages, please contact the technical office (TB) at Biberach an
der Riss!
1250 HC
Connection data: 400V AC, 50 Hz / 440V AC, 60 Hz
Control voltages: 115V AC / 24V DC
For further details, see chap. 17 "Electrical connections".
Mains tolerances:
Supply voltage: 3x 400V +/- 10%
Frequency: 50 Hz +/- 1%
Supply voltage: 3x 440V +/- 10%
Frequency: 60 Hz +/- 1%
Danger resulting from electrical energy!

- Work on the electrical equipment of the crane may only be carried out by electrical
specialists in accordance with the electrotechnical regulations.
- Connection, earthing and protective devices must comply with the local guidelines!
- Permissible line cross sections may not be exceeded!
- For every intervention directly involving the frequency converter, it is imperative that
the electrical feed is disconnected before waiting for the capacitors to discharge!
2 Ambient conditions
Temperature range in the switchgear cabinet - 12°C to +60°C
Air-conditioning measures are necessary wherever deviating temperatures are
prevalent!
See "Air-conditioning measures for switchgear cabinets".
Storage temperature - 40°C to +70°C
Maximum relative moisture 93% (IEC 68-2-3 for storage / transport)
Maximum relative moisture 95% non-condensing operation

Maximum height above sea level 1000 meters without any reduction in output
Caution!
Avoid moisture and condensation in the switchgear units (switchgear cabinets)!
Moisture or condensation in switchgear units can cause direct damage to assemblies of
the electrical equipment!
1250 HC 40 / 49516 2 - 23
Components
3 Prerequisites for power supply

The mains supply must always correspond with the connection values of the crane.
➔ see Connection data.
Fixed mains connection via site junction box (4-pin with protective earth PE).
➔ See chap. 4.3 "Information regarding the connection of cranes with FC drives"
Earthing measures required.
In-phase connection (rotating field) of the power supply cable.
➔ Error message E553 ➔ "Emergency Stop" appears if the rotating field is incorrect.
The permissible line cross-section may not be fallen short of!

Electrical connections by specialist personnel only!
4 Electrical regulations and protective measures
4.1 Regulations
● Protective measures; Protection against hazardous electric shocks, DIN VDE 0100
part 410 (see also publication IEC 60364-4-41)
● Earthing, protective earth, potential equaliser, DIN VDE 0100 part 540
(see also publication IEC 60364-5-54)
4.2 Protective measures on the building site
● The crane is supplied from the site junction box (DIN EN 60439-4).
The site junction box must be capable of withstanding any electrical, mechanical and
thermal demands, as well as any humidity demands to which it may be subjected.
● Different regulations for permissible network type and electrical protective measures
→ Refer to the respective national regulations!
4.3 Information regarding the connection of cranes with FC drives

Due to the B6-switching generally applied in the input of the intermediate circuit for frequency
converters, a non-pulsating DC residual current can occur in the event of an earth fault which
could block the triggering of an FI circuit breaker in accordance with DIN VDE 0664.
In accordance with DIN EN 50178, the fault current protective device with pulse train-
sensitive F1 circuit breakers may not be applied as the sole protective measure against
indirect contact for these circuits.
If necessary, protection on the mains supply side for indirect contact must be established
alternatively, e.g. via surge protective devices or by integrating AC/DC-sensitive FI circuit
breakers (e.g. from Siemens or ABB). It is imperative however, that a separate circuit is
established. A branching off to pulse train-sensitive FI circuit breakers in accordance with

DIN VDE 0664, as is generally found in the utilisation of site junction boxes, is not
permissible in accordance with DIN VDE 0664.
2 - 24 1250 HC 40 / 49516
Components
4 Electrical regulations and protective measures
4.4 Protective measures from the manufacturer
● Protective conductor rails in the switching station for incoming and outgoing protective
earths.
A protective conductor is carried along as an additional wire in all lines to the electrical
operating equipment.
● Single-phase control transformer with electrically insulated coils for feed of the control
circuit.
The control transformer is connected to two outer conductors on the primary side. On the
secondary side, one control phase is earthed and the second control phase features one
line protection switch per control circuit. The secondary side of the control transformer
thus forms a TN-C-system. The line protection switches are effective as a protective
measure for indirect contacts.
● A light transformer can be an autotransformer or an isolating transformer.

For configuration as an autotransformer, the same protective measure is effective for the
light circuit and the crane. For configuration as an isolating transformer, one phase of the
secondary circuit is earthed. The secondary side forms a TN-S-system.
The socket outlet circuits up to 10 A (16 A) for single-phase operation are protected with a
nominal fault current ¦ ΙΔn ≤ 30 mA by way of fault current protective devices.
● Emergency-Stop, see chap.5 "Emergency-Stop safety device".

1250 HC 40 / 49516 2 - 25
Components
5 Safety device: Emergency-Stop
The safety switchgear unit (+A-F10) features three enabling contacts as NO (normally open)
circuits and one signalling contact as a normally closed circuit. Three LED's indicate the
operation mode and the function.
Upon actuation of the Emergency-Stop button (red mushroom button with

rotary release), the main contactor is deactivated. Power supply to all drives is
disconnected. All brakes are engaged (including the slewing gear brake).
Switching station S1/S2:
+A-F10
2 LED's
Operation modes:
SUPPLY
Mains ON / Emergency Stop not actuated!
Mains ON / Emergency Stop actuated!
K1,K2
Mains OFF!
Emergency Stop actuated: (safety switching device has been triggered)

- Check Emergency Stop chain!
The following equipment has been integrated in the Emergency-Stop chain:

- Emergency-Stop control stand (crane cab)
- Emergency-Stop on the radio remote-control (optional)
- Emergency-Stop on the control panel for free jib slewing on the tower foot
(optional)
- Emergency-Stop limit switch on the floor hatch in the crane cab (optional)
- Emergency-Stop limit switch on the trap doors in the jib (optional)
Resetting the Emergency Stop:

If the safety switching device (Emergency Stop) is triggered, the control of the crane shuts
down.
The error message E553 appears in the display (radio or EMS).
- Establish and remedy the cause of the Emergency-Stop being triggered.

- Activate the control via the key.
- The error message E553 is extinguished in the display (radio or EMS).
2 - 26 1250 HC 40 / 49516
Components
6 Lightning protection / electrostatic charge

DIN EN 62305 part 1-4
It is the responsibility of the operator prior to start-up to determine whether it is necessary
to take measures towards lightning protection and/or earthing, as regards electrical
charging, and to undertake the appropriate earthing measures wherever required!
Whether or not the crane should feature lightning protection depends on the respective directives
and decrees of the responsible regulatory authorities, in accordance with the accident-prevention
guidelines of the trade association, the recommendations of the property insurance company etc.
or in compliance with the contract of the construction company!
rail-going crane Galvanised strip metal

30 mm x 3.5 mm
• Each rail is to be earthed at each
end, or if the rail lengths exceed
20 m, every 20 m. If no other
earthing bars are featured, an
earthing rod featuring a minimum
1.5 m penetration depth will
suffice.
• For structures featuring steel blitz1.dsf

reinforcement in the foundations,
a connecting line is to be Earthing rod which
established between
M 10 screw must be driven at least
reinforcement and rail.
with spring washer 1.5 m into the ground
• Equipment, machines and metallic pipelines must be connected with the rails within a
periphery of up to 20 m around the track.
• The bridging of rail joints already connected with steel connection plates is not
necessary for the lightning protection.
• A lightning protection potential equaliser is required for protection of the electrical
equipment on the building site upon connection of the mains supply.
stationary crane
Top slewing cranes: Galvanised strip metal Bottom slewing cranes:
(those which are not 30 mm x 3.5 mm
connected with the steel
reinforcing of the or
foundation for the insulated copper
structure!) rope, at least 16 mm²
Nut
M 10 screw
Earthing rod which Spring washer

blitz1.dsf must be driven at

least 1.5 m into the
ground 09-2008
1250 HC 40 / 49516 2 - 27
Components
6 Lightning protection / electrostatic charge

DIN EN 62305 part 1-4
It is the responsibility of the operator prior to start-up to determine whether it is necessary

to take measures towards lightning protection and/or earthing, as regards electrical
charging, and to undertake the appropriate earthing measures wherever required!
Whether or not the crane should feature lightning protection depends on the respective directives
and decrees of the responsible regulatory authorities, in accordance with the accident-prevention
guidelines of the trade association, the recommendations of the property insurance company etc.
or in compliance with the contract of the construction company!
Climbing inside the building
For structures featuring steel reinforcement in the foundations, a connecting line is to be

established between reinforcement and climbing equipment.
When using climbing cranes which do not remain connected with the foundation of the
building, the surrounding frame of the crane must be connected twice.
2x
insulated copper rope
at least 16 mm²
Connection:
M 10
External frame of the
screw
crane
2x
insulated copper rope
at least 16 mm²
Spring washer
and nut
Rails of the building

earthing rods
09-2008
2 - 28 1250 HC 40 / 49516
Components
Elektrical equipment for crane 1250 HC
7 Electrical equipment 1250 HC
1. Earthing, see lightning protection

2. Site junction box *,
is not included within the delivery scope!
3. Free jib slewing with Emergency-Stop
(optional)
4. Mains supply cable(s)
5. Slipring assembly with isolating switch and
slewing gear sensor [°], see point 12.
Plug sockets for climbing hydraulics (16/32A)
6. Cab, control stand P1 with EMS-2
7. Switching station S1/S2
8. Load measuring axle [t]
9. Load moment sensor [mt]
10. Wind sensor [m/s]
11. Aircraft warning light "red" (optional)
12. Centralised lubrication system and slewing
gears, see also point 5.
13. Trolley travel gear with trolley travel sensor [m]
14. Hoist gear with hoist gear sensor [m]
15. Travel gear motors / travel limit switch
(optional)
16. Cable drum with magnetic coupling (optional)
17. Switchgear cabinet S3 (optional)
* The site junction box ❷ must be fitted with an AC/DC-sensitive FI circuit breaker!
Cranes with foundation anchor: *Undercarriage:

The crane is connected directly onto the 3
slipring assembly of the ball slewing ring 17
support.
16
Cranes with undercarriage*: (optional)
2
Switchgear cabinet S3 featuring cable

drum 15
(mains supply cable) and magnetic
coupling for control of the travel gear 1
motors is integrated in the undercarriage.
(*optional = not featured as standard)
1250 HC 40 / 49516 2 - 29
Components
7 Electrical equipment
7.1 Cabling (without sensors)
Trolley travel motor Hoist motor

Brake Brake
PTC thermistor PTC thermistor
Terminal boxes
Plug connections
S1/S2
CS 31 - Bus
Cab /
control stand
Control / supply
Heater and lighting
Slewing gears (3x)

Brakes
PTC thermistor
Slipring assembly
with isolating switch
Plug sockets 16A/32A

for climbing hydraulics
Power supply cable
Free jib slewing with

Emergency-Stop
(optional)
Site junction box

(Not included within the
delivery scope!)
2 - 30 1250 HC 40 / 49516
Components
7 Electrical equipment
7.2 Electric crane erection
Connect the power supply cable (see "Prerequisites for power supply") on the slipring
assembly into the ball slewing ring support. The entire electrical equipment around the
slewing platform is ready for operation!
Switch the "Erection Operation" switch (switching station S1/S2) to "Erection".

For functioning of the key switch, see chap. 9.3 / 9.4 "PLC key"!
Following conclusion of erection, return the erection switch to "Operation"!
Connect switching station S1/S2 (on counter-jib).

Plug connections: - Hoist gear line
- Bus cable
- Control cable
- Heater cable
Connect trolley travel gear (on jib).

- Motor line as far as trolley
- Sensor line as far as trolley
Connect travel gear (optional).

Connect travel gear supply cable and control cable of the rail-going crane at terminal box X5.
Connect free jib slewing and Emergency-Stop (optional) at terminal box X5.
Climbing hydraulics (optional)

A double plug socket (16A / 32A) is situated in the ball slewing ring support for electrical
connection of the climbing hydraulics. Safeguarding of the plug socket is ensured via the
circuit breaker (40 A) in switching station S1. For configuration with travel gear 2x7.5kW, the
circuit breaker (40 A) is already installed.
Setting and scaling the crane control, see "Handbook for Litronic cranes".
1250 HC 40 / 49516 2 - 31
Components
8 System summary: Crane control (AC31)
Control stand
P1
Switchgear cabinet
S1/S2 S1/S2
SMC
KT 98 KT 98 S FC slewing gear
(AC31) (AC31S)
RS 232 CS31 ARCNET CS31 ARCNET

Travel gear
Optional
FC trolley
travel gear
EMS display
(crane cab)
B1 B2 B3 B4 B5 B6 B7
CL EAR ENT ER
Remote data AKS PLC

transfer inputs and outputs Sensors (see point to )
Optional Optional
CSM- RS 485 Radio-receiver

module
Optional
P1
PLC
inputs and
outputs
CSM- RS 485
module Control stand and
control lever
PLC
inputs and outputs
FC hoist gear
(*optional = not featured as standard)
2 - 32 1250 HC 40 / 49516
Components
8 System summary: crane control
8.1 Switching station S1/S2 (counter-jib)
PLC-control: (AC31/S)
The PLC-control is comprised of central units "KT98" and "KT98S", with integrated binary and
analogue Input/Output assemblies. Both central units and the EMS-2 are connected with one
another via a coaxial cable (ARCNET). The CS31 system bus connects the CSM module
(RS485), as well as binary and analogue Input/Output assemblies with the PLC central units.
Electronic Monitoring System (EMS-2)

The EMS is supplied with power (24V DC) via the COM 2
interface. Data exchange with the PLC is resulted via the BNC
connection (ARCNET).
The EMS is installed in the crane cab and serves scaling and
display of the sensors.
Sensors (see chap. 8 System summary)

The sensors (point 1-7) are connected to an analogue input
assembly of the PLC central unit (KT98S) via the plug panel.
All sensors are to be considered integral components of the
electrical equipment! As safety within the vicinity of the crane is
dependent upon these sensors, it is particularly important that
correct setting and functional safety is ensured.
Slewing gear sensor in degrees [°] Wind sensor in meters per second [m/s]
Trolley sensor in meters [m] Hoist sensor in meters [m]
Load measuring axle in tons [t] Travel gear sensor in meters [m]
Load moment sensor in meter tons [mt] See "Manual for Litronic tower cranes".
Control stand and control lever
The control signals received from the control stand and control lever are read in via the
binary and analogue inputs and transferred via the BUS-system to the PLC central unit.
1250 HC 40 / 49516 2 - 33
Components
9 Switching station S1 / S2
Plug panel for connection of the

sensor lines.
2 4 5 6 7
PLC central units, see system 1 3
summary and keypad +A-KF10 / H- 8
KF10 11
9
Emergency-Stop safety Switching station
switchgear unit (+A-F10) S1/S2
10
Transformers for control voltages

24V DC / 115V AC
Circuit breaker for S1/S2, S0 and
drives
Surge protection equipment
Temperature control for Heater and air-conditioning unit
Frequency converter (FC) trolley travel gear
Frequency converter (FC) slewing gear
Frequency converter (FC) hoist gear
11 Light transformer and braking resistors with fan
9.1 Access control resistor cabinet S1/S2
The doors of the resistor cabinet (S1/S2) are

safeguarded by limit switches for safety reasons.
The drives of the crane are shut down as soon as
the access doors are opened.
9.2 Temperature control in the switching station 20°C 35°C

The temperature in the switching station is maintained at
between approx. 15°C and approx. 35°C via an electrical
heater and an air-conditioning system. Actual temperature
depends essentially upon the current crane operation (heat
from output) and external influences (weather conditions).
Temperature controllers for heater and ventilation or air-
conditioning are installed in the switching station.
Heating is activated from < 20°C Air-conditioning is activated from > 35°C .
0° 10° 20° 35° 40° 50°C

Heating Cooling
OFF
See also chap. 9.3 / 9.4 PLC key (1) "Temperature range"!
2 - 34 1250 HC 40 / 49516
Components
9.3 PLC key 1/E "+A-KF10" (S1)
[1] [2] [3]
[4]
[5]
1.) Temperature range: (red)

The keypad monitors the temperature in the
= Under temperature min. 0°C switchgear cabinet. If the temperature exceeds or
falls short of the temperature range (0 - 55°C), al l
drives are shut down, or if not yet active, drives
= Over temperature max. 55°C can no longer be activated.
2.) Operating display: (yellow)

= Display Control ON
3.) Key switch: Operating modes For servicing work on the crane only!
= Working mode
= Erection ➜ W 557 - for erection and for climbing of the crane.
= Scaling ➜ W 556 - the EMS-2 switches to the first scaling screen.

- all software limit switches are no longer active!
= Teaching ➜ W 555 - Teach operation can not be activated without

previous scaling of the sensors.
- M 090 = ABB-limitation function not active.
- Teach operation is restricted for 90 min.
= 125 % overload ➜ W 558 - The 125% test is not possible in LM2 operation.
- The tolerance is effective up to 128% of the max.
load.
4.) EMS-interface (25-pin) - NOT ACTIVE!
5.) DIP switch - NOT ACTIVE!

1250 HC 40 / 49516 2 - 35
Components
9.4 PLC key 2/E "+H-KF10" (S2 / S3)
[1] [2] [3]
1.) Temperature range:

The keypad monitors the temperature in the
= Under temperature min. 0°C switchgear cabinet. If the temperature exceeds or
falls short of the temperature range (0 - 55°C),
the control shuts down the hoist gear, or if not yet
= Over temperature max. 55°C active, the hoist gear can no longer be activated.
2.) Operating display:

= Display Control ON
3.) Key switch: Operating modes For servicing work on the crane only!
= Release brake (bleed) - Brake released ➜ W 559

- EC-H crane: In S2 ➜ release hoist gear brake.
- HC-L crane: In S4 ➜ release luffing gear brake.
2 - 36 1250 HC 40 / 49516
Components
9 Switching station S1 / S2
9.5 Activation and deactivation devices

- Keep switchgear cabinets and switching stations closed at all times. Access is only
permitted to authorised personnel in possession of a key or special tool.
- Should work on voltage-carrying parts become necessary, a second person should be
introduced to switch off the main switch wherever necessary.
This summary shows the correlations of the most important deactivation devices.
Control stand Lighting, heating and S0

air-conditioning for the
Lighting, heating
switching station S1/S2
and air- S05 / P1
conditioning
Circuit breaker
+A-Q2
Overvoltage
protection
+A-F41 / -F42
S1/S2
Main switch
+A-Q1
Crane switch
+A-Q0
crane control
+A-W1
Slipring assembly
with isolating
switch
Supply cable
The site junction box must be provided for use on the building site!
Slipring assembly with isolating switch

The slipring assembly comprises sliprings for the power
supply cable, lighting, free jib slewing and Emergency-
Stop.
The terminal connections and screw connections are
located in a lockable terminal box (X5) beneath the
slipring assembly.
The switch on the slipring assembly isolates the

electrical power supply cable to the switching station
S1/S2, S0 and to the crane cab (➜ main switch)
1250 HC 40 / 49516 2 - 37
Components
9.5 Activation and deactivation devices
Circuit breaker (+A-Q1) for switching station S1/S2

Switching station S1/S2 => Control hoist gear, trolley and
slewing gear.
The main switch (+A-Q1) allows the disconnection of voltage +A-Q1
to the entire switching station S1/S2.
Lighting, plug sockets, heating and air-conditioning remain
active.
Installation: Switching station S1/S2
Surge protection
The supply cable is safeguarded by a surge protection (+A-F41 /42).
Fuse breaker: 125A 400V

Lightning current arrester: PU 3B 275VAC
+A-F42
Check display:
green = Equipment OK
red = Equipment has been triggered!
+A-F41
CAUTION: To prevent damage to the electrical
equipment of the crane, triggered equipment must be
replaced!
Circuit breaker (+A-Q2) for switching assembly S0

Circuit breaker (+A-Q2) allows the disconnection of
voltage to the entire switching assembly S0 and to the +A-Q2
crane cab. Heating, air-conditioning and lighting will also
be shut down.
Circuit breaker (+A-Q0) "Crane control"

Circuit breaker (+A-Q0) allows the disconnection of
voltage to the entire control of the crane drives.
2 - 38 1250 HC 40 / 49516
Components
10 Crane cab
10.1 Electrical cabinet S05

- Control cable to control stand P1 with Emergency-Stop and
EMS-2.
- Switchgear unit for heater, air-conditioning, lighting, plug
sockets, windshield washing system and central lubrication
system, aircraft warning light (not featured as standard)
Operating elements (see chapter "Operation")

Plug sockets 230V AC
Timer: Cab heating
Button: Release slewing gear brake 1 2 3 5 6
Button: Free jib slewing
Button: Cab light
➅ Button: Building site lighting 4
10.2 Control stand P1

The control stand P1 is connected with switching
station S1/S2 via a bus line (Arcnet).
The control lever is equipped with: P1

- Deadman switch
- Automatic return of control lever S05
- Button for slewing gear brake
- Hoist gear positioning key
Operating elements (see chapter "Operation")

Left-hand side: Right-hand side:
Horn Control ON / OFF
Gear selector switch hoist gear Emergency-Stop
Windshield washing system Windshield wiper
Bridging "Limit switch hoist raised" Lamp red (error message, see EMS)
Illuminated key
Ventilation / heating
1250 HC 40 / 49516 2 - 39
Components
11 Switching the control on and off

Switching on the control voltage
- Switch on the main switch in switching station S1/S2.
- Press the "Control ON" button in the crane cab, see chapter "Operation".
The control can only be switched on if all control levers are in the neutral position and
all Emergency-Stop buttons have been released!
Deactivating the control voltage

- Press the "Control OFF" button, see chapter "Operation".
- via deadman function, see chapter "Operation".
Actuation of free jib slewing only possible with control voltage deactivated!
12 Signal sensor
1
Signal horn for overload (102-110%)
Signal horn for the crane operator

2
See also chap. 14 "Optional equipment".
13 Control of the drives
Motors wit frequency converter (FC)

A frequency converter is an electrical unit which converts a fixed mains voltage with fixed
frequency into a variable output voltage with variable frequency. This allows stepless speed
control of the three-phase asynchronous motor.
The frequency converter is connected with the PLC via binary and analogue I/O assemblies.
The analogue outputs of the PLC transfer the set value to the frequency converter (FC).
Operation of the drives

Control of the drives is resulted via the control lever in the control stand. All movements which
can be initiated via the control lever can be executed simultaneously.
- Never wrench the control lever!
- Execute the individual switching stages slowly!
2 - 40 1250 HC 40 / 49516
Components
Hoist gear
Drive: Squirrel-cage motor with Danfoss frequency converter (stepless control lever with
positioning mode). The hook speed is resulted in accordance with the degree of
inclination of the control lever (pushbutton not pressed).
The basic speed range

The load can be moved steplessly. The attainable speed range with maximum load is
between: 0 rpm and..1125 rpm at 65 kW FC hoist gears (2-speed)
0 rpm and..1500 rpm at 110 kW FC hoist gears (3-speed).
Maximum speed is attained with full deflection of the control lever. With lighter loads and full
deflection of the control lever, the speed is increased to maximum in relation to the load:
4500 rpm at 65 kW FC hoist gears (2-speed)
3000 rpm at 110 kW FC hoist gears (3-speed).
Speed load diagram, see operating instructions for the crane operator, "Technical
data, hoist gear".
Positioning mode (pushbutton in right-hand control lever)

The positioning mode is applied in the basic speed range (see above). This allows the
positioning of "suspended" loads at lower speeds (around zero), without engaging the brake.
Positioning mode is activated by pressing the pushbutton on the control lever, thus
Press the pushbutton and hold pressed during the positioning procedure.
If the control lever is manoeuvred into the neutral position from the "Lift" or "Lower" position
with the pushbutton pressed, the converter remains engaged. This allows stepless fine
positioning around the zero point between "Lift" and "Lower" as desired, thus the load is
retained by the motor in a "suspended state" with the brake released. This positioning mode
is completely independent of the respective load. If the pushbutton is actuated during normal
operation, the drive is operated at the speed in the basic speed range which corresponds
with the control lever position.
Controlled load transfer with "Apply brake".

Application of the brake at set value specification zero is resulted in dependence of the
speed. The drive runs to the preset ramp close to zero speed. The frequency converter (FC)
then relays a braking command by way of an output relay.
Speeds which are blocked in positioning mode:

- 1125 rpm - 4500 rpm at 65 kW FC hoist gears (2-speed)
- 1500 rpm - 3000 rpm at 110 kW FC hoist gears (3-speed)
1250 HC 40 / 49516 2 - 41
Components
Trolley travel gear (18.5 kW / 11.0 kW)
Drive: Squirrel-cage motor with KEB frequency converter (stepless control lever).
The output frequency of the frequency converter, and thus the speed of the trolley travel gear
motor can be steplessly and continuously regulated with the control lever from approx. 2.5
Hz (KEB) in the start position up to approx. 75 Hz. For resulting speeds, see the operating
instructions for the crane operator, "Technical data, trolley travel gear".
Load-dependent speed reduction for the trolley travel gear with PLC-control:
The maximum speed for the trolley travel gear is adapted to the corresponding load. Thus,
the trolley travel gear is automatically assigned the correct maximum speed upon full
deflection of the respective control lever.
Example: A crane with maximum load can still be operated with a maximum 33% of its
maximum speed.
Reversal of slewing direction is also executed electronically as an acceleration and delay

limitation in the frequency converter, whereby acceleration or braking is always implemented
evenly, even upon wrenching or countering of the control lever. The drive is thus secured
against countering.
The drive is braked by returning the control lever back into the neutral position. If the output
frequency of 2.5 Hz (KEB) is fallen short of, the drive is shut down and the mechanical brake
is engaged.
Slewing gear (3x 11.0 kW)
Drive: Squirrel-cage motor with KEB frequency converter (stepless control lever).
The output frequency of the frequency converter, and thus the speed of the slewing gear
motor can be steplessly and continuously regulated with the control lever from approx. 2.5
Hz (KEB) in the start position up to approx. 120 Hz. For resulting speeds, see the operating
instructions for the crane operator, "Technical data, slewing gear".
Reversal of slewing direction is also executed electronically as an acceleration and delay

limitation in the frequency converter, whereby acceleration or braking is always implemented
evenly, even upon wrenching or countering of the control lever. The drive is thus secured
against countering.
When initiating movement, the control lever must be deflected to an extent that ensures only
slow movement of the jib. Load conditions and weather conditions are always influential for
this action.
See the operating instructions for the crane operator, "Wind load control"
When initiating movement and countering, execute the control lever stages slowly
to ensure that the load does not begin oscillating.
When countering, do not pull the control lever suddenly in the opposite direction.
2 - 42 1250 HC 40 / 49516
Components
14 Optional equipment (not featured as standard)
14.1 Free jib slewing on the tower foot

The free jib slewing with Emergency-
Stop is mounted on the tower foot and
connected to terminal box X5.
14.2 Emergency-Stop
Additional "Emergency-Stop" buttons which are not featured as standard can be fitted in the
entrance area of the crane. The sliprings required for this are provided or are featured in the
slipring assembly. See chap. 5 "Emergency-Stop" and circuit diagram.
14.3 Access monitoring

14.3.1 Floor hatch in the crane cab
A bell system is fitted in the slewing platform and a limit switch in the floor hatch of the cab to
monitor access into the crane cab. The bell system notifies the crane operator of a person's
intention to access the crane cab. Upon opening of the floor hatch, the limit switch is enabled
and opens the Emergency-Stop circuit. (➜ Emergency-Stop)
14.3.2 Trapdoors in the jib
The trapdoors in the jib allow easy access to the trolley. A limit switch is fitted to each of the
trapdoors for the purpose of monitoring access. Upon opening of a trapdoor, the limit switch
is enabled and opens the Emergency-Stop circuit. (➜ Emergency-Stop)
14.4 Temperature monitoring -25°C

In ambient temperatures of less than -25°C, no loads exceeding 500 kg can be lifted.
Loads of 500 kg and more can only be lowered and the trolley can only be manoeuvred
"inwards" towards the tower. Installation of this temperature monitoring includes an
additional temperature monitor with gauge in switchgear cabinet S2.
See chapter 18 Appendix "Temperature monitoring -25°C".
14.5 Signal lamps
The aircraft warning lights are mounted at the highest

point of the crane (tower head, jib head) and remain
active 24 hours a day.
The "ABB bridged" signal lamp is fitted upon request of

the customer.
1250 HC 40 / 49516 2 - 43
Components
14.6 Radio remote-control with and without feedback (HBC)
For the installation of a radio remote-control, the "Radio" interface module must be mounted in
switchgear cabinet S1. The "Radio" interface module is connected with the crane control (PLC)
via terminal strip X1 and a sensor plug.
See chapter 18 Appendix "Radio interface module".
Installation of radio receiver:
Slewing platform
14.7 Remote data transfer (DFÜ)
For the installation of a remote data transfer (DFÜ), the "DFÜ" assembly with radio antenna and
a circuit breaker (16A) must be mounted in switchgear cabinet S1. Following installation of the
"DFÜ" assembly, a valid SIM card with enabled CSD-data service must be inserted in the
MODEM.
See chapter 18 Appendix "DFÜ assembly".
See Litronic handbook, chapter 1.1.4 System summary: Litronic crane control.
The "LIKOM" software package including MODEM is available as an option for the "DFÜ"
assembly.
For the DFÜ connections through a telephone line or wireless (mobile phone), the Liebherr
crane must be equipped with a "DFÜ" assembly. A standard personal computer (PC with
Windows operating system) with "LIKOM" software package and featuring a respectively
configured modem connection serves as a communication partner.
LIKOM is a terminal program for data exchange between a personal computer (PC) and the
machine control (PLC) of a Liebherr tower crane. All data is transmitted and received via a serial
interface between PC and PLC control. The data received from the PC is collected in the
LIKOM, represented on the display screen and if necessary, stored on a storage medium (hard
drive, ...).
For further information regarding the DFÜ, refer to the LIKOM handbook.
2 - 44 1250 HC 40 / 49516
Components
14.8 Interface for the anti-collision system (AKS)
For the installation of an anti-collision system (AKS), the AKS interface module and a slewing
angle sensor must be installed in the crane. Following installation of the AKS control , the
optional "AKS" must be enabled in the crane control (➜ EMS).
See chapter 18 Appendix "AKS interface module".
See Litronic handbook, chapter 2.2.8.9 Activating and deactivating the anti-collision system.
The optional "AKS" is deactivated as standard (not active). Upon activation, the crane control
(during normal operation) detects the connected AKS network (active = responds to the signals
of the AKS). If the AKS network is not detected, all drives become blocked and the E406 error
message appears in the EMS.
The AKS control must be set to "Torque control"!
14.9 Tower and building site lighting

For installation of the lighting for tower and building site, a light transformer which corresponds
with the respective output (autotransformer or isolating transformer) must be installed.
For configuration as an autotransformer, the same protective measure is effective for the light
circuit and the crane. For configuration as an isolating transformer, one phase of the secondary
circuit is earthed. The secondary side forms a TN-S-system.
14.10 Optical wind display

The "optical wind displays" allows reading of the
actual wind speeds outside of the crane cab by way of their
large numerical display (LED ).
In most cases, the wind displays can also be mounted
directly onto the tower foot.
1250 HC 40 / 49516 2 - 45
Components
15 Maintenance of the electrical system
15.1 Switchgear cabinet / switching station
Electrical energy. Contact with voltage-carrying parts in the switchgear cabinet or

switching station can lead to fatal electric shocks.
Disconnect the mains connections before commencing work on the switchgear
cabinets / switching stations! Set the main switch to "0" (mains disconnected).
Checking the contactors
► Black colouring does not necessarily indicate damage, the contactors should therefore
never be filed!
► In the event of a short circuit: Check the contactor contacts. They may be burnt or
even welded.
Checking the connecting screws

► The connecting screws must be securely fastened to the terminal strips and
switchgear units.
Any terminal screws which have fallen out could cause hazardous electrical faults!
Resistors
Loose screw connections causes scaling and disruptions.
Risk of damage to the motor!
► Ensure secure seating of the screw connections!
► When replacing, use chrome-plated or cadmium-plated material!
► Insert original resistors only!
2 - 46 1250 HC 40 / 49516
Components
15.2 Electrical machines
Antifriction bearings
The operating temperature rises considerably with excessive amounts of grease!
Use bearing greases of the same type! See lubricant chart.
Lubricant: Lithium-soap hot bearing grease (drop point 160°C)

See lubricant chart under "Antifriction bearings".
Maintenance: After 10 000 operating hours, clean with benzene and fill in new grease
Filling amount in the bearing: Full
Filling amount in the empty spacing inside the housing: Fill to approx. 30-
50%
Bearings with sealing washers
Bearings with sealing washers are lubricated throughout their service life and are
therefore maintenance-free.
► Under no circumstances should the bearing be washed out!

► Do not heat the bearings prior to installation!
Slipring assemblies in the slewing platform (maintenance after 6 months)
Inspect the slipring assemblies and carbon brushes for slipring squirrel-cage motors
regularly.
► Under no circumstances should the bearing be washed out!

► Do not heat the bearings prior to installation!
► Remove any wear from carbon brushes from the entire slipring assembly and its
contact points, thus.
scrub with brush or paintbrush,
rub using a dry cloth or
blow out with dry and oil-free compressed air.
► Check length of the carbon brushes and replace as necessary. See Spare-parts
lists.
1250 HC 40 / 49516 2 - 47
Components
15.3 Limit switches in general
Freedom-of-movement! Cleanliness!
OK!
Inspect cover and
seal!
Cable entries
Kinked
OK! Loose! and
sheered!
Examples:
Limit switches Sensors
Load measuring axle Motors and pumps
2 - 48 1250 HC 40 / 49516
Components
16 Calculating the supply cables or residual length

- Improper installation of the power supply can lead to serious accidents.
- Work on the electrical equipment of the crane may only be carried out by electrical
specialists in accordance with the electrotechnical regulations.
- Distribution, earthing and protective devices must correspond with the local guidelines!
Stationary crane:
- Connection from site junction box to slipring assembly in the ball slewing ring support.
Rail-going crane:
- Connection from main distributor via the slip contacts of a current collector.
- Connection from site junction box via a motor cable drum or spring cable drum.
Calculating the supply cable
Diagram: Travel distance
Supply cable ~"remaining Travel distance

_____________------------------------------------------------------------------------------------------_________________________
length" 2
Site junction
box Incoming supply in the middle!
Overall length:
LGes = Overall length [ m ]
LRest = Residual length [ m ] From site junction box to
the slipring assembly in the slewing ring support.
LKran = Supply cable laid within the crane [ m ].
LHH = Erection and hook height of crane [ m ].
Lweg/2 = Half travel distance with feed in the middle of the travel distance. If the feed is not
precisely in the middle (travel section), the longer section should be regarded.
LGes = Permissible overall length [ m ] of supply cable

LKran = Overall length in the crane [ m ]
A = Permissible cable cross-section [ mm² ]
(taking the drop in voltage into consideration)
Un = Operating voltage [ V ]
IDauer = Continuous current [ A ]
cosϕ = Phase shift angle
1250 HC 40 / 49516 2 - 49
Components
17 Explanations for "Electrical connections"
17.1 Currents
1 Continuous current [ A ]: Total nominal voltage of all motors with coincidence factor
- of 0.8 for top-slewing cranes
- of 0.7 for bottom-slewing cranes
2 Peak current [ A ]: Max. current which can occur under the following conditions.
Prerequisite:
- All drives are powered with a coincidence factor of 0.7 and 0.8
taken into consideration.
Squirrel-cage motor: (hoist motor)
- Upshifting via different numbers of poles
Slipring rotor: (hoist motor)
- Maximum occurring current during interconnection of rotor
stages (approx. 2 x IN)
3 Line protection:
The supply cable from the feed point on the building site to the crane must be protected
against thermic overload and against short circuit. This protection can be achieved via:
- Line protection fuses with gl-characteristic curve
- Line circuit breaker with tripping characteristics B and C.
- Adjustable protective organs
(circuit breaker in accordance with DIN EN60947-2, DIN VDE 0660, Part 101 or motor
protection switch DIN EN60947-4-1, DIN VDE 0660, Part 102)
Caution: When using line protection fuses:

Observe the stipulated allocations of the line protection fuses
to the insulated lines rated cross-sections!
The current charge of the line may not exceed the rated
current of the fuse.
When using a line protection circuit breaker or an

adjustable protective organ:
The permissible current load of line is the same as the
nominal current of the line!
17.2 Diesel aggregate / autotransformer
1 Continuous output [ kVA ]: Total electrical intake of the nominal output of all motors,
taking the coincidence factor into consideration.
The continuous output is calculated:
Continuous current × Mains voltage3 × × 10-3
2 - 50 1250 HC 40 / 49516
Components
17.2 Diesel aggregate / autotransformer
2 Peak output [ kVA ]: Maximum output which the crane assumes under the following
conditions:
Prerequisite:
- All drives are powered with a coincidence factor of 0.7 and 0.8
taken into consideration.
- Upshifting via the different numbers of poles
- Maximum occurring output during interconnection of the rotor
stages
3 Activation power [ kVA ]: This power is yielded:

Prerequisite:
- All other drives are shut down!
- Upshifting via different numbers of poles
- Switching on in stage 1 "Lifting"
Caution: The diesel aggregate being used for the crane must be
configured at least for continuous output.
4 Braking action or
Drive chain loss [ kW ]: Output which occurs at the shaft of the diesel engine when the
hoist motor is working with full load and speed when lowering.
The diesel engine must be able to brake this load.
Note: Diesel engines can brake approx. 15-20% of their nominal

output.
17.3 Permissible length of the supply cables (see also "Calculating the supply cable")
Lines 1 and 2 Permissible line cross-section and permissible overall length

taking the drop in voltage into consideration.
With squirrel-cage motors, the peak current was used as a
basis to calculate the drop in voltage.
The continuous current has been taken into consideration for
slipring motors.
Line 3 Cable length which is laid from the hoist motor to the
connection point on the ball slewing ring support.
Line 4 Residual length which can be used for the supply cable from
site junction box to the connection point on the ball slewing ring
support.
1250 HC 40 / 49516 2 - 51
Components
2 - 52 1250 HC 40 / 49516
3 Specifications
All data regarding the crane and its components can be obtained in this chapter. The data for lifting
capacity indicates the load limitations which are not to be exceeded under any circumstances. The
Erection weight section includes the weights of the crane parts and thus the required hook heights of
the auxiliary crane.
1250 HC 40 / 49516 3-1

Specifications Instruction Manual
Complete crane
3.1 Complete crane
3.1.1 Lifting capacity
Warning!
The specified lifting capacity is only valid for the standard configuration of the free-standing crane
(standard hoisting heights and standard jib lengths). For greater special hoisting heights, the addi-
tional rope weight must be taken into consideration. For further information, see: Rope weights. The
lifting capacity is thus reduced accordingly.
1250 HC as 40t-Version: load capacity diagram (4-fall operation)
Intersection points [m]

Lifting capacity [kg]
Radius [m]
Tab. 3-1 Lifting capacity 1250 HC as 40t Version: load capacity diagram (4-fall operation)
Jib 82,1 m 76,3 m 64,7 m 53,1 m 41,5 m

(Radius) (79,6 m) 73,8 m) (62,1 m) (50,5 m) (38,8 m)
Radius [m] Maximum lifting capacity [kg]

79,60 11000
79,00 11120
78,00 11310
77,00 11510
Tab. 3-2 Lifting capacity 1250 HC as 40t Version: load capacity table (4-fall operation)
3-2 1250 HC 40 / 49516

Instruction Manual Specifications
Complete crane
Jib 82,1 m 76,3 m 64,7 m 53,1 m 41,5 m

(Radius) (79,6 m) 73,8 m) (62,1 m) (50,5 m) (38,8 m)

76,00 11720
75,00 11930
74,00 12140
73,80 12190 13000
73,00 12370 13190
72,00 12590 13430
71,00 12830 13670
70,00 13070 13920
69,00 13320 14180
68,00 13570 14450
67,00 13830 14720
66,00 14100 15010
65,00 14380 15300
64,00 14670 15600
63,00 14960 15910
62,10 15230 16190 17500
62,00 15260 16220 17530
61,00 15580 16550 17880
60,00 15900 16890 18240
59,00 16230 17240 18620
58,00 16580 17600 19000
57,00 16940 17980 19400
56,00 17300 18360 19810
55,00 17690 18760 20230
54,00 18080 19180 20670
53,00 18490 19610 21130
52,00 18910 20050 21600
51,00 19360 20510 22090
50,50 19580 20750 22350 24000
50,00 19810 20990 22600 24270
49,00 20290 21490 23130 24820
48,00 20780 22010 23680 25390
47,00 21290 22550 24250 25990
46,00 21830 23110 24850 26610

45,00 22390 23690 25470 27260
44,00 22970 24300 26120 27930
43,00 23580 24940 26800 28640
42,00 24210 25600 27500 29370
41,00 24870 26300 28240 30140
1250 HC 40 / 49516 3-3

Complete crane
Jib 82,1 m 76,3 m 64,7 m 53,1 m 41,5 m

(Radius) (79,6 m) 73,8 m) (62,1 m) (50,5 m) (38,8 m)

40,00 25570 27030 29020 30940
39,00 26300 27790 29830 31780
38,80 26450 27950 30000 31960 32000
38,00 27060 28590 30680 32660 32690
37,00 27870 29440 31580 33590 33600
36,00 28730 30340 32540 34560 34550
35,00 29690 31350 33610 35590 35550
34,00 30710 32420 34750 36660 36600
33,00 31800 33560 35960 37800 37700
32,00 32950 34770 37250 39000 38870
31,00 34180 36060 38620 40000 40000
30,00 35500 37440 40000 40000 40000
29,00 36900 38910 40000 40000 40000
28,00 38410 40000 40000 40000 40000
27,00 40000 40000 40000 40000 40000
26,00 40000 40000 40000 40000 40000
Point of inter-
27,02 28,30 30,05 31,21 31,08
section [m]
1250 HC as 20t-Version: load capacity diagram (2-fall operation)

Intersection points [m]
Lifting capacity [kg]
Radius [m]
Tab. 3-3 Lifting capacity 1250 HC as 20t Version: load capacity diagram (2-fall operation)
3-4 1250 HC 40 / 49516

Complete crane
Jib 82,1 m 76,3 m 64,7 m 53,1 m 41,5 m

(Radius) (81,0 m) (75,2 m) (63,5 m) (51,9 m) (40,2 m)

81,00 12500
80,00 12680
79,00 12860
78,00 13050
77,00 13240
76,00 13440
75,20 13600 14500
75,00 13640 14540
74,00 13850 14760
73,00 14070 14990
72,00 14290 15220
71,00 14510 15460
70,00 14740 15700
69,00 14980 15960
68,00 15230 16210
67,00 15480 16480
66,00 15740 16760
65,00 16010 17040
64,00 16280 17330
63,50 16420 17480 19000
63,00 16560 17630 19160
62,00 16860 17940 19500
61,00 17160 18260 19840
60,00 17470 18580 20000
59,00 17790 18920 20000
58,00 18120 19270 20000
57,00 18470 19640 20000
56,00 18820 20000 20000
55,00 19190 20000 20000
54,00 19570 20000 20000
53,00 19960 20000 20000
52,00 20000 20000 20000
51,90 20000 20000 20000 20000

51,00 20000 20000 20000 20000
50,00 20000 20000 20000 20000
49,00 20000 20000 20000 20000
48,00 20000 20000 20000 20000
47,00 20000 20000 20000 20000
Tab. 3-4 TLifting capacity 1250 HC as 20t Version: load capacity table (2-fall operation)
1250 HC 40 / 49516 3-5

Complete crane
Jib 82,1 m 76,3 m 64,7 m 53,1 m 41,5 m

(Radius) (81,0 m) (75,2 m) (63,5 m) (51,9 m) (40,2 m)

46,00 20000 20000 20000 20000
45,00 20000 20000 20000 20000
44,00 20000 20000 20000 20000
43,00 20000 20000 20000 20000
42,00 20000 20000 20000 20000
41,00 20000 20000 20000 20000
40,20 20000 20000 20000 20000 20000
40,00 20000 20000 20000 20000 20000
39,00 20000 20000 20000 20000 20000
Point of intersec-
52,91 56,03 60,54 51,90 40,20
tion [m]
Tab. 3-4 TLifting capacity 1250 HC as 20t Version: load capacity table (2-fall operation)
Rope weights
Note
For cranes featuring greater special hook heights, the lifting capacity is reduced in accordance with
the additional weight of the hoist rope.
Rope weight [kg/m]
Rope diameter [mm] Rope designation
PC-EUROLIFT PDD 915 CZ PDD 1315 C

10 0.51 - 0.47
11 0.61 - 0.59
12 0.73 - 0.69
13 0.86 - 0.80
14 0.99 - 0.93
15 1.14 - 1.06
16 1.29 1.19 1.20
17 1.46 1.35 1.36
18 1.64 1.51 1.52
19 1.82 1.68 1.70

20 2.03 1.86 1.89
21 2.23 2.05 2.08
22 2.44 2.25 2.28
23 2.67 2.46 2.49
24 2.93 2.68 2.70
Tab. 3-5 Rope weight
3-6 1250 HC 40 / 49516

Complete crane
Rope weight [kg/m]
Rope diameter [mm] Rope designation
PC-EUROLIFT PDD 915 CZ PDD 1315 C

25 3.16 2.91 2.94
26 3.41 3.15 3.17
27 3.69 3.39 3.44
28 3.97 3.65 3.69
29 4.24 3.91 3.96
30 4.55 4.19 4.26
31 - 4.47 4.53
32 5.17 4.77 4.84
33 - 5.07 5.12
34 5.86 - 5.44
35 - - 5.74
36 6.53 - -
38 7.30 - -
40 8.07 - -
Tab. 3-5 Rope weight
1250 HC 40 / 49516 3-7

Components
3.2 Components
3.2.1 Hoist gear

FU* Hoist Gear Type: WiW 300 VZ 427
Designation Value Unit

Motor output 110 kW
Rated torque, motor 716 Nm
Speed 0 - 3000 U/min
Tab. 3-6 Technical data for hoist gear WiW 300 VZ 427 - Motor E 12.0898-000/200

Total transmission ratio gear 1 i=1:122,253
Total transmission ratio gear 2 i= 1:70,901
Total transmission ratio gear 3 i= 1:42,453
Tab. 3-7 Technical data for hoist gear WiW 300 VZ 427 - Gear WiW 300 VZ 415-741.000

Brake clamping force 2x 16800 N
Release pressure 50 bar
Tab. 3-8 Technical data for hoist gear WiW 300 VZ 427 - Brake BRE 3300 BY 404

Rope drum nominal diameter 920 mm
Rope layers 6 -
Rope diameter 27 mm
Rope grooves 44,5 (left-handed, Lebus) Windings
Tab. 3-9 Technical data for hoist gear WiW 300 VZ 427 - Rope drum WiW 300 VZ 423-742.000
* Frequency converter
3-8 1250 HC 40 / 49516

Components
40 t / 4-run / stepless
Due to the positioning mode, the hoist speed can be reduced to 1/4 in the respective stage.
Load [kg]
Hoist speed [m/min]

Fig. 3-1 Output curve for hoist gear WiW 300 VZ 427 - 40 t - 4-run / stepless
Designation Speed 1st gear / limit 2nd gear / limit 2nd gear / limit
[rpm] switch switch switch
Max. load in con- 40.0 t/ 22.5 t/ 12.5 t/
1500
stant load range HS12Q HS13Q HS14Q
Monitoring of load 45.0 t/ 24.3 t/ 13.5 t/
1900
motor speed REF 1 HS20Q HS22Q HS24Q
Monitoring of load 35.0 t/ 18.9 t/ 10.5 t/
2500
motor speed REF 2 HS21Q HS23Q HS25Q
Fig. 3-2 Reference values overload protection for hoist gear WiW 300 VZ 427 - 40t - 4-run / step-
less
Gang Speed [rpm] Max. hoisting load [kg] Speed [m⁄min]

0 - 1500 40000 0 - 14
1st gear
0 - 3000 24000 0 - 22
0 - 1500 22500 0 - 24
Gear 2
0 - 3000 12900 0 - 38
0 - 1500 12500 0 - 40
Gear 3
0 - 3000 6400 0 - 64
Fig. 3-3 Output values for hoist gear WiW 300 VZ 427 - 40 t - 4-run / stepless
1250 HC 40 / 49516 3-9

Components
20 t / 2-run / stepless
Due to the positioning mode, the hoist speed can be reduced to 1/4 in the respective stage.
Load [kg]
Hoist speed [m/min]

Fig. 3-4 Output curve for hoist gear WiW 300 VZ 427 - 20 t - 2-run / stepless
Gear Speed [rpm] Max. hoisting load [kg] Speed [m⁄min]

0 - 1500 20000 0 - 27
1st gear
0 - 3000 11800 0 - 44
0 - 1500 11000 0 - 47
Gear 2
0 - 3000 5600 0 - 77
0 - 1500 5400 0 - 79
Gear 3
0 - 3000 1700 0 - 128
Fig. 3-5 Leistungswerte Hubwerk WiW 300 VZ 427 - 20 t - 2-strang / stufenlos
3 - 10 1250 HC 40 / 49516
Components
3.2.2 Slewing gear

FU* Slewing gear type: DRW 200 AZ 403 with rotary encoder
FU* Slewing gear type: DRW 200 AZ 404 without rotary encoder

Motor output 11 kW
Rated torque, motor 61 Nm
Speed 0 - 1720 rpm
Slewing platform slewing speed 0 - 0,6 rpm
Tab. 3-10 Technical Data Slewing Gear DRW 200 AZ 403/404 - Motor

Gesamtübersetzung 1:300 i=
Tab. 3-11 Technical Data Slewing Gear DRW 200 AZ 403/404 - Gear

Max. possible braking moment 120 Nm
Tab. 3-12 Technical Data Slewing Gear DRW 200 AZ 403/404 - Brake BFK 458 18E
1250 HC 40 / 49516 3 - 11
Components
3.2.3 Trolley travel gear

FU* Trolley travel gear type: KAW 200 KY 001

Motor output 11,0 kW
Rated torque, motor 71,5 Nm
Speed 1460 U/min
Tab. 3-13 Technical data for trolley travel gear KAW 200 KY 001 - Motor
Lifting capacity
[kg]
Trolley travel speed 40 000 0 - 68 m/min
Tab. 3-14 Technical data for trolley travel gear KAW 200 KY 001 - Trolley travel speed

Total transmission ratio 1:112,41 i=
Max. output torque 8200 (c=1.0) Nm
Tab. 3-15 Technical data for trolley travel gear KAW 200 KY 001 - Gear

Braking moment 50 Nm
Tab. 3-16 Technical data for trolley travel gear KAW 200 KY 001 - Brake BM 15 HR

Rope drum nominal diameter 700 mm
Rope layers -
Rope diameter 16 mm
Rope grooves 46 (lleft-handed, Lebus) Windings
Tab. 3-17 Technical data for trolley travel gear KAW 200 KY 001 - Rope drum
3 - 12 1250 HC 40 / 49516
3.2.4
1250 HC 40 / 49516
Output [kW] Drive units Currents at 440V/60Hz Power [kW] Generating set / autotransformer Permissible length of supply cable 4)
Instruction Manual
Fuse/
Hoist gear
Travel gear
Peak power
Total length
Peak current
Slewing gear
Power switch
Cross section
on the crane 3)
Brake power 2)
Remaining length
Trolley travel gear

Connecting power
Continuous power
Continuous current 1)
kW kW kW kW A A A kVA cos ϕ kVA cos ϕ kVA cos ϕ kW mm2 m m m
- 170 197 2x144 118 0,92 194 0,92 115 0,92 75 2x 4x50 273 45 228
65 18,5 3x11
Electrical connection data
- 162 184 2x144 112 0,92 189 0,92 115 0,92 68 2x 4x50 286 45 241
65 11,0 3x11
- 221 248 336 153 0,92 271 0,92 177 0,92 104 2x 4x50 161 45 116
110 18,5 3x11 4x10,6 288 299 336 200 0,92 318 0,92 177 0,92 113 2x 4x70 225 45 180
- 214 236 336 148 0,92 266 0,92 177 0,92 103 2x 4x50 165 45 120
110 11,0 3x11 4x10,6 281 292 336 194 0,92 313 0,92 177 0,92 112 2x 4x70 232 45 187
Tab. 3-18 Electrical connection data 1250 HC
1) at factor for simultaneous motions of 0,8

2) at the engine shaft
3) up to the connection on the ball slewing ring support
4) at 3% voltage drop for the continuous current
3 - 13
Components
Specifications
Components
3.2.5 Current data
Continuous current
Total nominal current of all motors with a factor for simultaneous motions
(in A)
Peak current
Maximum current which can occur in the following circumstances:
(in A)
Precondition: All crane drives are operated taking into account

the factor for simultaneous motions.
Switching up via the different numbers of poles

Squirrel-cage motor:
When switching through the rotor stages
Slipring motor:
(approx. 2 x IN)
3.2.6 Power set / autotransformer
Total electrical power output of all motors taking into account the factor for
Continuous power
simultaneous motions.
(in kVA)
(calculation: continuous current x mains voltage x √3 x 10-3)
Peak power
Maximum power consumption of the crane in the following circumstances:
(in kVA)
Precondition: All crane drives are operated taking into account

the factor for simultaneous motions.
Squirrel-cage motor: Switching up via the different numbers of poles

Slipring motor: When switching through the rotor stages
Connecting power
(in kVA)
Pre condition:
All other crane drives are switched off.
Squirrel-cage motor: Switching up via the different numbers of poles

Slipring motor: When switching through the rotor stages
Value recorded at the motor shaft when the hoisting motor operates at max-
Brake power
imum load and speed in the lowering direction.
(in kW)
The motor must be able to brake this load.
3 - 14 1250 HC 40 / 49516
Ambience / Climatisation
3.3 Ambience / Climatisation
3.3.1 Mains power supply, ambient and storage conditions for top-slew-
ing cranes
Mains power supply
Caution!
Damage to electrical components.
Connected loads of the crane must comply with the connected loads of the mains power supply.
X Please contact the Technical Office (TB) in the event of deviating connected loads.
Network tolerances
Network tolerances
Distribution voltage 3 x 400 V ± 10%
Frequency 50 Hz ±1%
Tab. 3-19 Network tolerances (3 x 400 V)
Network tolerances
Distribution voltage 3 x 480 V + 5% - 10%
Frequency 60 Hz ±1%
Tab. 3-20 Network tolerances (3 x 480 V)
Ambient conditions
For further information, see: Chap. 3.3.2 Cli-

Working temperature for cranes
mate control for switch cabinets
Storage temperature (crane disassembled) a) - 40°C to + 65°C
Maximum relative humidity 93% (IEC 68-2-3 during storage / transport)
Maximum relative humidity 95% (non-condensing operation)
1000 meters (without effecting a reduction in
Maximum height above sea level
output)
Tab. 3-21 Ambient conditions for top-slewing cranes
a. At temperatures below -25°C, electronic components must be heated.
1250 HC 40 / 49516 3 - 15
Storage conditions for crane components with switchgears
Notice!
Moisture or condensation in the switchgears can cause direct damage to assemblies of the electri-
cal equipment.
X Avoid moisture or condensation in the switchgears (switchgear cabinets).
Upright storage
X To prevent moisture and condensation occurring in the switchgear cabinets, the crane cabin, as
well as all other switchgears (e.g. hoist gear switchgears or luffing gear switchgears, etc.) must be
stood upright during storage.
Flat storage
Should it not be possible to store the cabin and the switchgears standing upright, the following in-
structions are to be observed.
X Close all access or exit hatches, as well as side windows and front windshields.
X Cover the crane cabin to protect against atmospheric influences.
3.3.2 Climate control for switch cabinets

This description applies for the following types of upper-slewing crane:
– EC-H
– EC-B
– EC-HM
– HC-L
– EL
– LC
The design and dimensions of the climate control unit of the switch cabinet depends on the following
criteria:
– Type and configuration of crane control
– Climatic zone where the application is being carried out (ambient temperature)
Cranes featuring contactor control
Climate control Temperature range

Standard (fan / heater) -25°C to +45°C
HEAT-PIPE with FC -25°C to +55°C
Tropicalisation with SL -25°C to +55°C
Tab. 3-22 Climate control for switch cabinets (contactor control)
Cranes featuring SPS-control

Standard (fan / heater) -25°C to +35°C
Tab. 3-23 Climate control for switch cabinets (SPS-control)
3 - 16 1250 HC 40 / 49516

HEAT-PIPE -25°C to +45°C
Tropicalisation -25°C to +55°C
Tab. 3-23 Climate control for switch cabinets (SPS-control)
Special measures for extreme temperatures
Note
Always contact the Technical Office (TB) to discuss special measures.

Special measures for very low temperatures a) -40°C to -25°C
Special measures with very high temperatures > +55°C
Tab. 3-24 Climate control for switch cabinets (extreme temperatures)
a. At temperatures below -25°C, electronic components must be heated.
1250 HC 40 / 49516 3 - 17
Criteria for the auxiliary crane
3.4 Criteria for the auxiliary crane
3.4.1 Crane configuration 1250 HC on 1250HC tower
Note
The specified hook heights X [m] for the auxiliary crane are valid for the example (see: Fig. 3-6) rep-
resented.
X The auxiliary crane must be adapted accordingly to suit varying crane configurations.
Fig. 3-6 Criteria for the auxiliary (crane base 1250 HC on 1250HC tower)
3 - 18 1250 HC 40 / 49516
Crane base tower system 1250 HC
Individ
Total Required hook
Height ual
Pos. Crane part weight height X [m] for
[m] weight
[t] auxiliary crane
[t]
Undercarriage (1)
Undercarriage rail-going
(a) 1250 HC stand- stationary on
ard anchor shoes
20,0
(b) Undercarriage tower section
Central ballast
(c)
block
Erection auxiliary device
Erection auxil-
(d) 0,65 2,7 — —
iary device
Foundation anchors 1250HC (2)

1 set of foundation anchors
C 032.001-372.111 / 9535 276 01 2,05 4x 0,47 —
H=0,425m
(e)
1 set of foundation anchors
C 036.020-372.111 / 9000 9694 2,10 4x 0,54 —
H=0,65m
Foundation an-
chors 1250HC
(f) 7,90 — 12,36 18,0
with Tower sec-
tion
on crane base
Tower 1250HC
(1) (2)
Tower section 2
(g) 31,5 22,0
standard
5,80 10,20 10,20

Tower section 3
(h) 37,5 28,0
standard
Climbing equipment (with hydrau-

(i) lic unit, platforms, ram and support 12,5 — 19,10 50,0 40,0 —
shoe)
Tab. 3-25 Criteria for the auxiliary (crane base 1250 HC on 1250HC tower)
1250 HC 40 / 49516 3 - 19
Individ
Total Required hook
Height ual
[m] weight
[t] auxiliary crane
[t]
Erection platforms
(j) 2 x 0,31 0,64 37,5 28,0
C 036.020-966.000 / 9001 3061
3 - 20 1250 HC 40 / 49516
Crane 1250 HC
Individ
Total Required hook
Height ual
[m] weight
[t] auxiliary crane
[t]
on crane base
Top part of crane
(1) (2)
Roller slewing ring support, slewing platform, cabin with platform and tower head
(k)
Roller slewing ring

1,50 10,3 — 39,0 29,0 —
bottom part
(l) Platforms with canin 4,20 — 2,7 39,5 29,5 —
Slewing platform cpl.

with
– roller slewing ring
– 3 x slewing gears
– platforms
2,70 — 34,30 40,0 30,5 —
– platform and cab-
in
support
(m) upper part
with
– platforms 4,20 — 44,60 41,5 32,2 —
in
support cpl.
Tower head cpl.

(n) with 12,30 — 10,5 54,0 44,5 —
– tie bars
1250 HC 40 / 49516 3 - 21
Crane 1250 HC
Individ
Total Required hook
Height ual
[m] weight
[t] auxiliary crane
[t]
on crane base
Top part of crane
(1) (2)
Counter-jib
Counter-jib without intermediate 22,4
— 27,50 42,5 33,5 —
counter-jib section (R23,7)
– counter-jib end section 6,60
– counter-jib heel section 5,10
– tie bars (for counter-jib without
3,24
intermediate counter-jib section)
– switching station 2,81
Hoist gear unit (without hoist rope)
with — — 42,5 33,5 —
– hoist gear WiW 300 VZ 427 or 6,50
(o)
– hoist gear WiW 300 VZ 423
– frame
– hoist rope Ø27mm and 525m
1,94
long
– frame 1,30
Counter-jib cpl. without intermedi- 29,05
— 32,00 42,5 33,5 —
ate counter-jib section (R30,3)
– tie bars (for counter-jib with in-
5,20
termediate counter-jib section) — — 42,5 33,5 —
– intermediate counter-jib sectiona 2,50
a. The intermediate counter-jib section is designed for the 1250 HC tower crane with 81.0 m,
75.2 m and 63.5 m jibs.
3 - 22 1250 HC 40 / 49516
Crane 1250 HC
Individ
Total Required hook
Height ual
[m] weight
[t] auxiliary crane
[t]
on crane base
Top part of crane
(1) (2)
Jib
max. radius / jib length
Jib part I with
– jib pivot section 79,6 m / 82,1 m
– intermediate jib sections or
– 2 trolleys 73,8 m / 76,3 m 30,80
– trolley travel gear with trolley or 42,5 33,5 —
travel ropes 62,1 m / 64,7 m
– tie bars 50,5 m / 53,1 m 23,20
– A-frame
(p) 38,8 m / 41,5 m 22,40
79,6 m / 82,1 m 19,00
Jib part II with
jib head section 73,8 m / 76,3 m 16,10
– intermediate jib sections 62,1 m / 64,7 m 13,00 42,5 33,5 —
– tie bars
50,5 m / 53,1 m 12,41
38,8 m / 41,5 m 8,20
hook block with

load hook 1,86
(2-fall operation)
(q)
Beam
1,00 1,00
(4-fall operation)
Counter-ballast A 7,10 — 47,5 38,5

(r)
block B 4,50 — 45,5 36,5
(s) The lifting slings must be at least approx 10.0 m in length.
1250 HC 40 / 49516 3 - 23
3.4.2 Crane configuration 1250 HC on 1250HC tower and 630EC-H foun-

dation anchors
Note
The specified hook heights X [m] for the auxiliary crane are valid for the example (see: Fig. 3-6) rep-
resented.
X The auxiliary crane must be adapted accordingly to suit varying crane configurations.
Tab. 3-29 Criteria for the auxiliary (crane base 1250 HC on 1250HC tower and 630EC-H foundatin
anchors)
Individ
Total Required hook
Height ual
[m] weight
[t] auxiliary crane
[t]
Undercarriage (1)
(a)
(b)
(c)
Erection auxiliary device

anchors)
3 - 24 1250 HC 40 / 49516
Individ
Total Required hook
Height ual
[m] weight
[t] auxiliary crane
[t]
Erection auxil-
(d) 0,65 2,7 — —
iary device
Foundation anchors 630EC-H reinforced (2) / C 048.007-371.111

(e) 1 set of foundation anchors 2,10 4x 0,8
Base tower
section
1250HC
(C036.020-338.000)
(f) 13,70 22,80 26,00 23,0
reinforced, with
foundation an-
chors 630EC-H
(C 048.007-371.111)
on crane base
Tower 1250HC
(1) (2)
Base
tower section
(g) 11,60 21,20 21,20 — 33,0
1250HC
(C036.020-337.000)
Tower section
1250HC
(h) 5,80 10,20 10,20 — 38,0

(C036.020-332.000)
standard
anchors)
1250 HC 40 / 49516 3 - 25
Individ
Total Required hook
Height ual
[m] weight
[t] auxiliary crane
[t]
Climbing equipment (with hydrau-
(i) lic unit, platforms, ram and support 12,5 — 19,10 — 50,0 —
shoe)
Erection platforms
(j) 2 x 0,31 0,64 39,0
C 036.020-966.000 / 9001 3061
anchors)
3 - 26 1250 HC 40 / 49516
Crane 1250 HC
Individ
Total Required hook
Height ual
[m] weight
[t] auxiliary crane
[t]
on crane base
Top part of crane
(1) (2)
Roller slewing ring support, slewing platform, cabin with platform and tower head
Roller slewing ring

(k) 1,50 10,3 — — 39,0 —
bottom part
(l) Platforms with canin 4,20 — 2,7 — 39,5 —

with
– platforms
2,70 — 34,30 — 41,5 —
in
support
(m) upper part
with
– platforms 4,20 — 44,60 — 42,2 —
in
support cpl.
Tower head cpl.

(n) with 12,30 — 10,5 — 54,5 —
– tie bars
anchors)
1250 HC 40 / 49516 3 - 27
Crane 1250 HC
Individ
Total Required hook
Height ual
[m] weight
[t] auxiliary crane
[t]
on crane base
Top part of crane
(1) (2)
Counter-jib
Counter-jib without intermediate 22,4
— 27,50 — 43,5 —
counter-jib section (R23,7)
– counter-jib end section 6,60
– counter-jib heel section 5,10
– tie bars (for counter-jib without
3,24
intermediate counter-jib section)
– switching station 2,81
Hoist gear unit (without hoist rope)
with — — — 43,5 —
– hoist gear WiW 300 VZ 427 or 6,50
(o)
– hoist gear WiW 300 VZ 423
– frame
– hoist rope Ø27mm and 525m
1,94
long
– frame 1,30
Counter-jib cpl. without intermedi- 29,05
— 32,00 — 43,5 —
ate counter-jib section (R30,3)
– tie bars (for counter-jib with in-
5,20
termediate counter-jib section) — — — 43,5 —
– intermediate counter-jib sectiona 2,50
anchors)
a. The intermediate counter-jib section is designed for the 1250 HC tower crane with 81.0 m,
75.2 m and 63.5 m jibs.
3 - 28 1250 HC 40 / 49516
Crane 1250 HC
Individ
Total Required hook
Height ual
[m] weight
[t] auxiliary crane
[t]
on crane base
Kranoberteil
(1) (2)
Jib
Jib part I with
– jib pivot section 79,6 m / 82,1 m
– intermediate jib sections or
– 2 trolleys 73,8 m / 76,3 m 30,80
– trolley travel gear with trolley or — 43,5 —
travel ropes 62,1 m / 64,7 m
– tie bars 50,5 m / 53,1 m 23,20
– A-frame
(p) 38,8 m / 41,5 m 22,40
79,6 m / 82,1 m 19,00
Jib part II with
jib head section 73,8 m / 76,3 m 16,10
– intermediate jib sections 62,1 m / 64,7 m 13,00 — 43,5 —
– tie bars
50,5 m / 53,1 m 12,41
38,8 m / 41,5 m 8,20
hook block with

load hook 1,86
(2-fall operation)
(q)
Beam
1,00 1,00
(4-fall operation)
Counter-ballast A 7,10 — — 48,5

(r)
block B 4,50 — — 46,5
(s) The lifting slings must be at least approx 10.0 m in length.
anchors)
1250 HC 40 / 49516 3 - 29
3 - 30 1250 HC 40 / 49516
Instruction Manual Corner pressures, foundation loadings and ballast
4 Corner pressures, foundation loadings

and ballast data
The information obtained in this chapter pertains in particular to stability of the crane. The corner
pressure tables also include essential data. As well as obtaining information regarding the pressures
which the support points are subjected to, it is also possible to determine whether the foundation soil
is suitable for erection of the crane. Furthermore, details of which central ballast is necessary for the
respective crane configurations are prescribed, as well as correct selection of the counter-ballast. If
the crane is to be erected on foundation anchors, the appropriate data allowing correct dimensioning
of the foundation can be obtained from the foundation loading tables.
The corner pressures, foundation loadings and ballast data only apply for the crane configu-
ration specified! For further information, see: Appendix Corner pressures, foundation loa-
dings and ballast data!
Corner pressures, foundation loadings and ballast data for special configurations can be acquired
upon request from Liebherr-Werk Biberach GmbH, Statics Department.
LBC/en/01/Ausgabe: 07.11
1250 HC 40 / 49516 4-1

Corner pressures, foundation loadings and ballast Instruction Manual
Foundation reaction forces
4.1 Foundation reaction forces
4.1.1 General notes on safety for foundation loading tables

– Sheet 1 of 2
Risk of accident!
Important information!
Risk of injury!
0.1.1. Notes on safety
Warning!
Risk of accident! Ensure compatibility of the Component list!
The static data may only be used if the crane erection corresponds with the configuration described,
and if the components being used have been selected in observation of the "Component
compatability list".
► For further information, see: Static data ›Component compatibility list‹.
Warning!
The foundation loadings are characteristic loads and do not include dynamic factors on dead weight
and hoist load.
Warning!
Risk of accident! Stability of the crane!
► Subsequent installation or removal of the climbing equipment affects stability of the crane, and
thus the resulting foundation loadings. Under these conditions, therefore, both foundation loading
tables "Foundation loadings with climbing equipment" and "Foundation loadings without climbing
equipment" should be observed as early as the application planning stage, and the respective,
more unfavourable values taken into account.
Warning!
For certain jib lengths, the crane cannot turn freely in the wind without the installation of an additional
wind sail.
► Install wind sails as required. For further information, see: Instruction manual, chapter ‘Erection’.
0.1.2. Notes
Note regarding EC-H cranes featuring 2/4-fall configuration

Observe the minimum and maximum radius.
► For further information, see: Data sheet and instruction manual, chapter ‘Erection’ ›Minimum and
maximum radius‹.
Note regarding EC-B cranes

The hook heights specified in the foundation loading tables always include the climbing tower
section.
4-2 1250 HC 40 / 49516

– Sheet 2 of 2
Note regarding EC-B cranes

Erection and dismantling of the crane without climbing equipment!
When erecting the crane without climbing equipment, the climbing tower section can be replaced with
a standard tower section.
0.1.3. Symbols used in the foundation loading tables
* Warning!
At this hook height, the climbing equipment must be lowered after erection!
xx Warning!
At this hook height, switching over to the LM2 load curve is not permissible!
► For further information, see: "Operating manual for the crane operator", "Control desk".
o
Warning!
At this hook height, mounting of a cabin is not permissible!
► Possible "without cab" only.
@
Warning!
At this hook height, operation with climbing tower section is not permissible!
► The climbing tower section must be replaced with a standard tower section.
1250 HC 40 / 49516 4-3

4.1.2 Initial use of the crane
LIEBHERR−WERK BIBERACH 07.04.2011 09:54:47

prsV1.41tpV3.06
00182158 krm1
sketch: some details possibly not accurate!
1250HC40: WN 49516, tower 1250HC on foundation anchor

storm conditions out of operation according DIN 1055: 1986
without climbing equipment
1x C036.020−333.000 slewing ring support 1250HC 2.1m
pos. of trolley out of operation

=======================
jib position
−−−−−−−−−−−−−−−−
80.0m − 6.50m
75.0m − 6.50m
63.0m − 6.50m
52.0m − 6.50m
40.0m − 6.50m
valid for hoist gears:

12x C036.020−332.000 tower section 1250HC 5.8m climb.
WIW300VZ427
92.4m
1x C036.020−337.000 tower section 1250HC 11.6m reinf.
1x C036.020−338.000 tower section 1250HC 11.6m reinf.
1x C048.007−372.111 foundation anchor 630EC−H 8xM45
FOUNDATION␣LOADING␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣␣st93dV1.50:V1.53

␣␣␣Jib␣␣␣␣MD␣␣␣␣Crane␣in␣operation␣␣␣Cr.␣o.␣of␣op.␣st.␣beh.␣Cr.␣o.␣of␣op.␣st.␣fro.␣␣␣␣Crane␣in␣erection␣␣␣
Tr.out␣o.[kNm]M␣[kNm]H␣[kN]␣V␣[kN]␣M␣[kNm]H␣[kN]␣V␣[kN]␣M␣[kNm]H␣[kN]␣V␣[kN]␣M␣[kNm]H␣[kN]␣V␣[kN]␣

80.0/␣6.5␣1159␣␣15795␣␣␣␣125␣␣␣3772␣␣19211␣␣␣␣395␣␣␣3648␣␣25280␣␣␣␣316␣␣␣3633␣␣16722␣␣␣␣␣96␣␣␣3035

75.0/␣6.5␣1073␣␣15909␣␣␣␣125␣␣␣3693␣␣18672␣␣␣␣395␣␣␣3547␣␣25761␣␣␣␣316␣␣␣3532␣␣14422␣␣␣␣␣96␣␣␣3005

63.0/␣6.5␣␣912␣␣16782␣␣␣␣125␣␣␣3613␣␣18627␣␣␣␣394␣␣␣3418␣␣25730␣␣␣␣315␣␣␣3403␣␣13707␣␣␣␣␣96␣␣␣2902

52.0/␣6.5␣␣708␣␣16890␣␣␣␣125␣␣␣3647␣␣18116␣␣␣␣394␣␣␣3380␣␣26128␣␣␣␣315␣␣␣3366␣␣10754␣␣␣␣␣96␣␣␣2793

40.0/␣6.5␣␣514␣␣16658␣␣␣␣125␣␣␣3529␣␣17939␣␣␣␣393␣␣␣3174␣␣26267␣␣␣␣315␣␣␣3159␣␣␣8492␣␣␣␣␣93␣␣␣2447

4-4 1250 HC 40 / 49516

4.1.3 Foundation reaction forces according DIN15019/DIN1055-4:1986
Crane 1250 HC 40 with climbing equipment

40 t / 4-fall operation
tower sections 1250HC (C036.020-332.000) / 5.8m
foundation anchors 500HC (C032.001-372.100)
– Sheet 1 of 6
Krantyp: 1250 HC 40
Turmaufbau: 1250HC40: WN_49516_2-4-Str._ts1250_fu500_DIN1055-4:1986_mKE

zuletzt geändert: 30.06.2011 15:33:35
ID: 00000823.fun
Berechnungsnummer: 00185826 krm1
Fig. 4-1 Component compatibility list 1250 HC 40
1250 HC 40 / 49516 4-5

– Sheet 2 of 6
Foundation reaction forces 1250 HC 40, Serial No. 49516

Crane stationary on foundation anchors, with climbing equipment
DIN15019/DIN1055-4:1986
(Hoist gear: WiW 300 VZ 427)
Radius: 80,00 m
Tower section: 5,80 m
Foundation anchors: 500HC / Standard (Drawing No. C 032.001-372.111)
Conditions for crane stability are:

Jib must be free to weathervane when out of operation!
M + ( H ⋅ h) L
Eccentricity : e = ≤
V +G 3
Ground pressure must not exceed maximum

allowable soil pressure!
2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
G = Weight of foundation
Position of trolley out of operation: 6,5 m
The loading given do not include factors
for dynamic effects.
Slewing moment in operation MD = 1159 kNm
30.06.2011
No. Of Hook- Crane in operation Crane out of operation Crane during erection
tower Storm from rear Storm from front
sections height M [kNm] H [kN] V [kN] M [kNm] H [kN] V [kN] M [kNm] H [kN] V [kN] M [kNm] H [kN] V [kN]
4 23,0 9255 80 2765 1469 190 2626 8831 152 2626 12176 52 2028
5 28,8 9736 85 2865 283 225 2741 10137 180 2727 12491 56 2128
6 34,6 10246 90 2966 1791 246 2842 11344 197 2827 12834 61 2229
7 40,4 10783 95 3066 3420 267 2943 12647 214 2928 13204 66 2330
8 46,2 11348 99 3167 5171 288 3043 14048 230 3029 13602 71 2430
9 52,0 11940 104 3268 7043 309 3144 15545 247 3129 14027 75 2531
10 57,8 12559 109 3368 9036 330 3244 17140 264 3230 14480 80 2631
11 63,6 13207 114 3469 11150 351 3345 18831 281 3330 14961 85 2732
12* 69,4 13208 118 3569 10230 343 3446 18095 275 3431 14795 90 2833
13* 75,2 13841 123 3670 12284 364 3546 19739 291 3532 15262 94 2933
* In this configuration the climbing equipment has to be lowered after erection!
4-6 1250 HC 40 / 49516

– Sheet 3 of 6

DIN15019/DIN1055-4:1986
Radius: 75,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
30.06.2011
4 23,0 9257 80 2686 1985 190 2525 9331 152 2525 9881 52 1998
5 28,8 9854 85 2786 354 225 2626 10636 180 2626 10196 56 2098
6 34,6 10363 90 2887 1272 246 2741 11841 197 2726 10538 61 2199
7 40,4 10900 95 2987 2899 267 2842 13143 213 2827 10908 66 2300
8 46,2 11464 99 3088 4648 288 2942 14542 230 2928 11305 71 2400
9 52,0 12056 104 3189 6517 309 3043 16037 247 3028 11730 75 2501
10 57,8 12675 109 3289 8508 329 3143 17630 264 3129 12183 80 2601
11 63,6 13322 114 3390 10621 350 3244 19320 280 3229 12663 85 2702
12* 69,4 13323 118 3490 9698 343 3345 18582 274 3330 12497 90 2803
13* 75,2 13956 123 3591 11751 364 3445 20225 291 3431 12963 94 2903
1250 HC 40 / 49516 4-7

– Sheet 4 of 6

DIN15019/DIN1055-4:1986
Radius: 63,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
30.06.2011
4 23,0 10163 81 2606 1999 189 2396 9325 152 2396 9174 51 1895
5 28,8 10566 85 2707 371 224 2497 10627 180 2497 9488 56 1995
6 34,6 10996 90 2807 1252 245 2612 11830 196 2597 9830 61 2096
7 40,4 11454 95 2908 2877 266 2713 13130 213 2698 10199 66 2197
8 46,2 11940 100 3008 4623 287 2813 14527 230 2799 10596 70 2297
9 52,0 12920 104 3109 6490 308 2914 16021 246 2899 11020 75 2398
10 57,8 13541 109 3210 8479 329 3014 17611 263 3000 11472 80 2498
11 63,6 14189 114 3310 10588 350 3115 19299 280 3100 11952 85 2599
12* 69,4 14191 119 3411 9664 342 3216 18559 274 3201 11785 89 2700
13* 75,2 14826 123 3511 11714 363 3316 20200 291 3302 12251 94 2800
4-8 1250 HC 40 / 49516

– Sheet 5 of 6

DIN15019/DIN1055-4:1986
Radius: 52,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
30.06.2011
4 23,0 10632 80 2640 2465 189 2359 9759 151 2359 6230 51 1786
5 28,8 11058 85 2741 841 224 2459 11058 179 2459 6544 56 1887
6 34,6 11512 90 2841 779 245 2574 12258 196 2560 6885 61 1987
7 40,4 11993 95 2942 2400 266 2675 13555 212 2661 7253 66 2088
8 46,2 12501 99 3042 4142 287 2776 14949 229 2761 7649 70 2189
9 52,0 13038 104 3143 6005 307 2876 16439 246 2862 8072 75 2289
10 57,8 13653 109 3244 7990 328 2977 18027 263 2962 8524 80 2390
11 63,6 14301 114 3344 10096 349 3077 19712 279 3063 9002 85 2490
12* 69,4 14302 118 3445 9167 342 3178 18969 273 3164 8835 89 2591
13* 75,2 14936 123 3545 11214 363 3279 20606 290 3264 9300 94 2692
1250 HC 40 / 49516 4-9

– Sheet 6 of 6

DIN15019/DIN1055-4:1986
Radius: 40,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
30.06.2011
4 23,0 10356 80 2522 2627 189 2152 9910 151 2152 4193 48 1440
5 28,8 10809 85 2622 1004 224 2253 11209 179 2253 4488 53 1541
6 34,6 11290 90 2723 614 245 2368 12408 196 2353 4810 58 1641
7 40,4 11799 95 2823 2234 265 2469 13703 212 2454 5160 62 1742
8 46,2 12335 99 2924 3975 286 2569 15096 229 2555 5537 67 1843
9 52,0 12899 104 3025 5837 307 2670 16586 246 2655 5942 72 1943
10 57,8 13490 109 3125 7821 328 2770 18172 262 2756 6374 77 2044
11 63,6 14109 114 3226 9925 349 2871 19856 279 2856 6834 81 2144
12* 69,4 14081 118 3326 8995 342 2972 19112 273 2957 6648 86 2245
13* 75,2 14706 123 3427 11041 362 3072 20749 290 3058 7094 91 2346
4 - 10 1250 HC 40 / 49516
Crane 1250 HC 40 without climbing equipment

foundation anchors 500HC (C032.001-372.100)
– Sheet 1 of 6
Krantyp: 1250 HC 40
Turmaufbau: 1250HC40: WN_49516_2-4-Str._ts1250_fu500_DIN1055-4:1986_oKE

ID: 00000821.fun
1250 HC 40 / 49516 4 - 11
– Sheet 2 of 6

Crane stationary on foundation anchors, without climbing equipment
DIN15019/DIN1055-4:1986
Radius: 80,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
1 5,6 8124 54 2224 4815 73 2085 6155 58 2085 11397 26 1487
2 11,4 8352 59 2324 4117 98 2186 6713 78 2186 11561 30 1588
3 17,2 8664 64 2425 3150 128 2287 7487 102 2287 11752 35 1688
4 23,0 9050 69 2526 2124 152 2387 8307 122 2387 11971 40 1789
5 28,8 9463 73 2626 1039 173 2488 9176 139 2488 12218 45 1889
6 34,6 9904 78 2727 287 194 2603 10141 155 2588 12492 49 1990
7 40,4 10373 83 2827 1614 215 2704 11203 172 2689 12794 54 2091
8 46,2 10869 88 2928 3063 236 2804 12362 189 2790 13123 59 2191
9 52,0 11392 92 3029 4633 257 2905 13618 205 2890 13480 64 2292
10 57,8 11943 97 3129 6324 278 3005 14971 222 2991 13864 68 2392
11 63,6 12522 102 3230 8137 299 3106 16420 239 3091 14276 73 2493
12 69,4 13128 107 3330 10070 320 3207 17967 256 3192 14716 78 2594
13 75,2 13762 111 3431 12125 340 3307 19611 272 3293 15183 83 2694
4 - 12 1250 HC 40 / 49516
– Sheet 3 of 6

DIN15019/DIN1055-4:1986
Radius: 75,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
1 5,6 8267 54 2145 5324 73 1984 6660 58 1984 6819 22 1009
2 11,4 8501 59 2245 4628 98 2085 7217 78 2085 6962 27 1109
3 17,2 8763 64 2346 3664 128 2186 7988 102 2186 7133 32 1210
4 23,0 9052 69 2447 2640 152 2286 8807 122 2286 7331 36 1310
5 28,8 9580 73 2547 1557 173 2387 9674 138 2387 7557 41 1411
6 34,6 10021 78 2648 352 194 2487 10637 155 2487 10196 49 1960
7 40,4 10489 83 2748 1093 215 2603 11698 172 2588 10498 54 2061
8 46,2 10985 88 2849 2540 236 2703 12855 188 2689 10826 59 2161
9 52,0 11508 92 2950 4108 256 2804 14110 205 2789 11183 63 2262
10 57,8 12059 97 3050 5797 277 2904 15461 222 2890 11567 68 2362
11 63,6 12637 102 3151 7608 298 3005 16910 239 2990 11978 73 2463
12 69,4 13243 107 3251 9539 319 3106 18455 255 3091 12417 78 2564
13 75,2 13877 111 3352 11592 340 3206 20097 272 3192 12884 82 2664
1250 HC 40 / 49516 4 - 13
– Sheet 4 of 6

DIN15019/DIN1055-4:1986
Radius: 63,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
1 5,6 9120 54 2065 5330 72 1855 6660 58 1855 8398 25 1354
2 11,4 9372 59 2166 4635 98 1956 7216 78 1956 8561 30 1455
3 17,2 9651 64 2266 3676 127 2057 7984 102 2057 8751 35 1555
4 23,0 9958 69 2367 2654 152 2157 8801 121 2157 8969 40 1656
5 28,8 10292 73 2468 1574 172 2258 9665 138 2258 9215 44 1756
6 34,6 10654 78 2568 372 193 2358 10627 155 2358 9488 49 1857
7 40,4 11044 83 2669 1071 214 2474 11685 171 2459 9789 54 1958
8 46,2 11461 88 2769 2515 235 2574 12841 188 2560 10117 59 2058
9 52,0 12373 92 2870 4081 256 2675 14093 205 2660 10473 63 2159
10 57,8 12925 97 2971 5767 277 2775 15442 222 2761 10856 68 2259
11 63,6 13504 102 3071 7575 298 2876 16889 238 2861 11267 73 2360
12 69,4 14112 107 3172 9504 319 2977 18432 255 2962 11705 78 2461
13 75,2 14746 111 3272 11555 340 3077 20072 272 3063 12171 82 2561
4 - 14 1250 HC 40 / 49516
– Sheet 5 of 6

DIN15019/DIN1055-4:1986
Radius: 52,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
1 5,6 9520 54 2099 5783 72 1818 7105 57 1818 5457 25 1245
2 11,4 9795 59 2200 5091 97 1919 7658 78 1919 5619 30 1346
3 17,2 10098 64 2300 4138 127 2019 8421 101 2019 5809 35 1447
4 23,0 10427 69 2401 3120 151 2120 9235 121 2120 6026 39 1547
5 28,8 10785 73 2502 2043 172 2220 10096 137 2220 6270 44 1648
6 34,6 11170 78 2602 845 193 2321 11055 154 2321 6543 49 1748
7 40,4 11582 83 2703 594 214 2436 12110 171 2422 6843 54 1849
8 46,2 12022 88 2803 2034 234 2537 13263 188 2522 7170 58 1950
9 52,0 12490 92 2904 3596 255 2637 14512 204 2623 7525 63 2050
10 57,8 13037 97 3005 5279 276 2738 15858 221 2723 7907 68 2151
11 63,6 13616 102 3105 7083 297 2838 17301 238 2824 8317 73 2251
12 69,4 14223 107 3206 9008 318 2939 18842 254 2925 8755 77 2352
13 75,2 14857 111 3306 11055 339 3040 20479 271 3025 9220 82 2453
1250 HC 40 / 49516 4 - 15
– Sheet 6 of 6

DIN15019/DIN1055-4:1986
Radius: 40,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
1 5,6 9162 54 1981 5940 72 1611 7260 57 1611 3476 22 899
2 11,4 9464 59 2081 5249 97 1712 7813 77 1712 3619 27 1000
3 17,2 9794 64 2182 4298 126 1813 8573 101 1813 3790 32 1101
4 23,0 10151 68 2283 3282 151 1913 9386 121 1913 3988 36 1201
5 28,8 10536 73 2383 2206 172 2014 10247 137 2014 4214 41 1302
6 34,6 10948 78 2484 1010 192 2114 11204 154 2114 4468 46 1402
7 40,4 11388 83 2584 428 213 2230 12259 171 2215 4749 51 1503
8 46,2 11856 87 2685 1867 234 2330 13410 187 2316 5058 55 1604
9 52,0 12351 92 2786 3428 255 2431 14658 204 2416 5394 60 1704
10 57,8 12874 97 2886 5109 276 2531 16003 221 2517 5758 65 1805
11 63,6 13424 102 2987 6912 297 2632 17446 238 2617 6149 70 1905
12 69,4 14002 106 3087 8836 318 2733 18985 254 2718 6568 74 2006
13 75,2 14626 111 3188 10881 339 2833 20621 271 2819 7014 79 2107
4 - 16 1250 HC 40 / 49516

base tower section climbable 1250HC (C036.020-337.000) / 11.6m
foundation anchors reinforced 630EC-H (C048.007-372.111)
– Sheet 1 of 6
Krantyp: 1250 HC 40
1250HC40: WN_49516_2-4-Str._ts1250_gts11.6m_fu630verst._DIN1055-
Turmaufbau: 4:1986_mKE
ID: 00000824.fun
1250 HC 40 / 49516 4 - 17
– Sheet 2 of 6

DIN15019/DIN1055-4:1986
Radius: 80,00 m
Tower section: 5,80 m / standard (1250HC / Drawing No. C036.020-332.000)
Base tower section: 11.6 m / climbable (1250HC / Drawing No. C036.020-337.000)
Foundation anchors: 630EC-H / reinforced (Drawing No. C 048.007-372.111)

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
30.06.2011
1 17,0 8782 75 2674 2805 160 2536 7763 128 2536 11876 47 1937
2 22,8 9235 80 2775 1565 184 2636 8755 147 2636 12163 51 2038
3 28,6 9716 85 2875 180 219 2751 10055 175 2737 12477 56 2138
4 34,4 10225 90 2976 1683 240 2852 11258 192 2837 12819 61 2239
5 40,2 10761 94 3076 3308 261 2953 12557 209 2938 13188 66 2340
6 46,0 11324 99 3177 5054 282 3053 13954 225 3039 13585 70 2440
7 51,8 11915 104 3278 6921 303 3154 15448 242 3139 14009 75 2541
8 57,6 12534 109 3378 8909 324 3254 17039 259 3240 14461 80 2641
9 63,4 13180 113 3479 11019 344 3355 18726 276 3340 14941 85 2742
10 69,2 13854 118 3579 13250 365 3456 20511 292 3441 15448 89 2843
11 75,0 14555 123 3680 15602 386 3556 22392 309 3542 15982 94 2943
12* 80,8 14473 128 3781 14322 379 3657 21369 303 3642 15733 99 3044
13* 86,6 15161 132 3881 16615 400 3757 23203 320 3743 16254 104 3144
4 - 18 1250 HC 40 / 49516
– Sheet 3 of 6

DIN15019/DIN1055-4:1986
Radius: 75,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
30.06.2011
1 17,0 8885 75 2595 3319 159 2435 8264 128 2435 9582 47 1907
2 22,8 9242 80 2696 2080 184 2535 9255 147 2535 9868 51 2008
3 28,6 9833 85 2796 458 219 2636 10553 175 2636 10182 56 2108
4 34,4 10342 90 2897 1164 240 2751 11755 192 2736 10523 61 2209
5 40,2 10877 94 2997 2786 261 2852 13053 208 2837 10892 66 2310
6 46,0 11441 99 3098 4531 281 2952 14448 225 2938 11288 70 2410
7 51,8 12031 104 3199 6396 302 3053 15940 242 3038 11712 75 2511
8 57,6 12650 109 3299 8382 323 3153 17529 259 3139 12164 80 2611
9 63,4 13296 113 3400 10490 344 3254 19215 275 3239 12643 85 2712
10 69,2 13969 118 3500 12719 365 3355 20999 292 3340 13149 89 2813
11 75,0 14670 123 3601 15069 386 3455 22879 309 3441 13683 94 2913
12* 80,8 14588 128 3702 13787 378 3556 21853 303 3541 13434 99 3014
13* 86,6 15275 132 3802 16078 399 3656 23686 319 3642 13955 104 3114
1250 HC 40 / 49516 4 - 19
– Sheet 4 of 6

DIN15019/DIN1055-4:1986
Radius: 63,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
30.06.2011
1 17,0 9772 76 2515 3330 159 2306 8260 127 2306 8875 46 1804
2 22,8 10146 80 2616 2095 183 2406 9249 147 2406 9161 51 1905
3 28,6 10548 85 2717 474 218 2507 10545 175 2507 9474 56 2005
4 34,4 10978 90 2817 1144 239 2622 11744 191 2607 9815 61 2106
5 40,2 11435 95 2918 2765 260 2723 13040 208 2708 10183 65 2207
6 46,0 11919 99 3018 4506 281 2823 14433 225 2809 10579 70 2307
7 51,8 12431 104 3119 6369 302 2924 15923 242 2909 11002 75 2408
8 57,6 13516 109 3220 8353 323 3024 17511 258 3010 11453 80 2508
9 63,4 14163 114 3320 10458 344 3125 19195 275 3110 11932 84 2609
10 69,2 14837 118 3421 12684 365 3226 20976 292 3211 12438 89 2710
11 75,0 15540 123 3521 15032 385 3326 22854 308 3312 12971 94 2810
12* 80,8 15458 128 3622 13747 378 3427 21826 302 3412 12721 99 2911
13* 86,6 16147 133 3723 16036 399 3527 23657 319 3513 13241 103 3011
4 - 20 1250 HC 40 / 49516
– Sheet 5 of 6

DIN15019/DIN1055-4:1986
Radius: 52,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
30.06.2011
1 17,0 10218 75 2549 3792 158 2268 8697 127 2268 5933 46 1696
2 22,8 10615 80 2650 2560 183 2369 9683 146 2369 6218 51 1796
3 28,6 11040 85 2751 944 218 2469 10976 174 2469 6530 56 1897
4 34,4 11492 90 2851 671 239 2584 12172 191 2570 6870 61 1997
5 40,2 11973 94 2952 2288 259 2685 13465 208 2671 7237 65 2098
6 46,0 12480 99 3052 4025 280 2786 14855 224 2771 7632 70 2199
7 51,8 13015 104 3153 5884 301 2886 16342 241 2872 8054 75 2299
8 57,6 13628 109 3254 7864 322 2987 17926 258 2972 8504 80 2400
9 63,4 14274 113 3354 9965 343 3087 19607 274 3073 8982 84 2500
10 69,2 14948 118 3455 12188 364 3188 21385 291 3174 9487 89 2601
11 75,0 15650 123 3555 14532 385 3289 23260 308 3274 10020 94 2702
12* 80,8 15568 128 3656 13244 377 3389 22230 302 3375 9769 99 2802
13* 86,6 16256 132 3757 15528 398 3490 24058 319 3475 10288 103 2903
1250 HC 40 / 49516 4 - 21
– Sheet 6 of 6

DIN15019/DIN1055-4:1986
Radius: 40,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
30.06.2011
1 17,0 9913 75 2431 3953 158 2062 8850 126 2062 3915 43 1350
2 22,8 10338 80 2532 2722 182 2162 9834 146 2162 4181 48 1450
3 28,6 10790 85 2632 1107 217 2263 11126 174 2263 4475 53 1551
4 34,4 11270 90 2733 507 238 2378 12321 191 2363 4796 57 1651
5 40,2 11778 94 2833 2122 259 2479 13614 207 2464 5144 62 1752
6 46,0 12313 99 2934 3858 280 2579 15003 224 2565 5521 67 1853
7 51,8 12875 104 3035 5716 301 2680 16489 241 2665 5924 72 1953
8 57,6 13466 109 3135 7695 322 2780 18072 258 2766 6356 76 2054
9 63,4 14083 113 3236 9795 343 2881 19752 274 2866 6814 81 2154
10 69,2 14729 118 3336 12016 364 2982 21529 291 2967 7301 86 2255
11 75,0 15420 123 3437 14358 385 3082 23403 308 3068 7815 91 2356
12* 80,8 15337 128 3538 13069 377 3183 22371 302 3168 7545 95 2456
13* 86,6 16024 132 3638 15352 398 3283 24198 318 3269 8046 100 2557
4 - 22 1250 HC 40 / 49516

– Sheet 1 of 6
Krantyp: 1250 HC 40
1250HC40: WN_49516_2-4-Str._ts1250_gts11.6m_fu630verst._DIN1055-
Turmaufbau: 4:1986_oKE
ID: 00000818.fun
1250 HC 40 / 49516 4 - 23
– Sheet 2 of 6

DIN15019/DIN1055-4:1986
Radius: 80,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σB = ≤σ
3⋅ L ⋅c
B perm .
L
c= −e
2
11.04.2011
0 11,2 8341 59 2334 4193 92 2196 6653 73 2196 11553 30 1598
1 17,0 8649 64 2435 3232 122 2297 7421 98 2297 11743 35 1698
2 22,8 9033 68 2536 2211 146 2397 8238 117 2397 11961 40 1799
3 28,6 9446 73 2636 1131 167 2498 9102 134 2498 12207 44 1899
4 34,4 9885 78 2737 190 188 2613 10063 150 2598 12480 49 2000
5 40,2 10353 83 2837 1513 209 2714 11122 167 2699 12780 54 2101
6 46,0 10848 87 2938 2958 230 2814 12277 184 2800 13109 59 2201
7 51,8 11370 92 3039 4523 251 2915 13529 200 2900 13464 63 2302
8 57,6 11920 97 3139 6209 272 3015 14879 217 3001 13848 68 2402
9 63,4 12498 102 3240 8017 292 3116 16325 234 3101 14259 73 2503
10 69,2 13103 106 3340 9946 313 3217 17868 251 3202 14697 78 2604
11 75,0 13736 111 3441 11997 334 3317 19508 267 3303 15163 82 2704
12 80,8 14396 116 3542 14168 355 3418 21245 284 3403 15656 87 2805
13 86,6 15084 121 3642 16461 376 3518 23080 301 3504 16177 92 2905
4 - 24 1250 HC 40 / 49516
– Sheet 3 of 6

DIN15019/DIN1055-4:1986
Radius: 75,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σB = ≤σ
3⋅ L ⋅c
B perm .
L
c= −e
2
11.04.2011
0 11,2 8490 59 2255 4703 92 2095 7157 73 2095 6955 27 1119
1 17,0 8751 64 2356 3746 122 2196 7923 97 2196 7124 31 1220
2 22,8 9039 68 2457 2727 146 2296 8738 117 2296 7322 36 1320
3 28,6 9563 73 2557 1648 167 2397 9601 133 2397 7547 41 1421
4 34,4 10002 78 2658 449 188 2497 10560 150 2497 10184 49 1970
5 40,2 10469 83 2758 992 208 2613 11617 167 2598 10484 54 2071
6 46,0 10964 87 2859 2434 229 2713 12771 184 2699 10812 58 2171
7 51,8 11486 92 2960 3998 250 2814 14022 200 2799 11167 63 2272
8 57,6 12036 97 3060 5682 271 2914 15369 217 2900 11550 68 2372
9 63,4 12613 102 3161 7488 292 3015 16814 234 3000 11961 73 2473
10 69,2 13218 106 3261 9415 313 3116 18356 250 3101 12399 77 2574
11 75,0 13851 111 3362 11464 334 3216 19995 267 3202 12864 82 2674
12 80,8 14511 116 3463 13633 355 3317 21730 284 3302 13357 87 2775
13 86,6 15198 121 3563 15924 376 3417 23563 301 3403 13878 92 2875
1250 HC 40 / 49516 4 - 25
– Sheet 4 of 6

DIN15019/DIN1055-4:1986
Radius: 63,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σB = ≤σ
3⋅ L ⋅c
B perm .
L
c= −e
2
11.04.2011
0 11,2 9360 59 2176 4711 91 1966 7156 73 1966 8553 30 1465
1 17,0 9639 64 2276 3758 121 2067 7918 97 2067 8742 35 1565
2 22,8 9944 68 2377 2741 145 2167 8731 116 2167 8959 39 1666
3 28,6 10278 73 2478 1665 166 2268 9592 133 2268 9204 44 1766
4 34,4 10639 78 2578 468 187 2368 10550 150 2368 9476 49 1867
5 40,2 11027 83 2679 970 208 2484 11605 166 2469 9775 54 1968
6 46,0 11443 87 2779 2410 229 2584 12756 183 2570 10102 58 2068
7 51,8 11886 92 2880 3971 250 2685 14005 200 2670 10457 63 2169
8 57,6 12902 97 2981 5653 271 2785 15351 217 2771 10840 68 2269
9 63,4 13480 102 3081 7456 292 2886 16793 233 2871 11249 73 2370
10 69,2 14087 106 3182 9381 313 2987 18333 250 2972 11687 77 2471
11 75,0 14720 111 3282 11426 333 3087 19970 267 3073 12152 82 2571
12 80,8 15381 116 3383 13593 354 3188 21703 283 3173 12644 87 2672
13 86,6 16070 121 3484 15882 375 3288 23534 300 3274 13164 92 2772
4 - 26 1250 HC 40 / 49516
– Sheet 5 of 6

DIN15019/DIN1055-4:1986
Radius: 52,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σB = ≤σ
3⋅ L ⋅c
B perm .
L
c= −e
2
11.04.2011
0 11,2 9783 59 2210 5166 91 1929 7598 73 1929 5611 30 1356
1 17,0 10084 64 2310 4219 120 2029 8355 96 2029 5799 34 1457
2 22,8 10413 68 2411 3207 145 2130 9165 116 2130 6016 39 1557
3 28,6 10769 73 2512 2135 166 2230 10023 132 2230 6259 44 1658
4 34,4 11153 78 2612 941 186 2331 10978 149 2331 6530 49 1758
5 40,2 11565 83 2713 493 207 2446 12030 166 2432 6829 53 1859
6 46,0 12004 87 2813 1929 228 2547 13178 183 2532 7156 58 1960
7 51,8 12470 92 2914 3486 249 2647 14424 199 2633 7509 63 2060
8 57,6 13014 97 3015 5164 270 2748 15767 216 2733 7891 68 2161
9 63,4 13592 102 3115 6964 291 2848 17206 233 2834 8300 72 2261
10 69,2 14198 106 3216 8885 312 2949 18743 250 2935 8736 77 2362
11 75,0 14831 111 3316 10926 333 3050 20376 266 3035 9200 82 2463
12 80,8 15491 116 3417 13090 354 3150 22107 283 3136 9692 87 2563
13 86,6 16179 121 3518 15374 375 3251 23934 300 3236 10211 91 2664
1250 HC 40 / 49516 4 - 27
– Sheet 6 of 6

DIN15019/DIN1055-4:1986
Radius: 40,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σB = ≤σ
3⋅ L ⋅c
B perm .
L
c= −e
2
11.04.2011
0 11,2 9450 59 2091 5324 91 1722 7752 73 1722 3612 27 1010
1 17,0 9779 63 2192 4380 120 1823 8508 96 1823 3781 31 1111
2 22,8 10136 68 2293 3369 144 1923 9317 116 1923 3979 36 1211
3 28,6 10519 73 2393 2298 165 2024 10174 132 2024 4204 41 1312
4 34,4 10931 78 2494 1106 186 2124 11127 149 2124 4456 46 1412
5 40,2 11370 82 2594 327 207 2240 12178 166 2225 4736 50 1513
6 46,0 11836 87 2695 1762 228 2340 13326 182 2326 5044 55 1614
7 51,8 12330 92 2796 3318 249 2441 14570 199 2426 5379 60 1714
8 57,6 12852 97 2896 4995 270 2541 15912 216 2527 5742 65 1815
9 63,4 13401 101 2997 6793 291 2642 17350 233 2627 6132 69 1915
10 69,2 13978 106 3097 8712 312 2743 18886 249 2728 6550 74 2016
11 75,0 14600 111 3198 10753 333 2843 20519 266 2829 6995 79 2117
12 80,8 15260 116 3299 12915 353 2944 22248 283 2929 7468 84 2217
13 86,6 15947 120 3399 15198 374 3044 24075 299 3030 7969 88 2318
4 - 28 1250 HC 40 / 49516

base tower section reinforced, not climbable 1250HC (C036.020-338.000) / 11.6m
– Sheet 1 of 6
Krantyp: 1250 HC 40
1250HC40: WN_49516_2-4-Str._ts1250_gts11.6m+gtv11.6m_fu630v_DIN1055-
Turmaufbau: 4:1986_mKE
ID: 00000825.fun
1250 HC 40 / 49516 4 - 29
– Sheet 2 of 6

DIN15019/DIN1055-4:1986
Radius: 80,00 m
Tower section: 5,80 m (1250HC / Drawing No. C036.020-332.000)
Base tower section: 11.6 m / reinforced, not climbable (1250HC / Drawing No. C036.020-338.000)

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
30.06.2011
1 28,6 9712 85 2904 71 213 2766 9950 170 2766 12473 56 2167
2 34,4 10220 89 3005 1552 233 2881 11153 187 2866 12815 61 2268
3 40,2 10756 94 3105 3177 254 2981 12453 203 2967 13184 65 2368
4 46,0 11320 99 3206 4923 275 3082 13849 220 3067 13581 70 2469
5 51,8 11911 104 3306 6790 296 3183 15343 237 3168 14005 75 2570
6 57,6 12530 108 3407 8778 317 3283 16934 254 3269 14457 80 2670
7 63,4 13176 113 3508 10888 338 3384 18621 270 3369 14936 84 2771
8 69,2 13850 118 3608 13119 359 3484 20406 287 3470 15443 89 2871
9 75,0 14551 123 3709 15471 380 3585 22288 304 3570 15978 94 2972
10 80,8 15280 127 3809 17944 401 3686 24266 321 3671 16540 99 3073
11 86,6 16036 132 3910 20538 422 3786 26342 337 3772 17130 103 3173
12* 92,4 16009 137 4011 19896 433 3887 25828 346 3872 16936 108 3274
4 - 30 1250 HC 40 / 49516
– Sheet 3 of 6

DIN15019/DIN1055-4:1986
Radius: 75,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
30.06.2011
1 28,6 9829 85 2825 588 212 2665 10449 170 2665 10178 56 2137
2 34,4 10337 89 2926 1033 233 2780 11650 186 2765 10519 61 2238
3 40,2 10873 94 3026 2656 254 2880 12948 203 2866 10888 65 2338
4 46,0 11436 99 3127 4400 275 2981 14343 220 2966 11284 70 2439
5 51,8 12027 104 3227 6265 296 3082 15835 237 3067 11708 75 2540
6 57,6 12645 108 3328 8251 317 3182 17425 253 3168 12159 80 2640
7 63,4 13291 113 3429 10359 338 3283 19111 270 3268 12638 84 2741
8 69,2 13965 118 3529 12588 359 3383 20894 287 3369 13145 89 2841
9 75,0 14666 123 3630 14938 379 3484 22774 304 3469 13679 94 2942
10 80,8 15394 127 3730 17409 400 3585 24751 320 3570 14241 99 3043
11 86,6 16150 132 3831 20002 421 3685 26825 337 3671 14830 103 3143
12* 92,4 16123 137 3932 19358 432 3786 26310 346 3771 14636 108 3244
1250 HC 40 / 49516 4 - 31
– Sheet 4 of 6

DIN15019/DIN1055-4:1986
Radius: 63,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
30.06.2011
1 28,6 10544 85 2745 605 212 2536 10440 169 2536 9470 56 2034
2 34,4 10973 90 2846 1013 233 2651 11639 186 2636 9810 60 2135
3 40,2 11430 94 2947 2634 254 2751 12935 203 2737 10179 65 2235
4 46,0 11915 99 3047 4375 274 2852 14329 220 2837 10575 70 2336
5 51,8 12892 104 3148 6238 295 2953 15819 236 2938 10998 75 2437
6 57,6 13511 109 3248 8222 316 3053 17406 253 3039 11449 79 2537
7 63,4 14158 113 3349 10327 337 3154 19090 270 3139 11927 84 2638
8 69,2 14833 118 3450 12553 358 3254 20871 286 3240 12433 89 2738
9 75,0 15535 123 3550 14901 379 3355 22749 303 3340 12967 94 2839
10 80,8 16265 128 3651 17369 400 3456 24724 320 3441 13528 98 2940
11 86,6 17022 132 3751 19959 421 3556 26796 337 3542 14116 103 3040
12* 92,4 16996 137 3852 19313 432 3657 26279 346 3642 13922 108 3141
4 - 32 1250 HC 40 / 49516
– Sheet 5 of 6

DIN15019/DIN1055-4:1986
Radius: 52,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
30.06.2011
1 28,6 11036 85 2779 1075 211 2498 10871 169 2498 6526 56 1926
2 34,4 11488 89 2880 540 232 2613 12067 186 2599 6865 60 2026
3 40,2 11968 94 2981 2157 253 2714 13360 202 2699 7233 65 2127
4 46,0 12476 99 3081 3894 274 2814 14751 219 2800 7628 70 2227
5 51,8 13011 104 3182 5753 295 2915 16238 236 2901 8050 75 2328
6 57,6 13624 108 3282 7733 316 3016 17822 252 3001 8500 79 2429
7 63,4 14270 113 3383 9834 337 3116 19503 269 3102 8978 84 2529
8 69,2 14944 118 3484 12057 357 3217 21281 286 3202 9483 89 2630
9 75,0 15645 123 3584 14401 378 3317 23156 303 3303 10015 94 2730
10 80,8 16375 127 3685 16866 399 3418 25128 319 3404 10576 98 2831
11 86,6 17131 132 3785 19452 420 3519 27197 336 3504 11163 103 2932
12* 92,4 17104 137 3886 18801 431 3619 26676 345 3605 10968 108 3032
1250 HC 40 / 49516 4 - 33
– Sheet 6 of 6

DIN15019/DIN1055-4:1986
Radius: 40,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
30.06.2011
1 28,6 10786 85 2661 1238 211 2292 11022 169 2292 4470 52 1580
2 34,4 11266 89 2762 376 232 2407 12217 185 2392 4791 57 1680
3 40,2 11773 94 2862 1991 253 2507 13509 202 2493 5140 62 1781
4 46,0 12308 99 2963 3727 274 2608 14898 219 2593 5516 67 1881
5 51,8 12871 104 3063 5585 295 2709 16384 236 2694 5920 71 1982
6 57,6 13461 108 3164 7564 315 2809 17967 252 2795 6351 76 2083
7 63,4 14079 113 3265 9664 336 2910 19647 269 2895 6810 81 2183
8 69,2 14724 118 3365 11885 357 3010 21424 286 2996 7296 86 2284
9 75,0 15415 123 3466 14227 378 3111 23298 302 3096 7810 90 2384
10 80,8 16144 127 3566 16691 399 3212 25269 319 3197 8352 95 2485
11 86,6 16899 132 3667 19276 420 3312 27337 336 3298 8921 100 2586
12* 92,4 16872 137 3768 18624 431 3413 26815 345 3398 8707 105 2686
4 - 34 1250 HC 40 / 49516

base tower section reinforced, not climbable 1250HC (C036.020-338.000) / 11.6m
– Sheet 1 of 6
Krantyp: 1250 HC 40
1250HC40: WN_49516_2-4-Str._ts1250_gts11.6m+gtv11.6m_fu630v_DIN1055-
Turmaufbau: 4:1986_oKE
ID: 00000822.fun
1250 HC 40 / 49516 4 - 35
– Sheet 2 of 6

DIN15019/DIN1055-4:1986
Radius: 80,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
0 22,8 9029 68 2564 2342 140 2426 8133 112 2426 11957 39 1828
1 28,6 9441 73 2665 1262 161 2527 8997 128 2527 12202 44 1928
2 34,4 9881 78 2766 60 181 2642 9959 145 2627 12475 49 2029
3 40,2 10348 82 2866 1382 202 2742 11017 162 2728 12776 54 2129
4 46,0 10843 87 2967 2827 223 2843 12172 179 2828 13104 58 2230
5 51,8 11366 92 3067 4392 244 2944 13425 195 2929 13460 63 2331
6 57,6 11916 97 3168 6079 265 3044 14774 212 3030 13843 68 2431
7 63,4 12494 101 3269 7886 286 3145 16220 229 3130 14254 73 2532
8 69,2 13099 106 3369 9815 307 3245 17763 245 3231 14693 77 2632
9 75,0 13732 111 3470 11866 328 3346 19404 262 3331 15158 82 2733
10 80,8 14392 116 3570 14037 349 3447 21141 279 3432 15652 87 2834
11 86,6 15080 120 3671 16330 370 3547 22975 296 3533 16173 92 2934
12 92,4 15795 125 3772 19211 395 3648 25280 316 3633 16722 96 3035
4 - 36 1250 HC 40 / 49516
– Sheet 3 of 6

DIN15019/DIN1055-4:1986
Radius: 75,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
0 22,8 9035 68 2485 2858 139 2325 8633 111 2325 7318 36 1349
1 28,6 9558 73 2586 1779 160 2426 9496 128 2426 9907 44 1898
2 34,4 9998 78 2687 580 181 2526 10456 145 2526 10180 49 1999
3 40,2 10465 82 2787 861 202 2641 11512 162 2627 10480 53 2099
4 46,0 10960 87 2888 2303 223 2742 12666 178 2727 10808 58 2200
5 51,8 11482 92 2988 3867 244 2843 13917 195 2828 11163 63 2301
6 57,6 12032 97 3089 5551 265 2943 15265 212 2929 11546 68 2401
7 63,4 12609 101 3190 7357 286 3044 16709 228 3029 11956 72 2502
8 69,2 13214 106 3290 9284 306 3144 18251 245 3130 12394 77 2602
9 75,0 13846 111 3391 11333 327 3245 19890 262 3230 12860 82 2703
10 80,8 14506 116 3491 13502 348 3346 21625 279 3331 13353 87 2804
11 86,6 15194 120 3592 15793 369 3446 23458 295 3432 13873 91 2904
12 92,4 15909 125 3693 18672 395 3547 25761 316 3532 14422 96 3005
1250 HC 40 / 49516 4 - 37
– Sheet 4 of 6

DIN15019/DIN1055-4:1986
Radius: 63,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
0 22,8 9940 68 2406 2872 139 2196 8626 111 2196 8955 39 1695
1 28,6 10273 73 2506 1796 160 2297 9487 128 2297 9199 44 1795
2 34,4 10634 78 2607 599 181 2397 10445 145 2397 9471 49 1896
3 40,2 11023 82 2708 839 202 2512 11500 161 2498 9771 53 1996
4 46,0 11438 87 2808 2279 222 2613 12652 178 2598 10098 58 2097
5 51,8 12347 92 2909 3840 243 2714 13900 195 2699 10453 63 2198
6 57,6 12898 97 3009 5522 264 2814 15246 211 2800 10835 68 2298
7 63,4 13476 101 3110 7325 285 2915 16689 228 2900 11245 72 2399
8 69,2 14082 106 3211 9250 306 3015 18228 245 3001 11682 77 2499
9 75,0 14716 111 3311 11295 327 3116 19865 262 3101 12147 82 2600
10 80,8 15377 116 3412 13462 348 3217 21599 278 3202 12640 87 2701
11 86,6 16066 120 3512 15751 369 3317 23429 295 3303 13160 91 2801
12 92,4 16782 125 3613 18627 394 3418 25730 315 3403 13707 96 2902
4 - 38 1250 HC 40 / 49516
– Sheet 5 of 6

DIN15019/DIN1055-4:1986
Radius: 52,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
0 22,8 10409 68 2440 3338 138 2159 9061 111 2159 6011 39 1586
1 28,6 10765 73 2540 2266 159 2259 9918 127 2259 6255 44 1687
2 34,4 11149 78 2641 1072 180 2360 10873 144 2360 6526 48 1787
3 40,2 11560 82 2742 362 201 2475 11925 161 2460 6825 53 1888
4 46,0 11999 87 2842 1798 222 2575 13074 177 2561 7151 58 1988
5 51,8 12466 92 2943 3355 243 2676 14319 194 2662 7505 63 2089
6 57,6 13010 97 3043 5033 264 2777 15662 211 2762 7886 67 2190
7 63,4 13588 101 3144 6833 284 2877 17101 228 2863 8295 72 2290
8 69,2 14193 106 3245 8754 305 2978 18638 244 2963 8732 77 2391
9 75,0 14826 111 3345 10796 326 3078 20272 261 3064 9196 82 2491
10 80,8 15487 116 3446 12959 347 3179 22002 278 3165 9688 86 2592
11 86,6 16175 120 3546 15243 368 3280 23830 294 3265 10207 91 2693
12 92,4 16890 125 3647 18116 394 3380 26128 315 3366 10754 96 2793
1250 HC 40 / 49516 4 - 39
– Sheet 6 of 6

DIN15019/DIN1055-4:1986
Radius: 40,00 m

M + ( H ⋅ h) L
V +G 3

2 ⋅ (V + G )
σ = ≤σ
3⋅ L ⋅c
B B perm .
L
c= −e
2
0 22,8 10131 68 2321 3500 138 1952 9212 110 1952 3974 36 1240
1 28,6 10515 73 2422 2429 159 2053 10069 127 2053 4199 41 1341
2 34,4 10926 77 2523 1237 180 2153 11023 144 2153 4452 45 1441
3 40,2 11365 82 2623 196 201 2268 12073 161 2254 4732 50 1542
4 46,0 11832 87 2724 1631 222 2369 13221 177 2354 5040 55 1642
5 51,8 12326 92 2824 3187 242 2470 14466 194 2455 5375 60 1743
6 57,6 12848 96 2925 4864 263 2570 15807 211 2556 5738 64 1844
7 63,4 13397 101 3026 6662 284 2671 17246 227 2656 6128 69 1944
8 69,2 13973 106 3126 8582 305 2771 18781 244 2757 6546 74 2045
9 75,0 14596 111 3227 10622 326 2872 20414 261 2857 6991 79 2145
10 80,8 15256 115 3327 12784 347 2973 22143 278 2958 7464 83 2246
11 86,6 15943 120 3428 15067 368 3073 23970 294 3059 7964 88 2347
12 92,4 16658 125 3529 17939 393 3174 26267 315 3159 8492 93 2447
4 - 40 1250 HC 40 / 49516
4.1.4 Counterballast
Counterballast for crane 1250 HC 40
2 / 4 - fall operation
Danger !
Incorrect selection of the counterballast blocks jeopardises stability of the crane. Different counter-
weights are required depending on configuration of the crane. Specifications for the counterweights
in featured in the table as follows apply for standard configu-ration of the free-standing crane (stan-
dard hook heights and standard jib lengths). For further information, see: the charts regarding cor-
ner pressures and foundation reaction forces.
X Select the counterballast blocks. See following tables.
X For the 82.1 m and 76.3 m jib lengths, install one ballast block A in the counter-jib before
installing jib section 2..
X The last ballast block A must only be removed from the counter-jib after removing jib section 2
of the 82.1 m or 76.3 m jib.
For further information, see: chapter Erection in the Instruction Manual.
Warning!
Improper manufacture of the counterballast blocks jeopardises stability of the crane. Production
must be resulted to Liebherr specifications. For further information, see Structural drawings for
counterballast blocks. It is imperative that the weight of the counterballast blocks are adhered to.
Density of reinforced concrete 2.4 t/m3.
X Weight the counterballast blocks prior to assembly.
Note
A wind sail of approx. 13.5 m² must be installed in the jib head of the 41.5 m jib.
For every special application of the crane with greater special hook heights (additional weight of the
hoist rope), or special armaments of the counter-jib (auxiliary winch, etc.) or jib (equipment etc.),
which could effect the weight of the crane components, please consult the Statics Department, Lieb-
herr-Werk Biberach GmbH for counterweight specifications and, if necessary, request delivery of a
copy.
A - ballast block (C 036.020-718.310) = 7,10 t
B - ballast block (C 036.020-718.320) = 4,50 t
1250 HC 40 / 49516 4 - 41
4.1.5 Counter-ballast arrangement
Hoist
WIW 300 VZ 427 (110 kW, 3-speed FU) FU - Frequency converter
gear
Counterjib No. of Arrangement of counterballast
Jib length Total
(end section counterbal-
[m]
C036.020-711.211) last blocks
weight [t] blocks1)
intermediate sec-
82,1
(Counterjib with 9xA + 1xB 68,400 A A A A A A A A A B
C 036.020- 8xA + 1xB 61,300 A A A A A A A A B

three-part
76,3
712.111)
6xA + 2xB 51,600 A A A A A A B B
tion
64,7
jib without
53,1 7xA + 2xB 58,700 A A A A A A A B B

(Counter-
no inter-
two-part
section)
mediate
41,5 5xA + 2xB 44,500 A A A A A B B
Tab. 4-1 Counterballast for crane 1250 HC 40 (4-fall / 40t; 2-fall / 20t)
1)
For the 82.1 m and 76.3 m jib lengths, install one ballast block A in the counter-jib before install-
ing jib section 2.
4 - 42 1250 HC 40 / 49516
EXAMPLE
Fig. 4-7 Arrangement of the counterballast blocks for crane 1250 HC 40

(a) Ballast blocks A (b) Ballast blocks B (c) Ballasting direction
Notes regarding installation

X Observe the order of installation.
For further information, see: chapter Erection in the Instruction Manual.
X For the 82.1 m and 76.3 m jib lengths, install one ballast block A in the counter-jib before in-
stalling jib section 2.
X Install the ballast blocks starting at the rear or farthest point from the crane tower (towards the to-
wer).
X The counterweight specifications in accordance with the jib can be obtained from the table.
X Install a wind sail of approx. 13.5 m² in the jib head of the 41.5 m jib. For further information, see:
chapter Erection in the Instruction Manual.
1250 HC 40 / 49516 4 - 43
4.1.6 Counterballast block „A“ with steel ballast frame

Weight: 7100 kg / Drawing No.: C 036.020 - 718.410. ident. no.: 9002 2318
4 - 44 1250 HC 40 / 49516
4.1.7 Counterballast block „A“ with steel ballast frame

Weight: 4500 kg / Drawing No.: C 036.020 - 718.420. ident. no.: 9002 2471
1250 HC 40 / 49516 4 - 45
4 - 46 1250 HC 40 / 49516
Instruction Manual Preparing for application of the crane
5 Preparing for application of the crane
This chapter helps you to plan the application for which the crane is to be used. A conscientious prep-
aration of the building site is essential for safe operation of the crane. Information can be obtained
here regarding which measures must be observed before commencing crane erection. The following
data allows you the opportunity to prepare the foundation and the rail tracks, in order that you may
begin erection of the crane immediately after it is delivered. Note also the Corner pressures, foun-
dation loadings and ballast data section in the handbook.
1250 HC 40 / 49516 5-1

Preparing for application of the crane Instruction Manual
Safe distances
5.1 Safe distances
Plan the application of the crane so that all safe distances can be maintained in every respective situ-
ation.
5.1.1 Safe distance to high-voltage power cables
Danger!
Contact with high-voltage electric power cables can lead to fatalities for the crane operator and per-
sons within immediate proximity of the crane.
X A safe distance in accordance wit the country-specific regulations must be maintained from high-
voltag electric power cables (for Germany: DIN 57105 / VDE 0105). Request the rate of voltage
at the electric supply company.
X If it is not possible to maintain this safe distance, the cables must be rendered voltage-free. This
condition must be guaranteed for the duration of operation.
Fig. 5-1 Maintain a safe distance from high-voltage electric power cables
Nominal voltage Minimum distance

up to 1kV 1m
between 1 kV and 110 kV 3m
If nominal voltage is not known 5m

Tab. 5-1 Minimum distances to high-voltage electric power cables in accordance with DIN 57105
VDE 0105
5-2 1250 HC 40 / 49516

Safe distances
5.1.2 Safe distance to parts in the immediate vicinity
Warning!
Danger of crushing due to moving crane parts.
A safe distance of 0.5 m must be maintained between moving crane parts (e.g. rail-going crane
base) and parts in the immediate vicinity.
X If this safe distance can not be maintained, cordon off the danger area.
Fig. 5-2 Safe distance to parts in the immediate vicinity

1250 HC 40 / 49516 5-3

Safe distances
5.1.3 Safe distance between tower cranes
Fig. 5-3 Safe distance between tower cranes and operating-range limiting system
(a) Operating-range limitation (b) Obstacle (e.g. building)
Warning!
Risk of collision when cranes are standing too close together.
X Maintain a safe distance between all parts of the tower cranes of at least 2 m
5-4 1250 HC 40 / 49516

Preparing the foundation
5.2 Preparing the foundation
Warning!
Stability of the crane will be seriously jeopardised as a result of unsuitable underground.
The permissible load capacity of the foundation soil should not be exceeded.
This must be mathematically verified by the operating company!
Before assembling on the foundation, check the load-bearing capacity of the soil. Pay attention to
the foundation reaction forces. For further information, see: Documentation Corner pressures, foun-
dation loadings and ballast data.
Warning
Improper preparation of the foundation will jeopardise stability of the crane.
Preparation must be carried out in accordance with Liebherr specifications. Pay attention to the
foundation reaction forces. For further information, see: Documentation Corner pressures, founda-
tion loadings and ballast data.
The operating company is solely responsible for any damage resulting from improper preparation of
the foundation or negligence of the soil conditions.
5.2.1 Foundation pit for foundation anchors

Fig. 5-4 Foundation pit (principle representation)

(a) Tower section (c) Foundation anchor (e) Supporting plate
(b) Foundation pit (d) Levelling screw
1250 HC 40 / 49516 5-5

Standard foundation anchor for tower system A [mm] B [mm]

120 HC 220 1125
140 HC 220 1125
170 HC 265 1135
185 HC 265 1135
256 HC 265 1135
355 HC 425 1325
500 HC 425 1625
630 EC-H 200 1625
Tab. 5-2 Dimensions for the foundation pit
X A tower section or base tower section is required for installation of the foundation anchors. Pro-
jection above finished concrete A and installation depth B of the foundation anchors must be
maintained. The tower section must be positioned with the climbing side situated at 90° to the wall
line of the building in order that the jib is positioned parallel to the wall of the building when the
crane is being climbed. For further information, see: chapter Erection in the Instruction Manual.
5.2.2 Foundation slabs for the undercarriage
Fig. 5-5 Foundation slabs for the undercarriage

(a) Foundation slab (b) Necessary block-out (c) Foundation for complete platform
5-6 1250 HC 40 / 49516

Undercarriage Track gauge C [m] A [mm] B [mm]

120 HC 4,6 150 1100
120 HC 4,5 150 1100
170 HC 4,6 200 1200
170 HC 4,5 200 1200
185 HC 6,0 200 1200
256 HC 6,0 200 1200
256 HC 8,0 200 1200
Tab. 5-3 Dimensions for foundation soil preparation for the application of foundation slabs
1250 HC 40 / 49516 5-7

Foundation
5.3 Foundation
Warning!
Stability of the crane will be seriously jeopardised as a result of unsuitable underground.
Foundation slabs and rail tracks must be laid in such a way that overload or collapse of the walls or
slopes of the foundation pit is not possible. This must be mathematically verified by the operat-
ing company! The distance to the foundation pit is dependent on the corner pressure of the crane
and on the soil condition (water content, friction, shear strength etc.)
X Before laying the foundation slabs or the rail track, check the load-bearing capacity of the soil.
Pay attention to the corner pressures. For further information, see: Documentation Corner pres-
sures, foundation loadings and ballast data.
Fig. 5-6 Slope
Dimension Designation
α Load entry angle
β Slope angle
S Safety strip
T Pit depth
U Distance sleeper to bottom of slope
Tab. 5-4 Slope and safety strip dimensions
α < 30° for filled-in or loosely compacted soil U=2xT

α < 45° for natural cohesive soil U=1xT
S > 1.0 m up to 12 t total weight
S > 2.0 m for more than 12 t total weight
Tab. 5-5 Angle of slope and safety strip
5-8 1250 HC 40 / 49516

Rail tracks for rail-going cranes
5.4 Rail tracks for rail-going cranes
5.4.1 Prerequisites for laying rail tracks

Stellen Sie sicher, dass folgende Voraussetzungen erfüllt sind:
The ground is level.
The rails are worn evenly.
The track is maintained.
The rail track is 2 to 3 m longer at each end than the required travel range of the tower crane.
A safe distance of at least 0.5 m is maintained beween movable crane parts and parts in the im-
mediate vicinity.
Maximum horizontal load of the track or rail:
– 1⁄7 of the specified corner pressures acting along the tracks
– 1⁄10 of the specified corner pressures acting across the tracks
5.4.2 Rail recommendation
Rail
in accordance Rail height Rail head

Crane base (in accordance
with DIN EN [mm] width [mm]
with DIN 5902)
13674-1:2008-01
120 HC / 132 HC 49 E1 (DIN S 49) 149 67
170 HC 49 E1 (DIN S 49) 149 67
185 HC / 200 HC 49 E1 (DIN S 49) 149 67
256 HC / 290 HC 54 E3 (DIN S 54) 154 67
355 HC / 390 HC 54 E3 (DIN S 54) 154 67
500 HC / 550 HC 54 E3 (DIN S 54) 154 67
630 EC-H 54 E3 (DIN S 54) 154 67
Tab. 5-6 Rail recommendation
1250 HC 40 / 49516 5-9

5.4.3 Rails on concrete sleepers
Warning!
The crane could topple if unsuitable sleepers are used.
Wooden sleepers are not permissible.
Only use concrete sleepers on unfrozen ground.
The foundation soil must be firm.
Fig. 5-7 Rails on sleepers
A Track gauge
B Sleeper length
C Sleeper distance
Tab. 5-7 Dimensions for rails on sleepers
The sleeper distance C is dependent on the rail size, however a maximum 0.6 m.
Stellen Sie sicher, dass folgende Voraussetzungen erfüllt sind:
The cross-section of the sleepers is at least 16 x 24 cm. Any forces which occur could be directed
into the earth through the road bed.
The track gauge A is maintained at all times (e.g. via gauge control rods)
Only use sleepers which do not lay under both rails (partial sleepers):
– as an intermediate sleeper under the outer rails for curves
– if these sleepers have been inspected
– if proof of their load capacity has been verified
5 - 10 1250 HC 40 / 49516
5.4.4 Rails on concrete strip foundation

Make sure that the following condition has been met:
The permissible compressive strength is not exceeded.
Nominal strength of concrete N/mm² 15 25 35 45
Permissible compressive strength in case of N/mm² 14.7 24.5 32.2 37.8

partial area loading
Tab. 5-8 Concrete strength values
X Perform a calculation of the foundation in compliance with the regulations of the structural analysis
for reinforced concrete. Take the corner pressures into account. For further information, see: Doc-
umentation Corner pressures.
X Ensure that the concrete strip foundations have a base which is proof against frost damage.
Fig. 5-8 Rails on concrete strip foundation

(a) Anchor bolt (b) Steel plates (c) Fastening plate
A Distance of the fastening plates
Tab. 5-9 Dimensions for rails on concrete strip foundation
X Fixing the rails to the foundation (see: Fig. 5-8). Distance of the fastening plates A maximum 0.6
m.
Note
Only use steel plates without inclination. Inclination of the rails increases wear of the rail wheels and
rails. Steel plates of the Deutsche Bahn AG company are not suitable due to their inclination.
X In order that the track gauge be maintained: Link together strip foundations.
1250 HC 40 / 49516 5 - 11
5.4.5 Rails on steel supports

Support of the steel girders is dependent on:
– Soil conditions
– Corner pressure of the crane
– Size of the steel support
Support options
– Bed of road metal
– Individual concrete foundations
– Concrete slabs
– Strip foundation
The steel support and the support must be calculated.
Fig. 5-9 Rails on steel supports

(a) Steel support (d) Fastening plate (g) Gauge control rod
(b) Rail (e) Beam connection (h) Anchor bolt
(c) Rail connection (f) Support for beam
5 - 12 1250 HC 40 / 49516
5.4.6 SRS-crane rail track system
Warning!
SRS-crane rail tracks may only be used up to 1300 kN corner pressure.
Fig. 5-10 SRS-crane rail tracks

(a) Fixed end stop (d) Movable part of end stop (g) Track bed
(b) Concrete sleeper (e) Fastening plate (h) Gauge control rod
(c) Rail (f) Schiene, Fahrendschalter (i) Rail connection
Prefabricated crane track system consisting of

– straight rail sections 6.0 m in length
– curved rail sections
– gauge control rods, rail points and crossings
1250 HC 40 / 49516 5 - 13
5.4.7 Track end protection
Fig. 5-11 Track end protection

(a) Fixed end stop (b) Movable part of end stop (c) Rubber buffer
X Strong end stops (firmly secured to the rails) must be provided at the ends of the rail track assem-
bly in such a way, that the distance between the stops and the wheel bogies is everywhere the
same.
5.4.8 Rail for travel limit switch
Fig. 5-12 Rail for travel limit switch

(a) Travel limit switch (b) Travel gear (c) Schiene, Fahrendschalter
X Set the ramp for the travel limit switch (c) so that upon actuation of the limit switch (a) the crane
comes to a standstill approx. 1.0 m before the track end protection.
The rail for the travel limit switch must be adjustable, both in height and to the side.
5 - 14 1250 HC 40 / 49516
5.4.9 Installation tolerances for crane rail tracks in accordance with VDI
3576
Tolerance group 2 (for construction cranes)

For cranes of load categories B1 - B3 in accordance with DIN 15018. Tolerance group 2 corresponds
with DIN 4132, February 1981.
L ≤ 15 m: A = ± 5 mm
Mean track gauge L
L 15 m:
[m]
A = ± (5 + 0.25 (L - 15)) mm
B = ± 10 mm
folgendes Stichmaß darf auf
Position of a rail in plan
einer Messlänge von 2,0 m
view
nicht überschritten werden: b
= ± 1.0 mm
C = ± 10 mm
Height of a rail (longitu-
dinal gradient)
nicht überschritten werden: c
= ± 2.0 mm
D = ± 1.0 ‰ of L,
max. ± 10 mm
Relative heights of rails
(lateral gradient)
for tower cranes: D = ± 2.0 ‰
(not controlled in DIN 4132)
E = inclination A1 B1 - incli-
Relative cant angle of nation A2 B2
rails
E = 0.5 ‰
Relative position of F = ± 1.0 ‰ of L,

end stops max. 20 mm
Tab. 5-10 Installation tolerances for crane tracks, tolerance group 2
1250 HC 40 / 49516 5 - 15
G = ± 8 ‰ of the rail head

Relative head cant de-
width K (with flat running sur-
viation
face)
Tolerance group 1*
Valid for cranes of load categories B4 - B6 in accordance with DIN 15018. Tolerance group 1 corre-
sponds with DIN 4132, February 1981.
L ≤ 15 m: A = ± 3 mm
Mean track gauge L
L 15 m:
[m]
A = ± (3 + 0.25 (L - 15)) mm
B = ± 5 mm
Position of a rail in plan
view
nicht überschritten werden: b
= ± ±1.0 mm
C = ± 10 mm
Height of a rail (longitu-
dinal gradient)
nicht überschritten werden: c
= ± 1.0 mm
Relative heights of rails D = ± 0.2 ‰ of L, max. ± 10

(lateral gradient) mm
E = inclination A1 B1 - incli-
Relative cant angle of nation A2 B2
rails
E = 0.5 ‰
Relative position of
F = ± 0.7 ‰ of L, max. 20 mm
end stops
5 - 16 1250 HC 40 / 49516
G = ± 8 ‰ of the rail head

Relative head cant de-
width K (with flat running sur-
viation
face)

1250 HC 40 / 49516 5 - 17
5.4.10 Laying rail tracks in curve
Fig. 5-13 Laying rail tracks in curve
120 HC
185 HC 256 HC 256 HC
Crane base 132 HC
200 HC 290 HC 290 HC
170 HC
Track gauge L 4.5 m /4.6 m 6.0 m 6.0 m 8.0 m
Inner radius b 8.5 m 12.0 m 12.5 m 18.0 m
Outer radius c 13.1 m 18.0 m 18.5 m 26.0 m
Tab. 5-12 Track gauge, inner radius, outer radius
Dimensions relate to the centre of the rail head.

The curve radii can be increased at any time in accordance with the available space. A greater curve
radius is more favourable to travel characteristics and the rail wheels. The greater the curve radius,
the less wear is resulted to the rail wheels. For rail tracks featuring curves in only one given direction,
the powered wheel bogies must be mounted on the outer side of the curve.
Note
Un-lubricated rail heads reduce life-expectancy of the travel gear rail wheels.
X To increase life-expectancy of the rail wheels: Lubricate the lateral running surface of the rail
head with graphitic grease.
5 - 18 1250 HC 40 / 49516
Lightning protection / protection against electrostatic charge
5.5 Lightning protection / protection against electro-

static charge
5.5.1 Fundamental notes

The operating company must check before start-up as to whether the measures for lightning protec-
tion and / or earthing regarding electrostatic charge are necessary, and if required, carry out the
appropriate earthing measures!
The local regulations include information concerning whether the crane must feature lightning protec-
tion.
5.5.2 Earthing measures for rail-going cranes
Fig. 5-14 Earthing the rail

(a) M10 screw with spring (b) Earthing rod which must be (c) Galvanized steel strip 30
washer driven at least 1.5 m into mm x 3.5 mm
the ground
Each rail must be earthed at each end and every 20 m. If no other earthing bars are available, an
earthing rod which must be driven at least 1.5 m into the ground is sufficient.
For buildings with steel reinforcement in the foundations, a connection link must be placed between
the reinforcement and one rail. Connect climbing cranes twice.
Equipment, machines and metal pipes must be connected to the rails within a perimeter of up to 20
m around the tracks.
It is not necessary to bridge rail joints which are connected with steel fishplates for lightning protec-
tion.
We recommend installation of an overvoltage arrester when connecting the mains for protection of
the electrical device for the structural members.
1250 HC 40 / 49516 5 - 19
Lightning protection / protection against electrostatic charge
5.5.3 Earthing measures for stationary cranes
Fig. 5-15 Earthing measures for stationary cranes

(a) Insulated copper rope (c) Galvanized steel strip 30 (e) Undercarriage fast-erecting
min. 16 mm2 mm x 3.5 mm crane
(b) Earthing rod which must be (d) M10 screw with spring
driven at least washer and nut
1.5 m into the ground
Top slewing cranes, which are not connected to the steel reinforcement of the building foundations.
5 - 20 1250 HC 40 / 49516
Electrical connection
5.6 Electrical connection
5.6.1 Regulations
– Protective measures; Protection against electric shock, DIN VDE 0100 part 410 (see also the IEC
publications 60364-4-41)
– Earthing, protective conductors, potential equalisation conductors, DIN VDE 0100 part 540 (see
alos the IEC publication 60364-5-54)
5.6.2 Protective measures on the construction site

A site junction box must be provided on the construction site. The site junction box must be able to
withstand any occurring electric, mechanical and thermic conditions, as well as any humidity condi-
tions.
The following guidelines must be observed:
– DIN EN 60439-4
– DIN VDE 0660 part 501 (or the respective national guidelines)
Due to varying guidelines for the permissible network configuration and electrical protective meas-
ures, the national guidelines must also be observed!
Notes concerning the connection of the cranes with frequency

converter driving units
The B6-wiring at the input of the intermediate circuit, employed as common practice with frequency
converters, may cause a non-pulsating fault direct current in the event of an earth contact. The fault
direct current can block the release of a residual current (FI) protective switch in accordance with DIN
VDE 0664.
In accordance with DIN EN 50178, it is not allowed to employ the residual current protection system
with pulse current sensitive residual current protective switches as the sole protective measure
against indirect contact .
If necessary, the power side protection against indirect contact must be realized in a different way,
e.g. by over-current protection devices or by the application of all current-sensitive FI-protective
switches (e.g. Siemens brand or ABB).
It is absolutely necessary however, to allocate an individual circuit. A derivacion by pulse current
sensitive FI-protective switches in accordance with DIN VDE 0664, employed as common practice in
site junction boxes, is not authorized according to DIN VDE 0664.
1250 HC 40 / 49516 5 - 21
5.6.3 Electrical connection to the site junction box
Warning!
Danger resulting from electrical energy.
Improper installation of the power supply can lead to serious accident
Electrical installation may only be carried out by an electrical specialist.
Distribution, earthing and protective devices must comply with the local guidelines
Note!
The site junction box must be provided by the customer.
Rail-going crane:
– Connection of the junction box via a motor-driven or spring-driven cable drum
Stationary crane:
– Connection of site junction box to slipring assembly in the slewing ring support
Line protection
The line from the site distribution to the crane has to be protected against thermical overload and
short circuit.
Protection can be arranged by means of the following measures:
– Line protection fuses with gl-characteristics
– Line protection switch with tripping characteristics B and C
– Adjustable protection devices (power switch according to DIN EN 60947-2, DIN VDE 0660 part
101 or motor protection switch according to DIN EN 60947-4-1, DIN VDE 0660 part 102)
Note
when using line protection fuses: Observe the instructions regarding the application in connec-
tion with insulated conductors.
X The line loading may not exceed the nominal current of the fuse.
when using a line protection switch or an adjustable protection device:

X The permissible load of the line equals the nominal current of the conductor.
Calculation of the supply cable

Total length:
LGes = LRest + L Kran
LRest = LHH + L Weg

-----------
2
LGes : Total length
5 - 22 1250 HC 40 / 49516
LRest : Remaining length from the site junction box to the slipring assembly in the ball slewing ring
support
LKran : Supply cable installed within the crane
LHH : Erection height or hook height of the crane
LWeg/2 : Half the travel distance for power supply in the middle of the travel lane. If the power supply
is located outside of the middle of the travel lane, the longer distance must be taken into
consideration.
Permissible total length of the supply cable:
56 ⋅ A ⋅ ( 0, 03 ⋅ U n )
LGes = ------------------------------------------------
-
1, 73 ⋅ I Dauer ⋅ cos ϕ
LGes : Permissible total length [m] taking the voltage drop into consideration
A: Permissible cable cross-section [mm2] taking the voltage drop into consideration
Un : Operating voltage [V]
IDauer : Continuous current [A]
cos ϕ : Phase-shift angle
Note
Values vary depending on the crane type. Calculation must be undertaken with the values which
relate to the respective crane. For further information, see: Chap. 3.3 Electrical connection data.
1250 HC 40 / 49516 5 - 23
5 - 24 1250 HC 40 / 49516
Instruction Manual Erection
6 Erection
This chapter has been compiled exclusively for properly qualified personnel. All information concerning
safe and quick erection of the crane can be obtained here. Starting at the base of the crane, erection
of the tower and the slewing part of the crane are explained step-by-step. The erection instructions
include all variants of the crane base.
If climbing equipment is to be used, the instructions regarding climbing must also be observed.
To ensure safe handling of the connecting material on the tower and on the slewing platform, the infor-
mation booklet "Pre-stressed high-tensile bolt connections on Liebherr tower cranes" must also be
noted.
1250 HC 40 / 49516 6-1

Erection Instruction Manual
Notes on safety for erection
6.1 Notes on safety for erection
6.1.1 Who is permitted to erect the crane?

Erection may only be carried out by properly qualified personnel. Following erection, the crane must be
inspected by an expert. The results of the inspection must be logged in the crane test record book.
6.1.2 Under which conditions may erection be carried out?
Warning!
Risk of accidents as a result of excessive wind speeds.
Should wind speeds exceed 12.5 m/s (45 km/h, wind force 6) during erection and climbing of the
crane, there is a risk of the crane toppling. Please note that unexpected wind speeds far exceeding
12.5 m/s could occur as a result of sudden gusts.
X Discontinue erection and climbing of the crane immediately if wind speeds exceed 12.5 m/s (45
km/h, wind force 6).
X Discontinue erection and climbing of the crane immediately if gusts exceed 12.5 m/s (45 km/h,
wind force 6).
– The building site for erection of the crane base must be prepared in accordance with the crane ap-
plication. For further information, see chapter: ›Corner pressures, foundation loadings and ballast
data‹ and ›Preparing for application of the crane‹.
– Power supply and space must meet the requirements. For further information, see chapter:
›Preparing for application of the crane‹.
– The cross-sections and lengths of the electric supply cables must correspond with the electrical con-
nections. For further information, see chapter: ›Specifications (electrical connection data)‹.
– Lightning protection and protection against electrostatic charge must be guaranteed. For further in-
formation, see chapter: ›Preparing for application of the crane‹.
– Make sure that the crane is visible.
– All crane parts must be free from ice and snow.
– For further information, see chapter: ›Preparing for application of the crane‹.
6.1.3 Which personal protective equipment must be worn?

The following must be worn:
– Safety helmet – Safety boots
– Protective gloves – Safety harness
6.1.4 Which additional guidelines must be observed?

– Local guidelines for accident-prevention
6-2 1250 HC 40 / 49516

Notes on safety for erection
6.1.5 Which dangers are resulted from the crane?
– Danger of crushing – Danger resulting from electrical energy

– Risk of toppling
1250 HC 40 / 49516 6-3

Fundamental notes on erection
6.2 Fundamental notes on erection
6.2.1 Tower connecting material
Warning!
Risk of jeopardising stability.
Improper tower connections can jeopardise the stability.
The bolts for the tower connection must comply with Liebherr-standard LN 31.
The nuts for the tower section must comply with Liebherr-standard LN 32.
X Check the connecting material, lubricate and tighten with the respective tightening torque. For fur-
ther information, see: Information booklet ›Prestressed high-tensile bolt connections on Liebherr
tower cranes‹ and chapter ›Pin installation‹.
Note
The following specifications on the tower connection apply to the following configurations:
– on foundation anchor 500 HC and tower 1250 HC.
or
– on foundation anchors 630 EC-H reinforced and tower 1250 HC.
For further information, see: Chapter ›Technical description‹.
6-4 1250 HC 40 / 49516

Fig. 6-1 Connecting material: roller slewing ring support and tower 1250 HC
Fig. 6-2 Connecting material: tower 1250 HC and foundation anchor 500 HC
1250 HC 40 / 49516 6-5

Fig. 6-3 Connecting material: tower 1250 HC and foundation anchor 630 EC-H
(a) Roller slewing ring support (i) Lock nut (q) Grundturmstück verstärkt
C 036.020-333.000 C 036.020-338.000
(b) Tower section 1250 HC (j) Cover (r) Foundation anchor 630 EC-H
C 036.020-332.000 C 048.007-372.111
(c) Tower section 1250 HC (k) Protecting cap (s) Bolt
C 036.020-332.000
(d) Sleeve (l) Base tower 1250 HC (t) Washer
C 036.020-337.000
(e) Taper (m) Foundation anchor 500 HC (u) Distance tube
C 032.001-372.100
(f) Safety channel (n) Safety channel (v) Nut
(g) Washer (o) Lock washer (w) Protecting cap
(h) Nut (p) Bolt
6-6 1250 HC 40 / 49516

Connection between:
Roller slewing Tower section (b) Tower section (c)

ring support (a)
- - -
Tower section (b) Tower section (c) Foundation
or base tower (l) anchor (m)
Sleeve (d) C 032.001-332.241

Quantity 8 8 8
Part No. 9535 345 01
Taper (e) C 032.001-332.242
Quantity 8 8 8
Part No. 9535 346 01
Safety channel (f) C 036.020-332.443
Quantity 4 4 4
Part No. 9000 9646
Washer (g) 37 St zinced, according to Liebherr standard LN 75
Quantity 8 8 8
Part No. 4200 137 01
(h) M 36 10 A3C according to Liebherr standard LN 32, crack-tested
Nut
similar to ISO 4032-10
Quantity 8 8 8
Part No. 4115 061 01
Lock nut (i) M 36 05 A3C ISO 4035
Quantity 8 8 8
Part No. 4117 013 08
Cover (j) PE M 36
Quantity 8 8 8
Part No. 1017 2855
Protecting cap (k) C 036.021-332.247-001
Quantity 8 8 8
Part No. 9080 0644
Safety channel (n) C 032.001-372.122
Quantity 4 4 4
Part No. 9535 278 01
Lock washer (o) 31,6 / 45 x 3,6 VS ZN5 / CN / T2
Quantity 8 8 8
Part No. 4239 130 01

Bolt (p) M 30 x 60 8.8 A3C ISO 4017
Quantity 8 8 8
Part No. 4065 251 01
Fig. 6-4 Connecting material: tower 1250 HC and foundation anchor 500 HC
1250 HC 40 / 49516 6-7

Connection between:
Base tower (l) Base tower reinforced (q)

- -
Base tower reinforced (q) Foundation
anchor reinforced (r)
Bolt (s) M 45x440 12.9 according to Liebherr standard LN 31, crack-tested
Quantity 32 32
Part No. 4062 905 01
Washer (t) 46 according to Liebherr standard LN 75
Quantity 64 64
Part No. 4215 041 01
Distance tube (u) 46 x 90 x 88 / C 103.001-336.246
Quantity 32 32
Part No. 9556 357 01
Nut (v) M 45 12 according to Liebherr standard LN 32, crack-tested
Quantity 32 32
Part No. 4115 184 01
Protecting cap (w) EP 800 / M 45
Quantity 32 32
Part No. 7790 145 01
Fig. 6-5 Connecting material: tower 1250 HC and foundation anchor 630 EC-H
6-8 1250 HC 40 / 49516

6.2.2 Slewing ring connecting material
Warning!
Improper connection can jeopardise the stability.
The bolts and nuts for the slewing ring connection must comply with Liebherr-standard LN 31 /
LN 32.
X Check the connecting material, lubricate and tighten with the respective tightening torque for pre-
stressed high-tensile bolt connections for ball slewing rings. For further information, see: Infor-
mation booklet Prestressed high-tensile bolt connections on Liebherr tower cranes.
Fig. 6-6 Slewing ring connection

(a) Roller slewing ring support (d) Bolt (g) Spacer
(b) Roller slewing ring (e) Nut (h) Spacer
(c) Slewing platform (f) Washer
1250 HC 40 / 49516 6-9

Connection between:
Roller slewing ring support (a) Roller slewing ring (b)

– –
Roller slewing ring (b) Slewing platform (c)
M 42x450 10.9 A3C according to Liebherr standard LN 31, crack-tested
Bolt (d)
similar to ISO 4014-10.9 A3C
Quantity 56 56
Part No. 4062 879 01
M 42 10 A3C acording to Liebherr standard LN 32, crack-tested
Nut (e)
similar to ISO 4032-10 A3C
Quantity 56 56
Part No. 4115 064 01
Washer (f) 43 St zinced, acording to Liebherr standard LN 75
Quantity 56 56
Part No. 4200 143 01
Drawing No. C 048.010-351.135
Spacer (g) –
- Top -
Quantity – 56
Part No. – 9705 827 01
Drawing No. C 048.010-351.135
Spacer (h) –
- Bottom -
Quantity 56 –
Part No. 9705 827 01 –
Tab. 6-1 Slewing ring connection, ID no. 9001 0684
6 - 10 1250 HC 40 / 49516
Tensioning tool
Bolt M 42 10.9 A3C
Stroke 10 mm
Operating pressure bar / p.s.i.
Pretensioning force kN
Tab. 6-2 Technical data for tensioning cylinder
1250 HC 40 / 49516 6 - 11
Preparing for erection
6.3 Preparing for erection
Warning!
Risk of toppling over of the crane due to improper manufacturing of the rail tracks and of the foun-
dation soil.
The crane operating company is responsible for any damage caused by improperly manufactured
rail tracks and foundation slabs, by an improper installation of the foundation anchors or by neglect-
ing the foundation site conditions and the load-bearing capacity of the soil.
X Check the load-bearing capacity of the soil. For further information, see: ›Documentation Corner
pressures, foundation loadings and ballast data‹.
X Check the rail track. For further information, see: Chapter ›Preparing for application of the
crane‹.
X Check the foundation. For further information, see: ›Documentation Corner pressures, founda-
tion loadings and ballast data‹.
X Check the foundation slabs. For further information, see: ›Documentation Corner pressures,
foundation loadings and ballast data‹.
Note
The auxiliary crane must be selected in accordance with crane configuration and erection weights.
For further information, see: Chapter ›Specifications‹.
Make sure that the following conditions have been met:

The additionally required tool for erecting the crane is provided.
The guide ropes for installing the jib and the counter-jib are provided.
6 - 12 1250 HC 40 / 49516
Mounting the guardails
6.4 Mounting the guardails
6.4.1 Handrail system (variable)

Variable handrails are combined to a modular design principle in varying lengths and heights in accordance
with Liebherr-standard LN 266. All handrails and handrail posts must be bolted and secured in accordance
with Liebherr-standard LN 266.
Fig. 6-7 Handrail components

(a) Handrail LN 266 (secured (d) Rail tube (half-height rail) (g) Identification surface cen-
in handrail socket) tre-to-centre distance
(b) Post (e) Handrail socket (h) Rail tube (transversal) as
handrail
(c) Rail tube (handrail) (f) Handrail LN 266 (fixed directly (i) Rail tube (transversal) as
to the structural element) half-height rail
Liebherr-stand- Centre-to-centre distance

Comment
ard LN 266 (system height)
LN 266-1 1000 not for new design - for SP-delivery only
LN 266-2 1100
LN 266-3 1500 not for new design - for SP-delivery only
LN 266-4 1620
Tab. 6-3 Handrail variants
1250 HC 40 / 49516 6 - 13
Fig. 6-8 Dimensions and configurations of the Handrails in accord. with Liebherr-standard LN 266
(A) System height (D) Centre-to-centre distance: (G) 2nd rail tube (possibly 2nd
Half-height rail - handrail half-height rail) - length
depending on configuration
(B) Centre-to-centre distance: (E) 1st rail tube (handrail) - (H) Max. distance between posts
Lower edge posts - half- length depending on con-
height rail figuration
(C) Centre-to-centre distance: (F) 2nd rail tube (half-height (I) Distance between successive
Half-height rail - half- rail) - length depending on handrails
height rail configuration
A B C D h I
LN 266-1 1000 500 - 500 max. 1900 50 - 100
LN 266-2 1100 580 - 520 max. 1900 50 - 100
LN 266-3 1500 500 500 500 max. 1900 50 - 100
LN 266-4 1620 580 520 520 max. 1900 50 - 100
Tab. 6-4 Dimensions (in mm) and config. of the handrails in accord. with Liebherr-standard LN 266
6 - 14 1250 HC 40 / 49516
Handrail LN266-4 2/-800/-700-700
Length of 3rd rail tube (2nd half-heigt rail

=> only for LN266-3 and LN266-4
Length of 2nd rail tube (half-height rail)
Length of 1st rail tube (handrail)
Number of posts
Handrail according to LN266-4
=> i.e. system height 1620 mm
Designation
Tab. 6-5 Designation of handrails
Installing the handrails
Fig. 6-9 Installing the posts

(a) Posts (fixed directly to the (d) Washer (g) Screw
structural element)
(b) Nut (e) Screw (h) Handrail socket
(c) Lock washer (f) Posts (fixing in the handrail
socket)
Fixed directly to the structural element:

X Secure the posts (a) with screws (e), washers (d), lock washers (c) and nuts (b) directly to the
structural element. (1)
Fixing in the handrail socket:

X Insert the posts (f) into the handrail socket (h) and clamp with screw (g). (1)
The screw (g) must be inserted into the lowest borehole of the post (f) (see magnifying
glass).
1250 HC 40 / 49516 6 - 15
Fig. 6-10 Mounting the rail tube (handrail)

(i) Posts (k) Rail tube (m) Tube bush
(j) Cotter pin (l) Cylinder head screw
X Push the rail tube (k) through the bushes (m) of the post (i). (2)
X Screw the ends of the rail tubes (k) via the through hole with a cylinder head screw (l) from above
into the tube bush (c) and clamp from below with a cylinder head screw (l). (3)
- or -
Clamp the ends of the rail tubes (k) with two cylinder head screws (l) from below. (4)
X Clamp all other tube bushes (m) of the posts (i) from below with two cylinder head screws (l). (4)
Note
If the end of the rail tube is only clamped with cylinder head screws, the rail tube must be secured
at this end with a cotter pin.
X Secure the rail tube (k) with a cotter pin (j). (5)
Caution
The rail tubes may not be thrust into the tube bushes (see: Fig. 6-10 detail „X“).
6 - 16 1250 HC 40 / 49516
Fig. 6-11 Installing the rail tube (half-height rail)

(n) Posts (p) Cotter pin (r) Square nut
(o) Rail tube (half-height rail) (q) Retaining ring (s) Cylinder head screw
X Insert the square nuts (r) into retaining rings (q) and screw in the cylinder head screws (s)
slightly. (6)
X Push the rail tube (o) through retaining rings (q). Align the rail tube (o) and clamp with cylinder
head screws (s). (7)
X Secure the rail tube (o) with two cotter pins (p). (8)
If the handrails feature two rail tubes (half-height rails), the second rail tube must be installed in exactly
the same way.
1250 HC 40 / 49516 6 - 17
Installing the rail tube (transversal)
Fig. 6-12 Installing the rail tube (transversal)

(a) Clamp (e) Screw (i) Post
(b) Square nut (f) Washer (j) Lock nut
(c) Cotter pin (g) Cylinder head screw
(d) Rail tube (h) Rail tube
X Secure two clamps (a) to two posts (i) with two screws (e) and washers (f). Tighten two lock nuts
(j) hand-tight. (1)
X Insert two square nuts (b) in two clamps (a) and screw in two cylinder head screws (g) slightly. (2)
X Push the rail tube (a) through two clamps (a), align and clamp with two cylinder head screws (g).
(3)
X Secure the rail tube (a) with two cotter pins (c). (4)
Fig. 6-13 Different configurations of rail tubes (transversal)

(k) Rail tube as half-height rail (l) Rail tube as handrail
Transversal running rail tubes can be used as handrails (l) and half-height rails (k).
6 - 18 1250 HC 40 / 49516
Fig. 6-14 Aligning the rail tube (transversal) horizontally

(m) Spirit level (o) Clamp (q) Rail tube
(n) Handrail (p) Lock nut
X Align the rail tube (q) horizontally by shifting the two clamps (o). (5)
X Tighten two lock nuts (p) tightly. (6)
6.4.2 Handrail system (welded)

Welded handrails are prefabricated in varying lengths and heights.
Fig. 6-15 Handrail components

(a) Handrail (fixing in hand- (c) Handrail (fixed directly to (e) Rail tube (continuation of hand-
rail socket) the structural element) rail) - secured via tube clamp
(b) Rail tube (transversal) - (d) Handrail (fixed directly to
secured via steel strap the structural element)
for tubes
1250 HC 40 / 49516 6 - 19
Installing the handrails
Fig. 6-16 Installing the handrail

(a) Handrail (fixed directly to the (d) Washer (g) Handrail (fixing in handrail
structural element) socket)
(b) Nut (e) Screw (h) Screw
(c) Lock washer (f) Vent plug (i) Handrail socket
Fixed directly to the structural element:

X Screw the handrails (a) with screws (e), washers (d), circlips (c) and nuts (b) directly to the struc-
tural element. (1)
Fixing in the handrail socket:

X Insert the guard rail (g) into the handrail socket (i) and clamp with screw (h). (1)
The screw (h) must be inserted into the lowest borehole of the handrail (g) (see magnifying
glass).
X Close all ends of the handrail with vent plugs (f). (2) LBC/en/01/Issued: 07.11
6 - 20 1250 HC 40 / 49516
Installing accessories
Accessories are fixed with tube clamps or steel straps for tubes.
Fig. 6-17 Installing accessories

(a) Nut (e) Handrail (i) Rail tube (as handrail)
(b) Washer (f) Steel strap for tubes (j) Rail tube (as half-height rail)
(c) Tube clamp (g) Vent plug (k) Round steel chain
(d) Rail tube (as handrail) (h) Nut (l) Screw
X Mount the rail tube (d) with two tube clamps (c) on the handrail (e) . Secure all tube clamps (c)
with screws (l), washers (b) and nuts (a). (1)
X Mount the rail tube (i) with four steel straps for tubes (f) to the guard rail (e) . Secure all steel straps
for tubes (f) with washers (b) and nuts (a) and lock with nuts (h). (2)
X Close all ends of the handrails with vent plugs (g). (3)
Span short distances (up to approx. 500 mm) between guard rails with round steel chains:
X Mount a round steel chain (f) with two tube clamps (f) on the guard rail (f). Secure all tube clamps
(c) with screws (l), washers (b) and nuts (a). (4)
1250 HC 40 / 49516 6 - 21
Installing the crane base
6.5 Installing the crane base
6.5.1 Installing the reinforced base tower section

Part No.: 9002 1971 / Drawing No.: C 036.020-338.000
Fig. 6-18 Sequence of pre-assembly

(a) Base tower section (e) Platform level 1 (i) Girder
(b) Cross-member (lower) (f) Cross-member (central) (j) Platform level 2
(c) Girder (g) Ladder with backguard (k) Cross-member (top)
(lower)
(d) Girder (h) Girder (l) Ladder with and without back-
guard (top)
6 - 22 1250 HC 40 / 49516
X Connect the corner posts and the diagonal members of the base tower section (a) and secure. (1)
X Install cross-member (b) and secure. (2)
X Install two girders (c, d) and secure. (3)
X Install platform level 1 (e) and secure. (4)
X Install cross-member (f) and secure. (5)
X Install the ladder with backguard (g) and secure. (6)
X Install two girders (h, i) and secure. (7)
X Install platform level 2 (j) and secure. (8)
X Install cross-member (k) and secure. (9)
X Install the ladder with backguard (l) and secure. (10)
Note
Designation of the base tower section panels. For further information

refer to the following description.
1250 HC 40 / 49516 6 - 23
Preparing the base tower section for installation
Warning!
Improper assembly of the tower section can lead to accidents.
X Secure the assembly components of the tower section against tipping.
Fig. 6-19 Preparing the base tower section for installation

(a) Corner post x 2 (e) Diagonal member x 16 (i) Pin x 16 (ø 60 x 340 x 275)
(C036.020-338.141) (C036.020-337.113)
(b) Corner post x (f) Diagonal member x 12 (j) Pin x 24 (ø 60 x 275 x 210)
2(C036.020-338.131) (C036.020-332.112)
6 - 24 1250 HC 40 / 49516

(c) Diagonal member x 4 (g) Diagonal member x 8 (k) Spring clip x 88
(C036.020-338.111) (C036.020-337.114)
(d) Diagonal member x 4 (h) Pin x 48 (ø 70 x 275 x 210) (l) Correct position of the flat
(C036.020-338.112) spot on the pin head
Note
The pin head of pins (h, i, j) are flattened on one side.
When installing, ensure correct position (l) of the flat spot.
Check the vertical position of the corner posts (a, b) using a spirit level.
X Connect corner posts (a, b) and diagonal members (c, d, e, f, g) with pins (h, i, j). Secure each
pin (h, i, j) with spring clip (k) (exact position and adjustment of the corner posts see: Fig. 6-
33). (1)
Installing the cross-member and platform level 1
Fig. 6-20 Installing the cross-member

(a) Corner post x 2 (c) Cross-member (lower) (e) Spring clip
(C036.020-338.141) (C036.020-337.122)
(b) Corner post x 2 (d) Pin LN 19
(C036.020-338.131) x 2 (ø 40 x 100 x 55)
X Connect one cross-member (c) (lower) and two corner posts (a) with two pins (d). Secure each
pin (d) with spring clip (e). (1)
Note
The two upper cross-members prevent unobstructed installation of the platforms.
X The second cross-member should only be installed subsequently, following installation of the
lower platform level.
1250 HC 40 / 49516 6 - 25
Installing the girders
Fig. 6-21 Installing the girders

(a) Girder (c) Washer (e) Nut
(C 036.020-332.361)
(b) Bolt (d) Lock washer (f) Girder
(C 036.020-332.351)
Note
When installing the girders (a) and (f), the connection plates for the platforms must point inwards.
X Install girder (f) on panel 1 and secure.
X Connect girder (a), (f) and four corner posts with four bolts (b). Secure each bolt (b) with two
washers (c), lock washer (d) and nut (e). (1)
6 - 26 1250 HC 40 / 49516
Installing platform level 1
Fig. 6-22 Installing platform level 1

(a) Girder (c) Platform 2 (e) Platform 3
(C 036.020-332.361) C 036.020-332.310 C 036.020-332.330
(b) Girder (d) Platform 1
(C 036.020-332.351) C 036.020-332.320
X Bolt platforms (c, d, e) to girders (a, b) and secure. For further information, see: ›Preparing the
tower section for installation‹ (Part No. 9000 7492 / Drawing No. C 036.020-332.000). (1)
1250 HC 40 / 49516 6 - 27
Installing the cross-member (central)
Fig. 6-23 Installing the cross-member (central)

(a) Corner post x 2 (c) Cross-member (central) (e) Spring clip
(C036.020-338.141) (C036.020-338.120)
(C036.020-338.131) x 2 (ø 40 x 190 x 145)
X Connect cross-member (c) and two corner posts (a) with two pins (d). Secure each pin (d) with
spring clip (e). (1)
6 - 28 1250 HC 40 / 49516
Installing the ladder (lower) with back guard
Fig. 6-24 Installing the ladder (lower) with back guard

(a) Ropes of the auxiliary crane (h) Bolt (n) Lock washer
(b) Ladder with back guard (i) Washer (o) Nut
(c) Clamp (j) Lock washer (p) Cross-member (central)
(d) Bolt (k) Nut (q) Guide plate
(e) Washer (l) Bolt (r) Cross-member (lower)
(f) Lock washer (m) Washer (s) Sealing plug
(g) Nut
X Install two sealing plugs (s) on the ladder (b). (1)

X Attach the auxiliary crane lifting slings (a) onto the ladder with back guard (b) and lower the ladder
into the tower section. (2)
X Connect ladder the with back guard (b) and the cross-member (p) with two bolts (d). Secure each
bolt (h) with two washers (i), lock washer (j) and nut (k). (3)
X Connect the clamp (c) and the cross-member (r) with two bolts (h). Secure each bolt (h) with two
washers (i), lock washer (j) and nut (k). (4)
X Connect two guide plates (q) for ladder (b) to the clamp (c) with two bolts (l). Secure each bolt (l)
with two washers (m), lock washer (n) and two nuts (o). (5)
1250 HC 40 / 49516 6 - 29
Installing the girders for platform level 2
Fig. 6-25 Installing the girders for platform level 2

(a) Girder (c) Washer (e) Nut
(C 036.020-332.361)
(b) Bolt (d) Lock washer (f) Girder
(C 036.020-332.351)
Note
When installing the girders (a) and (f), the connection plates for the platforms must point inwards.
X Install girder (f) on panel 1 and secure.
X Connect girder (a), (f) and four corner posts with four bolts (b). Secure each bolt (b) with two
washers (c), lock washer (d) and nut (e)1.
6 - 30 1250 HC 40 / 49516
Installing platform level 2
Fig. 6-26 Installing platform level 2

(a) Girder (c) Platform 2 (e) Platform 3
(C 036.020-332.361) C 036.020-332.310 C 036.020-332.330
(b) Girder (d) Platform 1
(C 036.020-332.351) C 036.020-332.320
X Bolt platforms (c, d, e) to girders (a, b) and secure. For further information, see: ›Preparing the
tower section for installation‹ (Part No. 9000 7492 / Drawing No. C 036.020-332.000). (1)
1250 HC 40 / 49516 6 - 31
Installing the cross-member (top)
Fig. 6-27 Installing the cross-member (top)

(a) Corner post x 2 (c) Cross-member (top) (e) Spring clip
(C036.020-338.141) (C036.020-338.117)
(C036.020-338.131) x 2 (ø 40 x 190 x 145)
X Connect cross-member (c) and two corner posts (a) with two pins (d). Secure each pin (d) with
spring clip (e). (1)
6 - 32 1250 HC 40 / 49516
Installing the ladder (top) with and without back guard
Fig. 6-28 Installing the ladder (top) with and without back guard
(a) Ropes of the auxiliary crane (h) Bolt (o) Nut
(b) Ladder with back guard (i) Washer (p) Cross-member (top)
(c) Clamp (j) Lock washer (q) Guide plate
(d) Bolt (k) Nut (r) Cross-member (central)
(e) Washer (l) Bolt (s) Sealing plug
(f) Lock washer (m) Washer (t) Ladder without back guard
(g) Nut (n) Lock washer (u) Sealing plug
X Install two sealing plugs (s) on the ladder (b). (1)

X Install four sealing plugs (u) on the ladder (t). (2)
X Attach the auxiliary crane lifting slings (a) onto the ladder with back guard (b) and lower the ladder
into the tower section. (3)
X Connect ladder the with back guard (b) and the cross-member (p) with two bolts (d). Secure each
bolt (d) with two washers (e), lock washer (f) and nut (g). (4)
X Connect the clamp (c) and the cross-member (r) with two bolts (d). Secure each bolt (d) with two
1250 HC 40 / 49516 6 - 33
washers (e), lock washer (f) and nut (g). (5)

X Connect two guide plates (q) for ladder (b) to the clamp (c) with two bolts (l). Secure each bolt (l)
with two washers (m), lock washer (n) and two nuts (o)6.
X Connect the ladder (t) and two guide plates (q) with four bolts (h). Secure each bolt (h) with two
washers (i), lock washer (j) and nut (k). (7)
6 - 34 1250 HC 40 / 49516
6.5.2 Preparing the base tower section for installation

Fig. 6-29 Sequence of pre-assembly

(a) Base tower section (e) Platform level 1 (i) Girder
(C 036.020-332.361)
(b) Cross-member (lower) (f) Cross-member (central) (j) Platform level 2
C 036.020-337.122 C 036.020-337.121
(c) Girder (g) Ladder with back guard (k) Cross-member (top)
(C 036.020-332.361) (lower) C 036.020-332.113
(d) Girder (h) Girder (l) Ladder with and without back
(C 036.020-332.351) (C 036.020-332.361) guard (top)
X Connect the corner posts and the diagonal members of the base tower section (a) and secure.
For further information refer to the following description. (1)
1250 HC 40 / 49516 6 - 35
X Install cross-member (b) and secure. (2)

X Install two girders (c, d) and secure. (3)
X Install platform level 1 (e) and secure. (4)
X Install cross-member (f) and secure. (5)
X Install the ladder with backguard (g) and secure. (6)
X Install two girders (h, i) and secure. (7)
X Install platform level 2 (j) and secure. (8)
X Install cross-member (k) and secure. (9)
X Install the ladder with back guard (l) and secure. (10)
For further information on the erection steps (2) to (10) see chap. ›Preparing the reinforced base tower
section for installation‹ (Part No.: 9002 1971 / Drawing No.: C 036.020-338.000).
Note
Designation of the base tower section panels. For further information

refer to the following description.
6 - 36 1250 HC 40 / 49516
Preparing the base tower section for installation
Warning!
Improper assembly of the tower section can lead to accidents.
X Secure the assembly components of the tower section against tipping.

(a) Corner post (f) Diagonal member x 16 (j) Pin x 40 (ø 70 x 275 x 210)
(C036.020-337.131) (C036.020-332.112)
(b) Corner post (g) Diagonal member x 8 (k) Spring clip x 80
(C036.020-337.141) (C036.020-337.113)
1250 HC 40 / 49516 6 - 37

(c) Corner post (h) Diagonal member x 4 (l) Pin x 8 (ø 60 x 340 x 275)
(C036.020-337.151) (C036.020-337.114)
(d) Corner post (i) Pin x 32 (ø 60 x 275 x 210) (m) Correct position of the flat
(C036.020-337.161) spot on the pin head
(e) Diagonal member x 12
(C036.020-332.111)
Note
The pin head of pins (i, j, l) are flattened on one side.
When installing, ensure correct position (m) of the flat spot.
Check the vertical position of the corner posts (a, b, c, d) using a spirit level.
X Connect corner posts (a, b, c, d) and diagonal members (e, f, g, h) with pins (i, j, l). Secure each
pin (i, j, l) with spring clip (k) (exact position and adjustment of the corner posts see: Fig. 6-33). (1)
6 - 38 1250 HC 40 / 49516
6.5.3 Preparing the tower section for installation
Mounting the erecting device (optional 1))

Designation Weight [t]

Erecting device complete. see ›Technical description‹
Tab. 6-6 Assembly weights
Warning!
Improper mounting of the erecting device can lead to accidents.
X Mount the erecting device horizontally (maximum inclination less than 2 ‰).
If this erecting device is used for long tower sections, ballast must be installed at the bottom to pre-
vent the unit from tipping over.
Fig. 6-31 Mounting the erecting device

(a) Ropes of the auxiliary crane (e) Carrier IV (i) Bolt
(b) Carrier I (f) Pin (j) Washer
1)
The erecting device is not part of the standard configuration and must be ordered separately.
1250 HC 40 / 49516 6 - 39
Fig. 6-31 Mounting the erecting device

(c) Carrier II (g) Cotter pin (k) Lock washer
(d) Carrier III (h) Bracket (l) Nut
X Hook carrier I (b) onto the ropes of the auxiliary crane (a), lift, set down onto the point of assembly
and align. (1)
X Hook carrier II (c) onto the ropes of the auxiliary crane, lift and guide into carrier I (a). (2)
X Connect carrier I (b) and carrier II (c) with two pins (f). Secure each pin (f) with two cotter pins
(g). (3)
X Mount carrier III (d) and carrier IV (e) (see stages 1-3).
X Align the preassembled erecting device. All carriers (b, c, d, e) must be positioned exactly at a
90° angle to one another. (4)
X Connect carrier I (b) and carrier III (d) with bracket (h). Connect the bracket (h) and both carriers
with four bolts (i). Secure each bolt (i) with washer (j), lock washer (k) and nut (l). (5)
Fig. 6-32 Hooking on the pressure plates

(m) Pressure plate (n) Mounting for corner post (o) Bolt
X Distribute eight pressure plates (m) around four supports (n) and hook on. (6)
X Screw in eight bolts (o) at each support (n) (carefully: Only insert the bolts (o) so far that they
bite). (7)
6 - 40 1250 HC 40 / 49516
6.5.4 Preparing the tower section for installation


Tower section complete see ›Technical description‹
Tab. 6-7 Erection weights
Preparing the side panels for installation
Fig. 6-33 Preparting the side panels for installation

(a) Support (e) Pin (ø 60 x 275 x 210)
(b) Corner post with connecting plates for climbing equipment (f) Diagonal member, long
(c) Corner post without connecting plates for climbing equipment (g) Diagonal member, short
(d) Spring clip (h) Pin (ø 70 x 275 x 210)
X Place one corner post (b) with connecting plates for climbing equipment and one corner post (c)
without connecting plates for climbing device onto supports (a) and secure against tipping (pre-
cise positioning and alignment of corner posts see: Fig. 6-33).
1250 HC 40 / 49516 6 - 41
Note
The pins (e) and (h) are flattened on one side of the pin head.
X When installing, ensure correct position (see: Fig. 6-33) of the flat spot.
X Connect three short diagonal members (g), two long diagonal members (f) and two corner
posts (b, c) with 6 pins (e) and 4 pins (h). Secure each pin (e) and (h) with spring clip (d).
X Preassemble the second side panel in precisely the same way as the first.
Mounting the side panels
Warning!
I
Improper mounting of the tower section can lead to accidents.

X Before mounting the tower section, secure the erecting device against tipping. Install ballast.
Fig. 6-34 Mounting the assembly aid onto the corner post
(a) Joint plate (d) Bolt (g) Shackle
(b) Pin (e) Nut (h) Assembly chain
(c) Washer (f) Corner post
6 - 42 1250 HC 40 / 49516
Mounting the assembly aid onto the corner post

X Insert two connecting plates (a) at the two corner posts (f). Secure each connecting plate (a) with
a pin (b), two washers (c), two bolts (d) and four nuts (e). (1)
Fig. 6-35 Mounting the side panels in the erecting device

(i) Shackle (l) Side panel 2 (n) Pressure plate

(j) Assembly chain (m) Erecting device (o) Bolt
(k) Side panel 1
Ensure that the following assembly equipment is on-hand:

Four assembly chains featuring a lifting capacity of 12000 kg - length: min. 10 m
Four shackles (values: high-tensile with straight studs / 6x safety / lifting capacity 12000 kg)
Ensure that the following prerequisites have been met:
1250 HC 40 / 49516 6 - 43
The erecting device is complete and has been mounted horizontally (For further information, see:
chap. Mounting the erecting device (optional )).
The pressure plates are hooked into the supports and the bolts for the pressure plates are screwed
completely outwards.
X Hook on the first side panel (k) on two corner posts using shackles (i) and assembly chain (j) (for
procedure see: Fig. 6-34), secure and lift the side panel (k). (2)
Note
Observe position and direction of connection plates for climbing equipment and the rest of the truss.
X The connection plates for the climbing device must be pointing outwards and the connection
plates for the rest of the truss must be pointing inwards (see: Fig. 6-35).
X Set down side panel 1 (k) in the supports of the erecting device (m). (3)
X Apply tension to the two corner posts and eight pressure plates (n) with 16 bolts (o). (4)
X Mount the second side panel (l) in the same way as the first. (5)
Fig. 6-36 Rechecking vertical positioning

(p) Corner post (q) Spirit level
X Recheck vertical positioning of the corner posts (p) using a spirit level (q). (6)
6 - 44 1250 HC 40 / 49516
X Check measurement A between the side panels:

Readjust as necessary by adjusting the bolts on the pressure plates.
Mounting the rest of the truss

Fig. 6-37 Mounting the rest of the truss

(a) Cross-member (d) Diagonal member, long (g) Spring clip
(b) Pin (ø 40 x 195 x 145) (e) Diagonal member, short (h) Bolzen (ø 70 x 275 x 210)
(c) Spring clip (f) Pin (ø 60 x 275 x 210)
1250 HC 40 / 49516 6 - 45
Note
The pins (b), (f), (h) are flattened on one side of the pin head.
X Ensure correct positioning (see: Fig. 6-37) of the flattened side.
X Connect one cross-member (a) (lower) and two corner posts with two pins (b). Secure each
pin (b) with spring clip (c). (1)
Note
The second, upper cross-member prevents unobstructed installation of the platforms.
X The second cross-member should only be mounted subsequently, following installation of the
platforms.
X Connect six short diagonal members (e), four long diagonal members (d) and four corner posts
with 20 pins (f). Secure each pin (f) with spring clip (g). (2)
X Connect six short diagonal members (e), four long diagonal members (d) and four corner posts
with 12 pins (f) and 8 pins (h). Secure each pin (f) and (h) with spring clip (g). (2)
Mounting the girder
Fig. 6-38 Mounting the girder

(a) Girder (d) Lock washer (g) Climbing side
(b) Bolt (e) Nut
(c) Washer (f) Girder
6 - 46 1250 HC 40 / 49516
Note
When mounting the girders (a) and (f), the connection plates for the platforms must point inwards.
X Install the girder (f) on the climbing side and secure.
X Connect two girders (a, f) and four corner posts with four bolts (d). Secure each bolt (d) with two
washers (c), lock washer (d) and nut (e).
Mounting the platforms (all-round)

Fig. 6-39 Mounting the platforms (all-round) (1)

(a) Ropes of the auxiliary crane (d) Girder (g) Washer
1250 HC 40 / 49516 6 - 47
Fig. 6-39 Mounting the platforms (all-round) (1)

(b) Platform 2 (e) Platform 1 (h) Lock washer
C 036.020-332.310 C 036.020-332.320
(c) Girder (f) Bolt (i) Nut

11 welded handrails have been preassembled and secured onto two platforms (b, e) in accordance
with Liebherr Standard LN 266.
For further information, see: chap. Fundamental notes on erection ›Installing the handrails‹.
X Secure two ropes of the auxiliary crane (a) onto platform 1 (e) and secure against slipping.
X Lift platform 1 (e) and set down onto the girder (c, d).
X Connect platform 1 (e) and girder (c, d) with four bolts (f). Secure each bolt (f) with two
washers (g), lock washer (h) and nut (i).
X Mount platform 2 (b) in exactly the same way.
6 - 48 1250 HC 40 / 49516
Fig. 6-40 Mounting the platform (all-round) (2)

(a) Ropes of the auxiliary crane (e) Platform 1 (i) Nut
C 036.020-332.320
(b) Platform 2 (f) Bolt (j) Platform 3
C 036.020-332.310 C 036.020-332.330
(c) Girder (g) Washer
(d) Girder (h) Lock washer

Two welded handrails have been preassembled and secured onto platform 3 (j) in accordance with
Liebherr Standard LN 266.
X Secure two ropes of the auxiliary crane (a) onto platform 3 (j) and secure against slipping.
X Lift platform 3 (j) and set down between platforms 1 (e) and 2 (b).
1250 HC 40 / 49516 6 - 49
X Connect platform 3 (j) and platform (e, b) with four bolts (f). Secure each bolt (f) with two
washers (g), lock washer (h) and nut (i).
Mounting the cross-member (top)
Fig. 6-41 Mounting the cross-member (top)

(a) Cross-member (top) (b) Pin (c) Spring clip
X Connect one cross-member (a) (top) and two corner posts with two pins (b). Secure each pin (b)
with a spring clip (c). (1)
6 - 50 1250 HC 40 / 49516
Mounting ladder with back guard
Fig. 6-42 Mounting ladder with back guard

(a) Ropes of the auxiliary crane (h) Bolt (o) Nut
(b) Ladder with back guard (i) Washer (p) Cross-member (top)
(c) Clamp (j) Lock washer (q) Erecting device
(d) Bolt (k) Nut (r) Cross-member (bottom)
(e) Washer (l) Bolt (s) Guide plate
(f) Lock washer (m) Washer
(g) Nut (n) Lock washer
X Hook the ladder with back guard (b) onto the ropes of the auxiliary crane (a), secure lower into the
tower section.
X Connect the ladder with back guard (b) to the cross-member (p) with two bolts (d). Secure each
bolt (d) with two washers (e), lock washer (f) and nut (g).
X Connect the clamp (c) to the cross-member (r) with two bolts (h). Secure each bolt (h) with two
washers (i), lock washer (j) and nut (k).
X Connect two guide plates (s) for ladder (b) to the clamp (c) with two bolts (l). Secure each bolt (l)
1250 HC 40 / 49516 6 - 51
with two washers (m), lock washer (n) and nut (o).
X Install four assembly aids on the corner posts of the tower section. (see chap. Fig. 6-34 “Mounting
the assembly aid onto the corner post” )
X Attach the assembly chains onto the completely preassembled tower section and secure.
X Loosen the 32 bolts on the mounting device (q). Lift the preassembled tower section and store in
preparation for subsequent use.
6 - 52 1250 HC 40 / 49516
6.5.5 Foundation anchor
Warning!
Improper installation of the foundation anchor-kit can lead to accidents.
X Maintain the projection above finished concrete A and the installation depth B of the foundation
anchor (see: Fig. 6-43).
X Mount the base tower section or tower secion vertically (maximum inclination ± 2 ‰).
Note
– The foundation must be prepared in accordance with the foundation calculation and the reinforce-
ment plan.
– The foundation reaction forces can be obtained from the foundation loading tables. For further in-
formation, see: Documentation for corner pressures, foundation loadings and ballast data.
– Prerequisites for the application of the stationary 1250 HC crane on foundation anchors must be
fulfilled. For further information, see: ›chap. 5 Preparing for crane application‹ and
›chap. 2 Components‹.
– The tower section must be positioned with the climbing side situated at 90° to the wall line of the
building to ensure that the jib is positioned parallel to the wall of the building when the crane is be-
ing climbed.
– The crane user is solely responsible for damage which occurs as a result of improper preparation
of the foundation or negligence of the soil conditions.
Tower and foundation anchor combinations
Designation Part No. Drawing No. / Length Weight [t]

Tower section cpl. 9000 7492 C 036.020-332.000 / 5.8m
Tower section cpl. 9080 0563 C 036.021-331.000 / 11.6m
Standard foundation anchor (kit) 9535 275 01 C 032.001-372.100
see ›Specifi-
Special foundation anchor (kit) 9000 9693 C 036.020-372.100
cations‹
Base tower section cpl. 9001 8232 C 036.020-337.000 / 11,6m
Base tower section reinforced cpl. 9002 1971 C 036.020-338.000 / 11,6m
Foundation anchor reinforced (kit) 9398 287 01 C 048.007-372.111
Tab. 6-8 Tower and foundation anchor combinations
1250 HC 40 / 49516 6 - 53
Fig. 6-43 Installation dimensions of the 500 HC standard foundation anchor for the 1250 HC tower
system
(a) Foundation anchors (C032.001-372.111) (c) Tower section
(b) Foundation pit (d) Borehole for drainage
Dimension in mm Designation
A 425 Projection above finished concrete of the foundation anchor kit
B 1625 Installation depth of the foundation anchor kit
Tab. 6-9 Installation dimensions of the 500 HC standard foundation anchor for the 1250 HC tower
system
6 - 54 1250 HC 40 / 49516
Fig. 6-44 Installation dimensions of the 1250 HC special foundation anchor for the 1250 HC tower
system
(a) Foundation anchor (C036.020-372.111) (c) Tower section
Tab. 6-10 Installation dimensions of the 1250 HC special foundation anchor for the 1250 HC tower
system
1250 HC 40 / 49516 6 - 55
Fig. 6-45 Installation dimensions of the 630 EC-H reinforced foundation anchor for the 1250 HC tow-
er system
(a) Foundation anchors (C 048.007-372.111) (c) Base tower section
Tab. 6-11 Installation dimensions of the 630 EC-H reinforced foundation anchor for the 1250 HC tow-
er system
6 - 56 1250 HC 40 / 49516
Installing the tower sections and the standard foundation anchors
Fig. 6-46 Mounting the assembly aid

(a) Mounting the tower (c) Pin (e) Nut
(b) Connection plate (d) Washer (f) Bolt

Four assembly chains featuring a lifting capacity of the complete weight of the tower section
with foundation anchors and a minimum length of 10 m (see table ›Tower and foundation an-
chor combinations‹).
Four shackles (values: high-tenile with straight studs / 6x safety / lifting capacity correspond-
ing to the complete weight of tower section with foundation anchors) (see table ›Tower and
foundation anchor combinations‹).
X Insert four connection plates (b) at the four corner posts. Secure each connection plate (b) with
one pin (c), two washers (d), two bolts (f) and four nuts (e). (1)
1250 HC 40 / 49516 6 - 57
Fig. 6-47 Lifting the tower section

(g) Assembly chain (h) Shackle (i) Mounting the tower
X Attach the assembly chains (g) onto the tower section (i) using four shackles (h) and secure. (2)
X Lift the tower section (i). (3)
6 - 58 1250 HC 40 / 49516
Fig. 6-48 Positioning standard foundation anchors (C032.001-372.111) and tower section
(j) Foundation anchor (kit) (o) Locknut (t) Bolt
(k) Mounting the tower (p) Sleeve (u) Assembly chain
(l) Safety channel (q) Taper (v) Climbing side of the tower
(m) Washer (r) Locking plate
(n) Nut (s) Lock washer
Warning
Danger of crushing when inserting the foundation anchor.
X Do not reach in between tower section and foundation anchor.
X Insert four foundation anchors (j) into the tower section (k). (4)
X Connect each foundation anchor (j) to the tower section (k) with two sleeves (p) and two tapers
(q). Bolt each taper (q) using safety channel (l), washer (m) and nut (n). Secure each nut (n) with
locknut (o). (5)
For further information, see the chap. ›Tower connecting material‹ and Appendix ›Information bro-
chure for prestressed high-tensile bolt connections on Liebherr tower cranes‹.

X Connect two tapers (q) and two locking plates (r) with two bolts (t). Secure two bolts (r) with two
lock washers (s). (6)
1250 HC 40 / 49516 6 - 59
Encasing the tower section in concrete in the foundation pit
Fig. 6-49 Ensuring correct insertion of the foundation anchor

(a) Spirit level (d) Assembly chain (g) Bolt
(b) Corner post of the tower (e) Assembly aid (h) Nut
section
(c) Mounting the tower (f) Climbing side (i) Foundation anchor (kit)
X Position the tower section (c) with the foundation anchor kit bolted, centrally and vertically into
the foundation pit on the supporting surface and level with four bolts (g) and four nuts (h). At the
same time, adhere to the installation depth of the foundation anchor kit (i) and observe the climb-
ing side of the tower section. (1)
Position the tower section with the climbing side situated at 90° to the wall line of the building.
X Fasten the foundation anchor kit (i) with wedges to hold it securely in position while the concrete
is being placed. Place reinforcing steel bars around the foundation anchors.
X Unhook the assembly chain (d) and dismantle the assembly aid (e).
X Ensure that the corner posts (b) are positioned vertically and that the surface of the tower section
is positioned horizontally using the spirit level (a) at each corner post. (2)
6 - 60 1250 HC 40 / 49516
Fig. 6-50 Encasing the foundation anchors in concrete

(j) Concrete (k) Foundation pit
X Pour concrete (j) into the foundation pit (k). (3)
Warning
Risk of the crane toppling if the concrete has not properly hardened.
X Before erecting the crane any further: Allow the concrete (j) to harden properly. (4)
1250 HC 40 / 49516 6 - 61
Installing the tower sections and the special foundation anchors

(a) Mounting the tower (c) Pin (e) Nut

Four shackles (values: high-tenile with straight studs / 6x safety / lifting capacity correspond-
ing to the complete weight of tower section with foundation anchors) (see table ›Tower and
foundation anchor combinations‹).
6 - 62 1250 HC 40 / 49516
Fig. 6-52 Lift the tower section

(g) Assembly chain (h) Shackle (i) Mounting the tower
X Attach the assembly chains (g) onto the tower section (i) using four shackles (h) and secure. (2)
1250 HC 40 / 49516 6 - 63
Fig. 6-53 Positioning special foundation anchors (C 036.020-372.100) and tower section
(j) Foundation anchor (kit) (p) Sleeve (v) Climbing side of the tower
(k) Mounting the tower (q) Taper (w) Protecting cap
(l) Safety channel (r) Locking plate (x) Spacer
(m) Washer (s) Lock washer (y) Cover with two bolts and two
washers
(n) Nut (t) Bolt
(o) Locknut (u) Assembly chain
Warning
Danger of crushing when inserting the foundation anchor.
X Do not reach in between tower section and foundation anchor.
X Insert four foundation anchors (j) into the tower section (k). (4)
X Connect each foundation anchor (j) to the tower section (k) with two sleeves (p) and two tapers
(q). Bolt each taper (q) using safety channel (l), washer (m) and nut (n). Secure each nut (n) with
locknut (o). (5)
For further information, see the chap. ›Tower connecting material‹ and Appendix ›Information
brochure for prestressed high-tensile bolt connections on Liebherr tower cranes‹.
X Connect two tapers (q), two spacers (x) and two locking plates (r) with two bolts (t). Secure two
bolts (r) with two lock washers (s). (6)
X Connect the cover (y) with two bolts. Secure two bolts with two lock washers. (7)
6 - 64 1250 HC 40 / 49516

(a) Spirit level (d) Assembly chain (g) Bolt
(b) Corner post of the tower (e) Assembly aid (h) Nut
section
(c) Mounting the tower (f) Climbing side (i) Foundation anchor (kit)
X Position the tower section (c) with the foundation anchor kit bolted, centrally and vertically into
the foundation pit on the supporting surface and level with four bolts (g) and four nuts (h). At the
same time, adhere to the installation depth of the foundation anchor kit (i) and observe the climb-
ing side of the tower section. (1)
Position the tower section with the climbing side situated at 90° to the wall line of the building.
X Fasten the foundation anchor kit (i) with wedges to hold it securely in position while the concrete
is being placed. Place reinforcing steel bars around the foundation anchors.
X Unhook the assembly chain (d) and dismantle the assembly aid (e).
1250 HC 40 / 49516 6 - 65

(j) Concrete (k) Foundation pit
X Pour concrete (j) into the foundation pit (k). (3)
Warning
X Before erecting the crane any further: Allow the concrete (j) to harden properly. (4)
6 - 66 1250 HC 40 / 49516
Installing the base tower section and 630 EC-H foundation anchors
Fig. 6-56 Attaching and lifting the base tower section (Drawing No. C036.020-338.000)
(a) Assembly chain (b) Base tower section

X Attach the four assembly chains (a) onto the base tower section (b), secure and lift. (1)
1250 HC 40 / 49516 6 - 67
Fig. 6-57 Positioning 630 EC-H foundation anchors (C048.007-372.111) and base tower section
(c) Foundation anchor (kit) (f) Spacer (i) Protecting cap
(d) Base tower section (not (g) Washer (j) Assembly chain
climbable)
(e) Bolt (h) Nut
Warning
Danger of tipping and crushing when positioning the base tower section onto the foundation an-
chors.
X Position the foundation anchors in accordance with the dimensions and secure against tipping.
X Do not reach in between base tower section and foundation anchors.
6 - 68 1250 HC 40 / 49516
X Position four foundation anchors (c) in accordance with the dimensions and secure against
tipping. (2)
X Position the base tower section (d) on the foundation anchors (c) and leave it suspended to the
assembly chains (j). (3)
X Connect each foundation anchor (c) to the base tower section (d) with eight bolts (e) and eight
spacers (f). Secure each bolt (e) with two washers (g) and nut (h). Cover each nut (h) with pro-
tecting cap (i). (4) see chap. Fig. 6-57 “Positioning 630 EC-H foundation anchors (C048.007-
372.111) and base tower section”
For further information see chap. ›Tower connecting material‹ and Appendix ›Information bro-
chure for prestressed high-tensile bolt connections on Liebherr tower cranes‹.


(a) Spirit level (c) Base tower section (not (e) Climbing side of the tower
climbable)
1250 HC 40 / 49516 6 - 69

(b) Corner post of the tower (d) Assembly chain (f) Foundation anchor kit
section
X Position the base tower section (c) with the foundation anchor kit bolted (f) centrally and verti-
cally into the foundation pit on the supporting surfaces and level. At the same time, adhere to the
installation depth of the foundation anchor kit (i) and observe the climbing side of the tower. (1)
X Fit the access ladder of the base tower section (c) to the access ladder of the tower. (2)
The tower must be positioned with the climbing side situated at 90° to the wall line of the building.
X Fasten the foundation anchor kit (f) with wedges to hold it securely in position while the concrete
is being placed. Place reinforcing steel bars around the foundation anchors. (3)
X Unhook the assembly chain (d). (4)

(g) Concrete (h) Foundation pit
X Pour concrete (g) into the foundation pit (g). (6)
6 - 70 1250 HC 40 / 49516
Warning
X Before erecting the crane any further: Allow the concrete (g) to harden properly. (7)
1250 HC 40 / 49516 6 - 71
Mounting the tower sections without climbing equipment
6.6 Mounting the tower sections without climbing equip-

ment
6.6.1 Installing the erection platforms (optional 1))

Part No.: 2x 9001 3061 / Drawing No.: C 036.020-966.000
Installing the erection platforms on the tower
Note
Two erection platforms are necessary for erecting the crane without climbing equipment.
X Observe the different assembly positions during installation.

Two variable handrails and seven welded handrails have been preassembled and secured to the
two erection platforms in accordance with Liebherr Standard LN 266.
The extendable platform is inserted for installing the tower and moved outwards for installing the roll-
er slewing ring support and secured accordingly.
The lateral handrails of the extendable platform are positioned and secured in accordance with the
respective erection to be carried out.
X Using shackles, hook the ropes of the auxiliary crane onto the four rope eyelets on the erection
platform and secure.
X Lift the erection platform and attach it to the tower section.
X Connect the tower section and the erection platform with two locking plates and four bolts. Secure
each bolt with washer, lock washer and two nuts. (1)
X Remove the ropes of the auxiliary crane.
X Install the second erection platform on the opposite side of the tower section. (2)
Procedure continues as with the first erection platform.
1)
Erection platforms are not part of the standard version and must be ordered separately.
6 - 72 1250 HC 40 / 49516
6.6.2 Installing the base tower section

Warning!
Improper installation of the tower sections can lead to accidents.
Mounting the tower sections vertically.
X Select the tower sections in accordance with configuration of the crane and details of the corner
pressure tables. For further information, see: chap. Specifications and documentation for corner
pressures, foundation loadings and ballast data.
X The respective tower fasteners must be used for installing the tower sections. For further infor-
mation, see the chap. Tower fasteners.
For further information, see: Information brochure ›Prestressed high-tensile bolt connections on
Liebherr tower cranes and chapter ›Installing the pin connection‹.

Assembly chains are hooked on and secured professionally in accordance with configuration of the
tower section.
The climbing side is positioned offset at 90° to the building wall. The jib is positioned parallel to the
building wall during climbing down of the crane.
The access points are adapted to ensure unobstructed access.
Four assembly chains featuring a lifting capacity of 12000 kg - length: min. 10 m each assembly
chain.
Mounting the assembly aid


(a) Tower section (c) Pin (e) Nut
1250 HC 40 / 49516 6 - 73

Fig. 6-61 Lifting the tower section (example)

(g) Assembly chain (h) Shackle (i) Tower section
X Attach the four assembly chains (g) onto the tower section (i) using four shackles (h) and
secure. (2)
X Lift the tower section (i). (3) LBC/en/01/Issued: 07.11
6 - 74 1250 HC 40 / 49516
Installing the base tower section
Fig. 6-62 Installing the base tower section

(a) Base tower section C 036.020- (d) Washer (g) Protecting cap
337.000
(b) Base tower section C 036.020- (e) Spacer
338.000
(c) Bolt (f) Nut
Warning
Danger of crushing when positioning the tower section.
X Do not reach in between tower section and tower section.
X Lift the base tower section (a) and position it onto the base tower section (b). (1)
X Connect all corner posts with eight bolts (c) and eight spacers (e) on each. Secure each bolt (c)
with sixteen washers (d) and sixteen nuts (f) and cover with sixteen protecting caps (g). (2)
For further information see chap.: ›Tower connecting material‹ and ›Information brochure ›Pre-
stressed high-tensile bolt connections on Liebherr tower cranes‹.
1250 HC 40 / 49516 6 - 75
Fig. 6-63 Checking vertical positioning of the tower section

(h) Spirit level (i) Corner post of the tower (j) Assembly aid
section
X Ensure that the corner posts (r) are positioned vertically and that the surface of the tower section
is positioned horizontally using the spirit level (q) at each corner post. (7)
X Unhook the assembly chain and remove the assembly aid (m). (8)
6.6.3 Installing the tower section

Part No.: 9000 7492 / Drawing No.: C 036.020-332.000 or
Warning!
Improper installation of the tower sections can lead to accidents.
Mounting the tower sections vertically.
X Select the tower sections in accordance with configuration of the crane and details of the corner
pressure tables. For further information, see: chap. Specifications and documentation for corner
pressures, foundation loadings and ballast data.
X The respective tower fasteners must be used for installing the tower sections. For further infor-
mation see: Chap. ›Tower connecting material‹ and chap.: ›‹Installing the pin connections on
tower sections‹.

Assembly chains are hooked on and secured professionally in accordance with configuration of the
tower section.
The climbing side is positioned offset at 90° to the building wall. The jib is positioned parallel to the
building wall during climbing down of the crane.
The access points are adapted to ensure unobstructed access.
Four assembly chains featuring a lifting capacity of 12000 kg - length: min. 10 m each assembly
chain.
6 - 76 1250 HC 40 / 49516
Fig. 6-64 Installing the assembly aid

(a) Tower section (c) Pin (e) Nut
1250 HC 40 / 49516 6 - 77
Fig. 6-65 Lifting the tower section (example)

(g) Assembly chain (h) Shackle (i) Tower section
X Attach the four assembly chains (g) onto the tower section (i) using four shackles (h) and
secure. (2)
Warning
Danger of crushing when positioning the tower section.
X Do not reach in between tower section and tower section.
X Position the tower section onto the tower section. At the same time, observe the climbing side of
the tower section. (4)
6 - 78 1250 HC 40 / 49516
Pinning and securing the tower sections
Fig. 6-66 Pinning and securing the tower sections

(a) Tower section 1250HC (e) Taper (h) Nut
C036.020-332.000
(b) Tower section 1250HC (f) Safety channel (i) Nut
C036.020-331.000
(c) Tower section 1250HC (g) Washer (j) Protecting cap
C036.020-337.000
(d) Sleeve
X Connect all corner posts with two sleeves (d) and two tapers (e) on each. Secure each taper (e)
with safety channel (f), washer (g) and nut (h). Secure each nut (h) with nut (i) and cover with
protecting cap (j). (5)
Weitere Informationen siehe Kap. ›Turmverbindungsmaterial‹ und siehe Kap.: ›‹Installing the pin
connections on tower sections‹.
1250 HC 40 / 49516 6 - 79
Fig. 6-67 Checking vertical positioning of the tower section

(k) Spirit level (l) Corner post of the tower (m) Assembly aid
section
X Ensure that the corner posts (r) are positioned vertically and that the surface of the tower section
is positioned horizontally using the spirit level (q) at each corner post. (7)
X Unhook the assembly chain and remove the assembly aid (m). (8)
6 - 80 1250 HC 40 / 49516
6.6.4 Installing the pin connections on tower sections
Fig. 6-68 Installing the pin connections on tower sections (Example)

(a) Sleeve (e) Nut (i) Bolt
(b) Taper (f) Lock nut (j) Foundation anchor 500 HC
(c) Safety channel (g) Locking platel (k) Tower section 1250 HC
(d) Washer (h) Washer
Note
X Clean the pin holes, sleeves and tapers before installing.
X Grease the sleeves and tapers.
Drawing-No. Projection = „ü“ [mm] Tightening torque [Nm]

C 036.020-332.000 20 800
C 036.020-337.000 20 800
Tab. 6-12 Projection „ü“ and tightening torque
X Insert the sleeves (a) (ensure correct projection „ü“ (see: Tab. 6-12) and maintain the arrange-
ment of the slots).
X Insert the tapers (b) into the sleeves (a) and place the safety channel (c) onto the tapers.
1250 HC 40 / 49516 6 - 81
Fig. 6-69 Projection „ü“ and position of safety channel (Example)

(l) Sleeve (o) Bolt (r) Nut
(m) Taper (p) Nut (s) Washer
(n) Safety channell (q) Lock nut (t) Locking plate
X Note: The safety channel (n) must rest against the tower section over its whole surface (see: Fig.
6-69).
X Secure two tapers (m) with two washers (s) and two nuts (r).
X Tighten the nuts (r) and thus pull the tapers (m) into the sleeves (l) (observe the tightening torque
(see: Fig. 6-68).
X Check projection „ü“ (see: Fig. 6-68) again.
X Secure the connections with lock nuts (q).
X Secure two tapers (m) with locking plate (t), two nuts (p) and two bolts (o).
6.6.5 Dismantling the erection platform

X Hook the ropes of the auxiliary crane onto the four rope eyelets on the erection platform and se-
cure.
X Loosen the bolts and nuts at the erection platform/tower section connection and set down the
erection platform.
X Remove the second erection platform using this procedure.
6 - 82 1250 HC 40 / 49516
6.6.6 Installing additional tower sections

For further information, see: chap. 6.6.3 Installing the tower section.
X After installing additional tower sections, bolt the ladder
(with drawing no. C 036.020-332.221 and part no. 9000 8017) to the lower ladder with four bolts.
Secure each bolt with two washers, lock washer and nut.
X Install the tower sections until the tower height for the respective hook height of the crane has
been reached. For further information, see: Documentation for corner pressures, foundation load-
ings and ballast data.
1250 HC 40 / 49516 6 - 83
6.6.7 Hooking the power supply cable onto the tower
Warning!
Improper installation of the power supply cable can lead to accidents.
X Hook the power supply cable professionally onto the tower, on the climbing side only and on the
outside of the tower only, at distances of approx. 15 m and secure.
X Hook the power supply cable onto the tower. Ensure that the cable is not taut and that it does
not become squashed at any point on the tower.
Caution!
Damage to the power supply cable .
X To prevent damage occurring at the supply lines: For tower heights in excess of 65 m,
retighten and then relieve tension in the supply lines from the bottom up.
Fig. 6-70 Installing the power supply cable onto the tower (example)
(a) Climbing side (f) Bolt (k) Bolt
(b) Tower section (g) Washer (l) Washer
6 - 84 1250 HC 40 / 49516
Fig. 6-70 Installing the power supply cable onto the tower (example)
(c) Power supply cable (h) Lock washer (m) Lock washer
(d) Cable support clamp (i) Nut (n) Nut
(e) Retaining bracket (j) Cable support clamp (o) Roller slewing ring support
Ensure that the following prerequisite has been met:

The retaining bracket (e) and the cable support clamp (d) are bolted together with two bolts (f). Each
bolt (f) is secured with washer (g), lock washer (h) and nut (i). (1)
X Hook the retaining bracket (o) onto the tower cross-member (b) on the climbing side (a) of the
tower, however, not in the middle. (2)
X Feed the power supply cable (d) into the cable support clamp ensuring that it is not taut. Secure
the cable support clamps (d) and (j) with four bolts (k). Secure each bolt (k) with washer (l), lock
washer (m) and nut (n). (3)
X Hook the power supply cable (c) onto the tower at 15 m intervals, as well as onto the tower section
beneath the roller slewing ring support (o) and secure.
- or -
X Insert the power supply cable into the roller slewing ring support (o) and bolt with cable support
clamps.
1250 HC 40 / 49516 6 - 85
Mounting the slewing platform and tower head
6.7 Mounting the slewing platform and tower head

Roller slewing ring support - lower part
Complete slewing platform (with slewing
gears, roller slewing ring support - upper part
and slewing connection) see: ›Criteria for the auxiliary crane‹
Platforms on slewing platform
Cabin with platform
Tower head
complete see: ›Criteria for the auxiliary crane‹
Tab. 6-13 Erection weights
Warning
Improper erection of the slewing platform and tower head can lead to accidents.
Weights of the slewing platform, or slewing platform and tower head, may not exceed the lifting ca-
pacities of the auxiliary crane. For further information, see: Chap. Specifications, ›Criteria for the
auxiliary crane‹.
X The respective tower and slewing ring connecting material must be used for installing the slewing
platform. For further information, see: Chap. Erection ›Tower and ball slewing ring connecting
material‹.
Note
Electrical connection for the climbing equipment on the roller slewing ring support must be estab-
lished on the climbing side of the crane following installation of the slewing platform with tower head.
The tower head must be installed so that the access ladder is situated on the climbing side of the
crane or on the counter-jib side.
Ensure that the following lifting tackle is on-hand:

4 lifting tackles (assembly chains) featuring sufficient lifting capacity and compliant with the re-
spective shackles.
Four shackles (e.g.: 4x Crosby G-2160 (125t lifting capacity) „Wide Body Shackle“ made of al-
loyed forged steel, safety factor 5:1)
6.7.1 Installing the slewing assembly with roller slewing ring support1)
Installing slewing platform, slewing ring and roller slewing ring sup-
1)
Roller slewing ring support
6 - 86 1250 HC 40 / 49516
port
Fig. 6-71 Installing slewing platform, slewing ring and roller slewing ring support
(a) Roller slewing ring sup- (i) Ladder (q) Cable guide
port, lower part
(b) Roller slewing ring sup- (j) Access platform for jib (r) Pin (x 4)
port, upper part
(c) Roller slewing ring (k) Clamp for platform (s) Assembly aid
(d) Slewing platform (l) Assembly aid (t) Axle support (x 8)
(e) Slewing gear (x 2) (m) Platform support (u) Bolt (x 16)
(f) Slewing gear (x 1) (n) Cover (v) Lock washer (x 16)
(g) Handrail (x 2) (o) Handrails and ladder (w) Bolt (x 16)
(h) Handrail (p) Counter-jib side (x) Nut (x 16)
X Bolt four assembly aids (l) to the roller slewing ring support lower part (a) with eight bolts (u). Se-
1250 HC 40 / 49516 6 - 87
cure each bolt (u) with two lock washers (v).

X Pin the roller slewing ring support lower part (a) to the roller slewing ring support upper part (b)
with four pins (r). Secure each pin (r) with two axle supports (t), four bolts (u) and four lock
washers (v).
X Lock the roller slewing ring support upper part (b) into position on each corner from both sides
with four bolts (w) and four nuts (x).
X Properly bolt the slewing platform (d) to the roller slewing ring (c) and secure. For further informa-
tion, see: ›Slewing ring connecting material‹.
X Properly bolt the roller slewing ring (c) to the roller slewing ring support upper part (b) and secure.
For further information, see: ›Slewing ring connecting material‹ and ›Prestressed high-tensile bolt
connections‹.
X Bolt the handrails (g, h) to the slewing platform (d) and secure.
X Bolt the platform support (m) to the slewing platform (d) and secure.
X Bolt the cover (n) to the slewing platform (d) and secure.
X Bolt the access platform for jib (j) to the slewing platform (d) and secure.
X Bolt the clamp for platform (k) and the cable guide (q) to the slewing platform (d) and secure.
X Bolt handrails and ladder (o) to the roller slewing ring support lower part (a) and secure. For fur-
ther information, see: ›Installing the handrails‹.
For further information, see: ›Spare parts list‹.
6 - 88 1250 HC 40 / 49516
Installing the erection platforms
Fig. 6-72 Installing the erection platforms

(a) Roller slewing ring support, (c) Erection platforms (e) Jib side
lower part
(b) Erection platforms (d) Slewing platform
X Bolt two erection platforms (b) to the roller slewing ring support (a) and secure.
X Pin the pre-assembled platforms (c) to the slewing platform (d) and secure.
1250 HC 40 / 49516 6 - 89
6.7.2 Installing the pre-assembled cabin on the slewing platform
Fig. 6-73 Installing the pre-assembled cabin on the slewing platform

(a) Roller slewing ring support (c) Cabin pre-assembled (e) Jib side
(b) Slewing platform (d) Counter-jib side
X Pin the pre-assembled cabin complete with platforms and ladder (c) to the slewing platform (b)
and secure.
For further information, see: ›Spare parts list‹. LBC/en/01/Issued: 07.11
6 - 90 1250 HC 40 / 49516
6.7.3 Installing the slewing assembly with roller slewing ring support
Warning
Danger of crushing when positioning onto the tower section.
X Do not reach in between tower section (h) and slewing platform (b).
Fig. 6-74 Installing the slewing assembly with roller slewing ring support
(a) Roller slewing ring support (d) Platform (g) Auxiliary crane assembly
chains
(b) Slewing platform (e) Ladder with back guard (h) Tower section
(c) Cabin pre-assembled (f) Counter-jib side
X Using shackles, attach the auxiliary crane assembly chains (g) onto the slewing platform (b) and
secure.
X Position slewing assembly (b) with roller slewing ring support (b) onto the tower section (h), bolt
to the tower section and secure. For further information, see: ›Tower and slewing ring connecting
material‹, ›Installing the pin connection‹ and ›Spare parts list‹.
1250 HC 40 / 49516 6 - 91
6.7.4 Preparing the tower head for installation
Warning
Risk of tower head toppling.
X The tower head may only be erected and mounted on firm and level underground.
Warning!
W
Risk of falling when climbing onto the tower head.

X Always put on a safety harness and hook it onto a secure point before walking out onto the tower
head.
Erecting the tower head
Fig. 6-75 Erecting the tower head

(a) Rope of the auxiliary crane (c) Connection plate (d) Connection plate
6 - 92 1250 HC 40 / 49516
Fig. 6-75 Erecting the tower head

(b) Tower head
X Secure four ropes of the auxiliary crane (a) to the four connection plates (c), lift the tower head,
transport to the erection site and set down. (1)
X Remove the four ropes of the auxiliary crane (a).
Warning
Risk of tower head toppling.
The tower head will drop immediately into the vertical position upon exceeding the vertical centre of
gravity.
X Support the auxiliary crane sufficiently to ensure that the torque is fully utilised.
X Raise the tower head slowly.
X Secure the two ropes of the auxiliary crane (a) to the two connection plates (d) and erect the tower
head. (2)
1250 HC 40 / 49516 6 - 93
Installing handrails and platforms
Fig. 6-76 Installing platforms and handrails on the tower head

(a) Handrail (e) Platforms (i) Rail tube
(b) Bolt (f) Strut (j) Hatch
(c) Washer (g) Pin (k) Erection ropes
(d) Tower head (h) Linch pin (l) Lock washer
X Bolt four handrails (a) to the bottom of the slewing platform (d) with 16 bolts (b) and 16
washers (c) and secure. (1)
X Bolt two struts (f) to two platforms (e), secure and install 10 variable handrails and four rail tubes
in accordance with Liebherr-standard LN 266 and secure. (2) For further information, see:
Chap. Fundamental notes on erection ›Installing the handrails‹ and ›Spare parts list‹.
X Close the hatch (j). Attach the ropes of the auxiliary crane (k) onto the platforms (e), secure and
lift the platforms. (3)
X Connect two platforms (e) to the tower head (d) with four pins (g). Secure each pin (g) with two
linch pins (h). (4)
6 - 94 1250 HC 40 / 49516
X Bolt two struts (f) of the platforms (e) to the tower head (d) and secure. (5)
X Insert the rail tube (i), connect to the platforms (e) and secure. (6)
Installing the access ladder
Fig. 6-77 Installing the access ladder

(a) Ropes of the auxiliary (f) Installing the access ladder (For further information, see: chap.
crane Fig. 6-78 Assembly details: Installing the access ladder onto the
platform)
(b) Access ladder (g) Installing the access ladder (For further information, see: chap.
Fig. 6-79 Assembly details: Installing the access ladder onto the
tower head (top))

(c) Tower head (h) Installing the access ladder (For further information, see: chap.
tower head (middle))
(d) Platform (i) Installing the access ladder (For further information, see: chap.
tower head (middle))
1250 HC 40 / 49516 6 - 95
Fig. 6-77 Installing the access ladder

(e) Folding platform (j) Installing the access ladder (For further information, see: chap.
Fig. 6-82 Assembly details: Installing access ladder and folding
platform onto the tower head (bottom)
X Secure the ropes of the auxiliary crane (a) onto the access ladder (b) and install the access
ladder (b) onto the tower head (c) (assembly details see: Fig. 6-78 – see: Fig. 6-82).
Assembly details
Fig. 6-78 Assembly details: Installing the access ladder onto the platform
(a) Bolt (c) Lock washer (d) Nut
(b) Washer
X Connect the access ladder (f) to the platform (e) with two bolts (a). Secure each bolt (a) with two
washers (b), locking washer (c) and nut (d).
Fig. 6-79 Assembly details: Installing the access ladder onto the tower head (top)
(e) Bolt (g) Lock washer (h) Nut
(f) Washer
6 - 96 1250 HC 40 / 49516
X Connect the access ladder to the tower head with bolt (e). Secure the bolt (e) with two washers (f),
locking washer (g) and nut (h).
Fig. 6-80 Assembly details: Installing the access ladder onto the tower head (middle)
(i) Bolt (k) Lock washer (l) Nut
(j) Washer
X Connect the access ladder to the tower head with bolt (i). Secure the bolt (i) with two washers (j),
lock washer (k) and nut (l).
Fig. 6-81 Assembly details: Installing the access ladder onto the tower head (middle)
(m) Bolt (o) Lock washer (p) Nut
(n) Washer
X Connect the access ladder to the tower head with bolt (m). Secure the bolt (m) with two
washers (n), lock washer (o) and nut (p).
1250 HC 40 / 49516 6 - 97
Fig. 6-82 Assembly details: Installing access ladder and folding platform onto the tower head (bot-
tom)
(q) Bolt (s) Lock washer (u) Bolt
(r) Washer (t) Nut (v) Nut
X Connect the access ladder to the tower head with two bolts (q). Secure the bolt (q) with two
washers (r), lock washer (s) and nut (t).
X Hook the folding platform into the access ladder with two bolts (u). Secure each bolt (u) with
nut (v).
6 - 98 1250 HC 40 / 49516
Installing the rope winches
Fig. 6-83 Installing the rope winches

(a) Rope winches (c) Washer (d) Nut
(b) Bolt
X Install the two rope winches (a) each with four bolts (b). Secure each bolt (b) with two washers (c)
and a nut (d).
1250 HC 40 / 49516 6 - 99
6.7.5 Installing the tower head
Fig. 6-84 Installing the tower head

(a) Shackle (e) Pin (i) Assembly aid
(b) Tower head (f) Axle support (j) Bolt
(c) 4 lifting tackles (assembly (g) Bolt (k) Nut

chains)
(d) Slewing platform (h) Lock washer
X Four shackles (a) (e.g.: 4x Crosby G-2160 (125t lifting capacity) „Wide Body Shackle“ made
of alloyed forged steel, safety factor 5:1) onto the tower head (b).
X Attach 4 lifting tackles (c) (assembly chains) featuring sufficient lifting capacity which is com-
pliant with the respective shackles (a) and the weight of the tower head to the tower head (b)
6 - 100 1250 HC 40 / 49516

and lift the tower head.

X Bolt four assembly aids (i) to the slewing platform (d) with eight bolts (g). Secure each bolt (g) with
lock washer (h).
X Lower the tower head (b) onto the slewing platform (d) and secure with four pins (e).
X Secure four pins (e) and the four assembly aids as well with eight axle supports (f). Secure each
axle support (f) with four bolts (g) and four lock washers (h).
X Lock the tower head (b) into position on each corner from both sides with two bolts (j) and two
nuts (k).
1250 HC 40 / 49516 6 - 101

Installing the tie bars on the tower head
Fig. 6-85 Installing the counter-jib tie bars on the tower head
(a) Tie bars (d) Cotter pin (g) Platforms
(b) Tower head (e) Erection ropes of the aux- (h) Slewing platform
liary crane
(c) Pin (f) Platform with handrail (i) Guide ropes
X Bolt the pre-assembled platform with handrail (f) to the slewing platform (h) and secure. (1)
X Bolt the platforms (g) to the slewing platform (h) and secure. (2)
X In order to prevent the steel constructioin from being damaged, secure the guide rope (i) to the tie
bars (a). (3)
X Attach the erection ropes (e) to the pre-assembled counter-jib tie bars (a), secure and lift the tie
bars. (4)
6 - 102 1250 HC 40 / 49516

X Connect the tie bars (a) to the tower head (b) with pins (c). Secure each pin (c) with two cotter
pins (d). (5)
For further information, see: ›Counter-jib tie bars‹ and ›Spare parts list‹.
Caution!
Moisture or condensation in the switching systems can cause damage to the assemblies in the elec-
trical equipment.
X Prevent all moisture or condensation from penetrating the switching systems (switchgear cabi-
nets).
X Before initial activation of the supply voltage, following lengthy operational downtimes or
periods of storage: examine the switchgear cabinets for the presence of moisture or conden-
sation.
X Should moisture be detected in the switching systems (switchgear cabinets), this must be erad-
icated prior to start-up of the crane (e.g. by way of preheating).
X Connect the power supply cable to switchgear cabinet S1.

ª The slewing platform can now be slewed under power.
1250 HC 40 / 49516 6 - 103

Mounting the counter-jib
6.8 Mounting the counter-jib
6.8.1 Counter-jib guying
Warning!
Improper combination of tie bars for the counter-jib guying can lead to accidents.
The tie bars for the counter-jib guying being installed for this crane type must be arranged, pinned
and secured in compliance with the drawing number and identification number prescribed.
Note
For this tower crane
- a three-part counter-jib has been provided for the 82.1 m, 76.3 m, 64.7 m jibs.
- a two-part counter-jib has been provided for the 53.1 m, 41.5 m jibs.
– The drawing number and identification number of the tie bars are stamped onto the respective
parts.
– All dimensions of the following drawings are represented in mm.
Counter-jib guying
Drawing No. C 036.020-814.100, Part No. 9000 9966
Pos. Designation Length Quantity Drawing no. ID no.

(a) Tie bar 2000 2 C 036.020-814.110 9000 9964
(b) Tie bar 3250 2 C 036.020-814.120 9000 9968
Tab. 6-14 Arrangement of counter-jib guying (two-part counter-jib)
6 - 104 1250 HC 40 / 49516

Counter-jib guying

(c) Tie bar 3250 2 C 036.020-814.130 9000 9972
(d) Tie bar 4380 2 C 036.020-814.140 9000 9973
(e) Tie bar 4380 2 C 036.020-814.150 9000 9977
(f) Connection plate 1 C 036.020-814.170 9000 9984
(g) Tie bar 1400 2 C 036.020-814.160 9000 9978
Tab. 6-14 Arrangement of counter-jib guying (two-part counter-jib)
Counter-jib guying
Pos. Designation Length Quanity Drawing no. ID no.

(a) Tie bar 2000 2 C 036.020-814.110 9000 9964
(b) Tie bar 3250 2 C 036.020-814.120 9000 9968

(c) Tie bar 3250 2 C 036.020-814.130 9000 9972
(d) Tie bar 4380 2 C 036.020-814.140 9000 9973
(e) Tie bar 4380 2 C 036.020-814.150 9000 9977
(f) Connection plate 1 C 036.020-814.170 9000 9984
(g)
Tab. 6-15 Arrangement of counter-jib guying (three-part counter-jib)
1250 HC 40 / 49516 6 - 105

Counter-jib guying
Pos. Designation Length Quanity Drawing no. ID no.

(h) Tie bar 2847 2 C 036.020-814.210 9001 0389
(i) Tie bar 2847 2 C 036.020-814.220 9001 0393
(j) Tie bar 1385 2 C 036.020-814.240 9001 2409
Tab. 6-15 Arrangement of counter-jib guying (three-part counter-jib)
6 - 106 1250 HC 40 / 49516

Tie bar connections (two-part counter-jib)
Tie bar connections (counter-jib guying pre-assembled)

Counter-jib guying
Drawing no. C 036.020-814.100, ID no. 9000 9966
Quan- Additional designa-

Pos. Designation ID no.
tity tion
(a) Tie bar 2000 4 C 036.020-814.111 9000 9965
Fig. 6-86 Tie bar connections (illustration shows the counter-jib guying in erection position)
1250 HC 40 / 49516 6 - 107

Counter-jib guying
Drawing no. C 036.020-814.100, ID no. 9000 9966
Quan- Additional designa-

Pos. Designation ID no.
tity tion
(b) Tie bar 3250 8 C 036.020-814.121 9000 9969
(c) Pin 80x328x243 form 500 14 according to LN 19 9001 0000
(d) Sleeve 108x12,5x40 14 9001 0001
(e) Bolt M 12x140 8.8 A3C 14 ISO 4014 4600 303
(f) Washer 12 A3C 28 ISO 7089 4200 016 01
(g) Nut M 12 10 galvanised 28 ISO 4032 4115 048 01
(h) Tie bar 4380 8 C 036.020-814.141 9000 9974
(i) Tie bar 1400 4 C 036.020-814.161 9000 9979
(j) Spacer 108x12,5x15 10 9000 9995
(k) Counter-jib end section C 036.020-711.200 9000 9710
(l) Tower head C 036.020-541.000 9000 9345
(m) Pin 80x270x235 form 200 2 LN 16 9974 123 01
(n) Cotter pin 13x112 4 ISO 1234 4330 110 01
(o) Spacer 38x5,6x150 14 9000 9971
(p) Bolt M24x280 10.9 A3C 14 according to LN 30-17 4062 074 01
(q) Bolt M 24 x140 10.9 A3C 8 ISO 4014 4600 124
(r) Spacer 38x5,6x25 4 9000 9981
(s) Nut M 24 B 05 galvanised 8 ISO 4035 1000 2633
(t) Connection plate 2 C 036.020-814.171 9000 9996
(u) Square tube 1 C 036.020-814.172 9000 9997
(v) Bolt M24x210 10.9 A3C 18 according to LN 30-17 4062 871 01
(w) Washer 24 A3C 80 ISO 7089 4200 024 01
(x) Nut M 24 10 galvanised 72 according to LN 30-17 4115 054 01
(y) Spacer 38x5,6x74 18 9688 224 01
Tie bar 2000 to tower head connec-
For further information, see: Fig. 6-87 and detail Z1
tion
Tie bar 1400 to counter-jib end sec-
(z) For further information, see: Fig. 6-87 and detail Z2
tion connection
Tie bar 3250 to tie bar 4380 connec-
tion
X Connect two pairs of tie bars 2000 (a) to four spacers (y) with four bolts (v). Secure each bolt (v)
with two washers (w) and two nuts (x) see: Fig. 6-86 and detail X.
X Connect two pairs of tie bars 3250 (b) to six spacers (o) with six bolts (p). Secure each bolt (p)
with two washers (w) and two nuts (x) see: Fig. 6-86 and detail Y.
X Connect two pairs of tie bars 3250 (b) to six spacers (y) with six bolts (v). Secure each bolt (v)
X Connect two pairs of tie bars 4380 (h) to eight spacers (o) with eight bolts (p). Secure each
bolt (p) with two washers (w) and two nuts (x) see: Fig. 6-86 and detail Y.
X Connect two pairs of tie bars 4380 (h) to eight spacers (y) with eight bolts (v). Secure each bolt (v)
6 - 108 1250 HC 40 / 49516

X Connect two pairs of tie bars 1400 (i) to four spacers (r) with four bolts (q). Secure each bolt (q)
with two washers (w) and nuts (x) and (s) see: Fig. 6-86 and detail S.
X Connect two connection plates (t) to square tube (u) with four bolts (q). Secure each bolt (q) with
two washers (w) and nuts (x) and (s) see: Fig. 6-86 and detail K.
Note
X When installing the counter-jib tie bars, make sure that the pins are installed with the tapered
ends facing outwards see: Fig. 6-86
X Connect tie bars 2000 (a) to the tower head (l) and secure. For further information, see: Fig. 6-87
and detail Z1.
X Connect tie bars 2000 (a) to tie bars 3250 (b) fitted with spacers (o), connect tie bars 3250 (b) fit-
ted with spacers (o) to tie bars 3250 (b) fitted with spacers (y), connect tie bars 4380 (h) fitted with
spacers (o) to tie bars 4380 (h) fitted with spacers (y), connect tie bars 4380 (h) fitted with
spacers (y) to connection plate (t) with eight pins (c). Secure each pin (c) with sleeve (d), bolt (e),
two washers (f) and two nuts (g) see: Fig. 6-86.
X Connect tie bars 1400 (i) to connection plate (t) with two pins (c). Secure each pin (c) with
sleeve (d), two spacers (j), bolt (e), two washers (f) and two nuts (g) see: Fig. 6-86.
X Pin tie bars 1400 (i) to the counter-jib end section (k) and secure. For further information, see: Fig.
6-87 and detail Z2.
X Pin tie bars 3250 (b) fitted with spacers (y) to tie bars 4380 (h) fitted with spacers (o) and secure.
For further information, see: Fig. 6-87 and detail Z3.
1250 HC 40 / 49516 6 - 109

Tie bar connections (counter-jib guying completely assembled)
Counter-jib guying
Drawing no. C 036.020-814.100, ID no. 9000 9966
Additional designa-
Pos. Designation Quantity ID no.
tion
(a) Tie bar 2000 see: Fig. 6-86 C 036.020-814.111 9000 9965
(b) Tie bar 3250 see: Fig. 6-86 C 036.020-814.121 9000 9969
(c) Pin 80x328x243 form 500 see: Fig. 6-86 according to LN 19 9001 0000
(d) Sleeve 108x12,5x40 see: Fig. 6-86 9001 0001
(e) Bolt M 12x140 8.8 A3C see: Fig. 6-86 ISO 4014 4600 303
(f) Washer 12 A3C see: Fig. 6-86 ISO 7089 4200 016 01
Fig. 6-87 Tie bar connections (illustration shows the counter-jib guying completely assembled)
6 - 110 1250 HC 40 / 49516

Counter-jib guying
Drawing no. C 036.020-814.100, ID no. 9000 9966
Additional designa-
tion
(g) Nut M 12 10 galvanised see: Fig. 6-86 ISO 4032 4115 048 01
(h) Tie bar 4380 see: Fig. 6-86 C 036.020-814.141 9000 9974
(i) Tie bar 1400 see: Fig. 6-86 C 036.020-814.161 9000 9979
(j) Spacer 108x12,5x15 see: Fig. 6-86 9000 9995
(k) Counter-jib end section see: Fig. 6-86 C 036.020-711.200 9000 9710
(l) Tower head see: Fig. 6-86 C 036.020-541.000 9000 9345
(m) Pin 80x270x235 form 200 see: Fig. 6-86 LN 16 9974 123 01
(n) Cotter pin 13x112 see: Fig. 6-86 ISO 1234 4330 110 01
Note
Tie bar connections of the counter-jib guying with installed counter-jib, see: Fig. 6-87 and de-
tails Z1, Z2 und Z3.
X Connect tie bars 2000 (a) to the tower head (l) with two pins (m). Secure each pin (m) with two
cotter pins (n) see: Fig. 6-87 and detail Z1.
X Connect tie bars 1400 (i) to the counter-jib end section (k) with two pins (c). Secure each pin (c)
with sleeve (d), three spacers (j), bolt (e), two washers (f) and two nuts (g) see: Fig. 6-87 and de-
tail Z2.
X Connect tie bars 3250 (b) fitted with spacers (y) to tie bars 4380 (h) fitted with spacers (o) with
two pins (c). Secure each pin (c) with sleeve (d), bolt (e), two washers (f) and two nuts (g) see:
Fig. 6-87 and detail Z3.
1250 HC 40 / 49516 6 - 111

Tie bar connections (three-part counter-jib)
Tie bar connections (counter-jib guying pre-assembled)
Counter-jib guying
Drawing no. C 036.020-814.200, ID no. 9001 0406
Additional designa-
tion
(a) Tie bar 2000 4 C 036.020-814.111 9000 9965
(b) Tie bar 3250 8 C 036.020-814.121 9000 9969
6 - 112 1250 HC 40 / 49516

Counter-jib guying
Drawing no. C 036.020-814.200, ID no. 9001 0406
Additional designa-
tion
(c) Pin 80x328x243 form 500 18 according to LN 19 9001 0000
(d) Sleeve 108x12,5x40 18 C 036.020-814.182 9001 0001
(e) Bolt M 12x140 8.8 A3C 18 ISO 4014 4600 303
(f) Washer 12 A3C 36 ISO 7089 4200 016 01
(g) Nut M 12 10 galvanised 36 ISO 4032 4115 048 01
(h) Tie bar 4380 8 C 036.020-814.141 9000 9974
(i) Tie bar 2847 8 C 036.020-814.211 9001 0390
(j) Spacer 108x12,5x15 10 9000 9995
(k) Counter-jib end section C 036.020-711.200 9000 9710
(l) Tower head C 036.020-541.000 9000 9345
(m) Pin 80x270x235 form 200 2 LN 16 9974 123 01
(n) Cotter pin 13x112 4 ISO 1234 4330 110 01
(o) Spacer 38x5,6x150 18 9000 9971
(p) Bolt M24x280 10.9 A3C 18 according to LN 30-17 4062 074 01
(q) Bolt M 24 x140 10.9 A3C 10 ISO 4014 4600 124
(r) Spacer 38x5,6x25 6 9000 9981
(s) Nut M 24 B 05 galvanised 10 ISO 4035 1000 2633
(t) Connection plate 2 C 036.020-814.171 9000 9996
(u) Square tube 1 C 036.020-814.172 9000 9997
(v) Bolt M24x210 10.9 A3C 24 according to LN 30-17 4062 871 01
(w) Washer 24 A3C 96 ISO 7089 4200 024 01
(x) Nut M 24 10 galvanised 86 according to LN 30-17 4115 054 01
(y) Spacer 38x5,6x74 24 9688 224 01
Tie bar 2000 to tower head
connection
Tie bar 2847 to counter-jib end
section connection
(z)
Tie bar 3250 to tie bar 4380
connection
Tie bar connection 4380
and 1385
(aa) Tie bar 1385 4 C 036.020-814.161 9000 9979
X Connect two pairs of tie bars 2000 (a) to four spacers (y) with four bolts (v). Secure each bolt (v)
X Connect two pairs of tie bars 3250 (b) to six spacers (o) with six bolts (p). Secure each bolt (p)
with two washers (w) and two nuts (x) see: Fig. 6-88 and detail Y.
X Connect two pairs of tie bars 3250 (b) to six spacers (y) with six bolts (v). Secure each bolt (v)
X Connect two pairs of tie bars 4380 (h) to eight spacers (o) with eight bolts (p). Secure each
bolt (p) with two washers (w) and two nuts (x) see: Fig. 6-88 and detail Y.
1250 HC 40 / 49516 6 - 113

X Connect two pairs of tie bars 4380 (h) to eight spacers (y) with eight bolts (v). Secure each bolt (v)
X Connect two pairs of tie bars 1385 (aa) to four spacers (o) with four bolts (p). Secure each bolt (p)
with two washers (w) and nuts (x) and (s) see: Fig. 6-88 and detail Y.
X Connect two pairs of tie bars 2847 (i) to six spacers (y) with six bolts (v). Secure each bolt (v) with
two washers (w) and two nuts (x) see: Fig. 6-88 and detail X.
X Connect two connection plates (t) to square tube (u) with four bolts (q). Secure each bolt (q) with
two washers (w) and nuts (x) and (s) see: Fig. 6-88 and detail K.
X Connect two pairs of tie bars 2847 (i) to four spacers (r) with four bolts (q). Secure each bolt (q)
with two washers (w) and nuts (x) and (s) see: Fig. 6-88 and detail S.
Note
X Connect tie bars 2000 (a) to the tower head (l) and secure. For further information, see: Fig. 6-89
and detail Z1.
X Connect tie bars 2000 (a) to tie bars 3250 (b) fitted with spacers (o), connect tie bars 3250 (b) fit-
ted with spacers (o) to tie bars 3250 (b) fitted with spacers (y), connect tie bars 4380 (h) fitted
with spacers (o) to tie bars 4380 (h) fitted with spacers (y), connect tie bars 1385 (aa) to tie bars
2847 (i) fitted with spacers (y), connect tie bars 2847 (i) fitted with spacers (y) to connection
plate (t) with seven pins (c). Secure each pin (c) with sleeve (d), bolt (e), two washers (f) and two
nuts (g) see: Fig. 6-88.
X Connect connection plate (t) to tie bars 2847 (i) fitted with spacers (r) with two pins (c). Secure
each pin (c) with sleeve (d), two spacers (j), bolt (e), two washers (f) and two nuts (g) see: Fig. 6-
88.
X Pin tie bars 2847 (i) fitted with spacers (r) to the counter-jib end section (k) and secure. For further
information, see: Fig. 6-89 and detail Z2.
X Pin tie bars 3250 (b) fitted with spacers (y) to tie bars 4380 (h) fitted with spacers (o) and secure.
For further information, see: Fig. 6-89 and detail Z3.
X Pin tie bars 1385 (aa) to tie bars 4380 (h) fitted with spacers (y) and secure. For further informa-
tion, see: Fig. 6-89 and detail Z4.
6 - 114 1250 HC 40 / 49516

Tie bar connections (counter-jib guying completely assembled)
Counter-jib guying
Drawing no. C 036.020-814.200, ID no. 9001 0406
Additional designa-
tion
(a) Tie bar 2000 see: Fig. 6-88 C 036.020-814.111 9000 9965
(b) Tie bar 3250 see: Fig. 6-88 C 036.020-814.121 9000 9969
(c) Pin 80x328x243 form 500 see: Fig. 6-88 according to LN 19 9001 0000
1250 HC 40 / 49516 6 - 115

Counter-jib guying
Drawing no. C 036.020-814.200, ID no. 9001 0406
Additional designa-
tion
(d) Sleeve 108x12,5x40 see: Fig. 6-88 C 036.020-814.182 9001 0001
(e) Bolt M 12x140 8.8 A3C see: Fig. 6-88 ISO 4014 4600 303
(f) Washer 12 A3C see: Fig. 6-88 ISO 7089 4200 016 01
(g) Nut M 12 10 galvanised see: Fig. 6-88 ISO 4032 4115 048 01
(h) Tie bar 4380 see: Fig. 6-88 C 036.020-814.141 9000 9974
(i) Tie bar 2847 see: Fig. 6-88 C 036.020-814.211 9001 0390
(j) Spacer 108x12,5x15 see: Fig. 6-88 9000 9995
(k) Counter-jib end section see: Fig. 6-88 C 036.020-711.200 9000 9710
(l) Tower head see: Fig. 6-88 C 036.020-541.000 9000 9345
(m) Pin 80x270x235 form 200 see: Fig. 6-88 according to LN 16 9974 123 01
(n) Cotter pin 13x112 see: Fig. 6-88 ISO 1234 4330 110 01
(aa) Tie bar 1385 see: Fig. 6-88 C 036.020-814.161 9000 9979
Note
Tie bar connections of the counter-jib guying with installed counter-jib, see: Fig. 6-89 and de-
tails Z1, Z2, Z3 and Z4.
X Connect tie bars 2000 (a) to the tower head (l) with two pins (m). Secure each pin (m) with two
cotter pins (n) see: Fig. 6-89 and detail Z1.
X Connect tie bars 2847 (i) fitted with spacers (r) to the counter-jib end section (k) with two pins (c).
Secure each pin (c) with sleeve (d), three spacers (j), bolt (e), two washers (f) and two nuts (g)
see: Fig. 6-89 and detail Z2.
X Connect tie bars 3250 (b) fitted with spacers (y) to tie bars 4380 (h) fitted with spacers (o) with
two pins (c). Secure each pin (c) with sleeve (d), bolt (e), two washers (f) and two nuts (g) see:
Fig. 6-89 and detail Z3.
X Connect tie bars 1385 (aa) to tie bars 4380 (h) fitted with spacers (y) with two pins (c). Secure
each pin (c) with sleeve (d), two spacers (j), bolt (e), two washers (f) and two nuts (g) see: Fig. 6-
89 and detail Z4.
6 - 116 1250 HC 40 / 49516

6.8.2 Preparing the counter-jib for installation
Warning!
Improper mounting of the counter-jib can lead to accidents.
The weights of the parts being mounted may not exceed the maximum lifting capacity of the auxiliary
crane.
X For further information, see: Chap. Specifications, Erection weights.
Note
For this tower crane
- a three-part counter-jib has been provided for jibs featuring 82.1 m, 76.3 m, 64.7 m.
- a two-part counter-jib has been provided for jibs featuring 53.1 m, 41.5 m.
X Ensure that arrangement and position of the handrails and rail tubes is kept.
Counter-jib configuration
Fig. 6-90 Counter-jib configuration

(a) Counter-jib two-part (c) Counter-jib end section (e) Counter-jib intermediate
section
(b) Counter-jib three-part (d) Counter-jib heel section
X Attach the erection ropes and secure. (Verify and mark the slinging points for the counter-jib sec-
tions.)
X Lay out the counter-jib sections onto supports on the assembly site in the proper order in accord-
ance with the counter-jib configuration.
For further information, see chap. Fig. 6-91 “Preassembling the counter-jib”
1250 HC 40 / 49516 6 - 117

Preparing the counter-jib for installation
Fig. 6-91 Preassembling the counter-jib

(a) Counter-jib two-part (g) Pin
(b) Counter-jib three-part (h) Cotter pin
(c) Counter-jib heel section (i) Correct position of the flat spot on the pin
head
(d) Intermediate counter-jib section (j) Handrail
(e) Counter-jib end section (k) Platforms
(f) Support (l) Catwalks
Note
The pins (g) are flattened on one side of the pin head.
X When installing, ensure correct position (see: Fig. 6-91) of the flat spot (i).
X Connect the counter-jib heel section (c) to the intermediate counter-jib section (d) or to the end
6 - 118 1250 HC 40 / 49516

section (e) with four pins (g). Secure each pin (g) with cotter pin (h).
X Install the catwalks (l) and platforms (k) in accordance with the configuration and secure. For fur-
ther information, see: Chap. ›Spare parts list‹.
X Install all handrails (j) in accordance with Liebherr-standard LN 266. For further information, see:
Chap. Erection ›Installing the handrails‹ and the respective ›Spare parts list‹.
Installing the switching station
Fig. 6-92 Installing the switching station

(a) Erection rope (f) Nut (x 20)
(b) Switching station (g) Access ladder

(c) Counter-jib heel section (h) Locknut (x 4)
(d) Bolt (x 10) (i) Bolt (x 4)
(e) Washer (x 20) (j) Handrail
X Attach the erection rope (a) onto the switching station (b), lift the switching station and position
onto the counter-jib heel section (c). (1)
1250 HC 40 / 49516 6 - 119

X Connect the switching station (a) to the counter-jib heel section (c) with 10 bolts (d). Secure each
bolt (d) with two washers (e) and hexagon nut (f). (2)
X Connect the access ladder (g) to the switching station (b) with four bolts (i). Secure each bolt (i)
with locknut (h). (3)
X Install all handrails (j) in accordance with Liebherr-standard LN 266. For further information, see:
Chap. Erection ›Installing the handrails‹ and the respective ›Spare parts list‹.
Installing the hoist gear
Fig. 6-93 Installing the hoist gear

(a) Hoist gear (e) Cotter pin
(b) Frame, hoist gear (f) Erection rope
(c) Counter-jib end section (g) Pin

(d) Pin (h) Cotter pin

Hoist gear (a) with frame (b) is properly pre-assembled.
Connections are secured.
Pressure screw is adjusted. For further information, see respective ›Spare parts list‹.
X Attach the erection rope (f) onto the hoist gear (a). Lift the hoist gear (a) with frame (b) and prop-
erly position the hoist unit onto the counter-jib end section (c). (1)
6 - 120 1250 HC 40 / 49516

X Connect the frame (b) to the counter-jib end section (c) with four pins (d) and four pins (g). Secure
each pin (d) with cotter pin (e) and each pin (g) with cotter pin (h). (2)
Installing the counter-jib guying
Warning!
Improper installation of the cross members can lead to accidents.
X Mount all individual parts correctly and in their entirety.
Installing the cross members
Fig. 6-94 Installing the cross members (example)

(a) Cross member (d) Counter-jib heel section
(b) Counter-jib end section (e) Pin
(c) Intermediate counter-jib section (f) Cotter pin
Note
Two cross members (a) must be secured to the connection plates on the counter-jib. Unless the
counter-jib can not be lifted.
X Connect two cross members (a) to the counter-jib (b, c, d) with four pins (e). Secure the pin (e)
1250 HC 40 / 49516 6 - 121

with cotter pin (f). (1)

Install the cross members according to the counter-jib slinging points. For further information, see chap.
“Slinging points of counter-jib”
Connecting the counter-jib guying to the counter-jib and secure
Note
Counter-jib tie bars layouts, see chap. ›Arrangement of the counter-jib guying‹ and ›Tie bar connec-
tions‹.
Fig. 6-95 Connecting the counter-jib guying to the counter-jib and secure
(a) Counter-jib heel section (h) Connection plate (o) Switching station
(b) Counter-jib intermediate (i) Two tie bars 2847 with spac- (p) Two tie bars 2847 with spac-
section ers 25mm long ers 74mm long
6 - 122 1250 HC 40 / 49516

Fig. 6-95 Connecting the counter-jib guying to the counter-jib and secure
(c) Pin (j) Counter-jib to counter-jib (q) Spacer
guying connection
(d) Sleeve (k) Counter-jib end section (r) Two tie bars 1400
(e) Bolt (l) Two tie bars 4380 with spac- (s) Counter-jib three-part
ers 150mm long
(f) Washer (m) Two tie bars 4380 with spac- (t) Counter-jib two-part
ers 74mm long
(g) Nut (n) Tie bars 1385
X Position the properly assembled counter-jib guying onto the counter-jib.

X Connect tie bars (i) or (r) to the counter-jib end section (k) with two pins (c). Secure each pin (c)
with sleeve (d), bolt (e), three spacers (q), two washers (f) and two nuts (g) see: Fig. 6-95.
For further information, see chap. ›Arrangement of the counter-jib guying‹ and ›Tie bar connections‹.
X Place tie bars 4380 on the switching station and secure them against slipping.
1250 HC 40 / 49516 6 - 123

Slinging points of counter-jib
Note
The counter-jib slinging points must correspond to the respective counter-jib configuration.
The erection ropes of the auxiliary crane must be located between the counter-jib tie bars.
Fig. 6-96 Slinging points of the two-part counter-jib

(a) Counter-jib (two-part) without hoist gear (d) Slinging points (two cross members with
shackle)
(b) Counter-jib (two-part) with hoist gear (e) Slinging points (one cross member with
shackle)
(c) Erection ropes of the auxliary crane (f) Length of erection rope approx. 10m
6 - 124 1250 HC 40 / 49516

Fig. 6-97 Slinging points of the three-part counter-jib

(a) (g) Counter-jib (three-part) without hoist gear
(b) (h) Counter-jib (three-part) with hoist gear
(c) Erection ropes of the auxliary crane (i) Slinging points (two cross members with
shackle)
(d) (j) Slinging points (two cross members with
shackle)
(e)
(f) Length of erection rope approx. 10m
1250 HC 40 / 49516 6 - 125

6.8.3 Installing the counter-jib
Warning!
Improper mounting of the counter-jib can lead to accidents.
The weights of the parts being mounted may not exceed the maximum lifting capacity of the auxiliary
crane.
X For further information, see: Chap. ›Specifications, Erection weights‹.
Fig. 6-98 Slinging points for the counter-jib with hoist gear unit and switching station
(a) Shackle (c) Ropes, auxiliary crane
(b) Cross member

Counter-jib tie bars have been properly pre-assembled.
The respective counter-jib tie bar assembly has been positioned onto the counter-jib, pinned and
secured.
Two pre-assembled tie bars 4380 (p) are secured with wire (o) to the eyelets of the switching station
to prevent them from slipping, see chap. Fig. 6-100 “Engaging and securing the counter-jib”
Hook on and secure the ropes of the auxiliary crane (c) onto the two cross members on the counter-
jib (b) using four shackles (a). (1)
X Mark the slinging points.

X Lift the counter-jib and ensure that the counter-jib is suspended horizontally. (2)
6 - 126 1250 HC 40 / 49516

Rectifying the problem

Counter-jib not suspended horizontally?
X Set down the counter-jib again and reposition the slinging points accordingly on the cross mem-
bers.
X Remove the old markings and mark the new slinging points.
1250 HC 40 / 49516 6 - 127

Fig. 6-99 Lifting the counter-jib to the mounting point on the tower head
(d) Tower head (f) Counter-jib (three-part)

(e) Guide rope (g) Counter-jib (two-part)
Warning
Risk of accident as a result of rotating counter-jib.
X Guide the counterjib using ropes (e) and prevent it from rotating.
6 - 128 1250 HC 40 / 49516

X Lift the counter-jib (f,g) to the mounting point on the tower head (d). (3)
Fig. 6-100 Engaging and securing the counter-jib

(h) Counter-jib (k) Axle support (n) Assembly aid
(i) Slewing platform (l) Lock washer (o) Wire locking
(j) Pin (m) Bolt (p) Tie bar 4380
X Bolt two assembly aides (n) and four axle supports (k) to the slewing platform (i) with four
bolts (m). Secure each bolt (m) with lock washer (l). (4)
X Insert the counter-jib (h) into the mountings on the slewing platform (i) and secure with two
pins (j). (5)
X Secure two pins (j) and the two assembly aids (n) as well with four axle supports (k). Secure each
axle support (k) with two lock washers (l) and two bolts (m). (6)
1250 HC 40 / 49516 6 - 129

Lowering the counter-jib into the guying
Danger!
Risk of crane toppling.
There is a serious risk of accident if the counter-jib is not properly supported by the guying.
Carefully lift the counter-jib with the auxiliary crane, avoiding diagonal pull, only as far as neces-
sary to pin and secure the counter-jib tie bars.
Fig. 6-101Installing the counter-jib guying

(a) Safety wire (e) Tie bar 4380 (i) Washer
(b) Switching station (f) Pin (j) Nut
(c) Counter-jib (g) Sleeve (k) Detail
(d) Tie bar 3250 (h) Bolt
6 - 130 1250 HC 40 / 49516

X Remove the safety wire (a) securing the tie bars (d) to the switching station (b). (1)
X Carefully lift the counter-jib (c) with the auxiliary crane only as far as necessary, to pin and se-
cure tie bars (d) and (e). (2)
X Swing out the tie bars (d). (3)
X Pin tie bars (d) to tie bars (e) with two pins (f). Secure each pin (f) with sleeve (g), bolt (h), two
washers (i) and two nuts (j), see detail (k). (4)
Fig. 6-102 Connecting the tie bars (counter-jib three-part)

(l) Tirfor winch (n) Tie bar 1385
(m) Tie bar 4380 (o) Tie bar connection see: Fig. 6-101 with detail (k)
X Remove the safety wire securing the tie bars to the cross member.
X Use the tirfor winch (l) to pull the two tie bars (m) and the two tie bars (n) together. (5)
X Pin two tie bars (m) to two tie bars (n) with two pins (h), see: Fig. 6-102. Secure each pin (f) with
sleeve (g), bolt (h), two washers (i) and two nuts (j), see: Fig. 6-101 with detail (k). (6)
1250 HC 40 / 49516 6 - 131

Fig. 6-103 Lowering the counter-jib into the guying

(p) Counter-jib (r) Guying
(q) Ropes of the auxiliary crane (s) Switching station
X Lower the counter-jib (p) until its weight is supported by the guying (r). (7)
X Unhook the auxiliary crane ropes (q) from the counter-jib.
X Lay the electric cables.

X Connect the switching station (s).
6 - 132 1250 HC 40 / 49516

6.8.4 Mounting the jib
6.8.5 Jib assembly
Warning!
Improper combination of the jib sections can lead to accidents.
X Arrange, pin and secure the jib sections being installed for a specific jib length for this crane type
in compliance with the drawing number and identification numbers prescribed.
Note
The drawing number and identification number of the jib sections are stamped onto the respective
parts.
All dimensions of the following drawings are represented in mm.
Arrangement of jib sections for the jib
82.1 m jib
Fig. 6-104 Arrangement of jib sections for 82.1 m jib, 1250 HC 50

(a) Jib heel piece (C036.020-611.111) (g) Jib intermediate section (C036.020-634.111)
(b) Jib intermediate section (C036.020-621.111) (h) Jib head piece (C036.020-641.111)
(c) Jib intermediate section (C036.020-631.111) (i) Max. radius, jib (4-fall operation)
(d) Jib intermediate section (C036.020-632.111) (j) Max. radius, jib (2-fall operation)
(e) Jib intermediate section (C036.020-635.111) (k) Slewing radius, jib
(f) Jib intermediate section (C036.020-633.111)
1250 HC 40 / 49516 6 - 133

76.3 m jib

(a) Jib heel piece (C036.020-611.111) (g) Jib intermediate section (C036.020-634.111)
(e) (k) Slewing radius, jib
64.7 m jib

(a) Jib heel piece (C036.020-611.111) (g)
6 - 134 1250 HC 40 / 49516

53.1 m jib

(b) (h) Jib head piece (C036.020-641.111)
41.5 m jib

(b) (h) Jib head piece (C036.020-641.111)
(d) (j) Max. radius, jib (2-fall operation)

(f) Jib intermediate section (C036.020-633.111) (l) Install the aluminium wind surface in the jib
head (approx. 13,5 m2)
1250 HC 40 / 49516 6 - 135

Warning!
Improper combination of tie bars for the jib guying can lead to accidents.
The tie bars for the jib guying being installed for a specific jib length for this crane type must be ar-
ranged, pinned and secured in compliance with the drawing number and identification number pre-
scribed.
Arrangement of tie bars for standard jib
82.1 m jib
Jib guying for 82.1 m standard jib

Drawing no. C 036.012-812.600, ID no. 9573 843 01

(a) Tie bar 2230 1 C036.012-812.211 9573 802 01
(b) Connection plate, tower head 500 1 C036.012-812.212 9573 805 01
(c) Tie bar 3340 1 C036.012-812.229 9573 847 01
(d) Tie bar 7700 1 C036.012-812.228 9573 846 01
(e) Tie bar 4480 1 C036.012-812.221 9573 807 01
(f) Tie bar 11500 1 C036.012-812.222 9573 809 01
(g) Connection plate, jib 1700 1 C036.012-812.240 9573 814 01
(h) Connection plate, tie bar 460 7 C036.012-812.230 9573 811 01
(i) Tie bar 3210 1 C036.012-812.251 9573 817 01
(j) Tie bar 3000 1 C036.012-812.252 9573 823 01
(k) Tie bar 9500 1 C036.012-812.253 9573 825 01
(l) Connection plate, jib 1300 1 C036.012-812.270 9573 830 01
(m) Connection plate, tie bar 500 3 C036.012-812.260 9573 827 01

(n) Jib guy frame - 1 C036.012-682.000 9573 629 01
(o) Tie bar 6230 1 C036.012-812.323 9573 834 01
(p) Tie bar 9970 1 C036.012-812.454 9573 841 01
(q) Tie bar 3160 1 C036.012-812.424 9573 837 01
(r) Tie bar 11070 1 C036.020-812.425 9573 839 01
Tab. 6-16 Arrangement of jib guying 82.1 m jib
6 - 136 1250 HC 40 / 49516


Drawing no. C 036.012-812.600, ID no. 9573 843 01

(s) Tie bar 5190 1 C036.020-812.626 9573 844 01
76.3 m and 64.7 m jib
76.3 m jib
64.7 m jib
Jib guying for 76.3 m and 64.7 m standard jib

Drawing no. C 036.012-812.400, ID no. 9573 836 01

(a) Tie bar 2230 1 C036.012-812.211 9573 802 01
(c) Tie bar 3340 1 C036.012-812.229 9573 847 01

(d) Tie bar 7700 1 C036.012-812.228 9573 846 01
(e) Tie bar 4480 1 C036.012-812.221 9573 807 01
(f) Tie bar 11500 1 C036.012-812.222 9573 809 01
Tab. 6-17 Arrangement of jib guying 76.3 m and 64.7 m jib
1250 HC 40 / 49516 6 - 137

Jib guying for 76.3 m and 64.7 m standard jib

Drawing no. C 036.012-812.400, ID no. 9573 836 01

(i) Tie bar 3210 1 C036.012-812.251 9573 817 01
(j) Tie bar 3000 1 C036.012-812.252 9573 823 01
(k) Tie bar 9500 1 C036.012-812.253 9573 825 01
(n) Jib guy frame - 1 C036.012-682.000 9573 629 01
(o) Tie bar 6230 1 C036.012-812.323 9573 834 01
(p) Tie bar 9970 1 C036.012-812.454 9573 841 01
(q) Tie bar 3160 1 C036.012-812.424 9573 837 01
(r) Tie bar 11070 1 C036.020-812.425 9573 839 01
Tab. 6-17 Arrangement of jib guying 76.3 m and 64.7 m jib
53.1 m jib

Drawing no. C 036.012-812.300, ID no. 9573 833 01

(a) Tie bar 2230 1 C036.012-812.211 9573 802 01
(c) Tie bar 3340 1 C036.012-812.229 9573 847 01
(d) Tie bar 7700 1 C036.012-812.228 9573 846 01

(e) Tie bar 4480 1 C036.012-812.221 9573 807 01
(f) Tie bar 11500 1 C036.012-812.222 9573 809 01
(i) Tie bar 3210 1 C036.012-812.251 9573 817 01
6 - 138 1250 HC 40 / 49516


Drawing no. C 036.012-812.300, ID no. 9573 833 01

(j) Tie bar 3000 1 C036.012-812.252 9573 823 01
(k) Tie bar 9500 1 C036.012-812.253 9573 825 01
(n) Jib guy frame - 1 C036.012-682.000 9573 629 01
(o) Tie bar 6230 1 C036.012-812.323 9573 834 01
41.5 m jib

Drawing no. C 036.012-812.200, ID no. 9573 801 01

(a) Tie bar 2230 1 C036.012-812.211 9573 802 01
(c) Tie bar 3340 1 C036.012-812.229 9573 847 01
(d) Tie bar 7700 1 C036.012-812.228 9573 846 01
(e) Tie bar 4480 1 C036.012-812.221 9573 807 01
(f) Tie bar 11500 1 C036.012-812.222 9573 809 01
(i) Tie bar 3210 1 C036.012-812.251 9573 817 01

(j) Tie bar 3000 1 C036.012-812.252 9573 823 01
(k) Tie bar 9500 1 C036.012-812.253 9573 825 01
1250 HC 40 / 49516 6 - 139

6.8.6 Preassembling jib
Warning!
Improper combination of the jib sections can lead to accidents.
The jib sections being installed for a specific jib length for this crane type must be arranged, pinned
and secured in compliance with the drawing number and identification number prescribed. For fur-
ther information, see: the chapter ›Jib arrangement‹.
Note
The jib is assembled in two parts (jib part 1 and jib part 2).
Preassembling jib section 1

Jib heel piece with trolley travel gear and trolley travel ropes
Intermediate jib section -621
2 trolleys with bottom hook blocks
A-frame
Guying rods
complete see ›Specifications‹
Tab. 6-20 Assembly weight of jib section 1 for 82.1 m, 76.3 m and 64.7 m jib

Jib heel piece with trolley travel gear and trolley travel ropes
2 trolleys with bottom hook blocks
A-frame
Guying rods
Tab. 6-21 Assembly weight of jib section 1 for 53.1 m and 41.5 m jib
6 - 140 1250 HC 40 / 49516

Fig. 6-109 Jib heel piece - fitting guard rails and platforms
(a) Jib heel piece (c) Washer (e) Nut
C036.020-611.000
(b) Bolt (d) Locking washer (f) Platform
X Fit and secure all guard rails to the jib heel piece (a) in accordance with Liebherr-standard
LN 266. For further information, see: the chapter Fundamental notes on assembly ›Fitting the
guard rails‹.
X Connect two platforms (f) and jib heel piece (a) with 8 bolts (b). Secure each bolt (b) with
washer (c), locking washer (d) and nut (e).
1250 HC 40 / 49516 6 - 141

Fig. 6-110 Jib intermediate section C 036.020-621.000

(g) Jib intermediate section

(h) Jib intermediate section
6 - 142 1250 HC 40 / 49516

Mounting the jib sections

Fig. 6-112 Preassembling the jib (jib section 1 for 64.7 m - 82.1 m jib length represented here as an
example)
(a) Jib heel piece (C036.020-611.000) (g) Cotter pin
(b) Jib intermediate section (C036.020-621.000) (h) Pin
1250 HC 40 / 49516 6 - 143

Fig. 6-112 Preassembling the jib (jib section 1 for 64.7 m - 82.1 m jib length represented here as an
example)
(c) Jib intermediate section (C036.020-631.000) (i) Cotter pin
(d) Pin (j) Pin
(e) Cotter pin (k) Cotter pin
(f) Pin (l) Support (H = approx. 3.4 m)
Note:
Ensure sufficient ground clearance (H = approx. 3.4 m) when fitting the jib sections together. The
trolley can then be pushed into the jib.
X Secure the ropes of the auxiliary crane to the jib heel piece (a), lift the jib heel piece and set down
onto two supports (l). (1)
X Secure the ropes of the auxiliary crane to the jib intermediate section (b), lift the jib intermediate
section and manoeuvre it towards the jib heel piece (a). (2)
X Connect the jib sections to the lower chords with two pins (d). Secure each pin (d) with a cotter
pin (e). (3)
X Connect the jib sections to the top chords with a pin (f). Secure the pin (f) with two cotter pins
(g). (4)
X Set the jib intermediate section (b) down onto the support.
X Secure the ropes of the auxiliary crane to the jib intermediate section (c), lift the jib intermediate
section and manoeuvre it towards jib intermediate section (b). (5)
X Connect the jib sections to the lower chords with two pins (h). Secure each pin (h) with a cotter
pin (i). (6)
X Connect the jib sections to the top chords with a pin (j). Secure the pin (j) with two cotter pins
(k). (7)
6 - 144 1250 HC 40 / 49516

Mounting the trolley
Fig. 6-113 Mounting trolley and bottom hook block

(a) Bottom hook block (d) Locking device (released)
(b) Ropes, auxiliary crane (e) Locking device (engaged - bottom hook block
(c) Trolley secured)
X Erect the bottom hook block (a) vertically and secure against tipping. (1)
X Hook the ropes (b) of the auxiliary crane onto the trolley (c), lift the trolley and insert into bottom
hook block. (2)
X Secure trolley (c) and bottom hook block (a) with the locking device (d, e). (3)
1250 HC 40 / 49516 6 - 145

Fig. 6-114 Mounting trolleys onto the jib

(f) Trolley I (i) Spring clip
(g) Trolley II (j) Pin
(h) Connecting brace
X Lift trolley I (f) and insert into jib intermediate section. (4)
X Mount second trolley with second bottom hook block (see: Fig. 6-113), lift and insert into jib inter-
mediate section. (5)
X Connect trolleys and two connecting braces (h) with four pins (j). Secure each pin (j) with a spring
clip (i). (6)
X Secure trolleys against moving.
6 - 146 1250 HC 40 / 49516

Mounting the A-frame
Fig. 6-115 Mounting the A-frame

(a) A-frame (c) Pin (e) Pin
(b) Spring clip (d) Stay bars (f) Spring clip
X Lift the A-frame (a) and manoeuvre it towards the jib intermediate section. (1)
X Connect the A-frame (a) and jib intermediate section with two pins (c). Secure each pin (c) with
two spring clips (b). (2)
X Swing the A-frame (a) forwards and mount onto the jib intermediate section using a stay bar
(d). (3)
X Secure the stay bar (d) with two pins (e). Secure each pin (e) with two spring clips (f). (4)
1250 HC 40 / 49516 6 - 147

Fitting tie bar retainers and jib suspensions
Fig. 6-116 Fitting tie bar retainers

(a) Tie bar retainer (e)
(b) Bolt (f)
(c) Washer (g)
(d) Nut
X Fit four tie bar retainers (a) (comprised of two clamping pieces respectively) onto the top chord.
Secure each tie bar retainer (a) with two bolts (b), four washers (c) and two nuts (d).
6 - 148 1250 HC 40 / 49516

Fig. 6-117 Fitting the jib suspensions

(h) Distance sleeve (k) Jib suspension, part 2 (m) Washer
(i) Jib suspension, complete (l) Bolt (n) Nut
(j) Jib suspension, part 1
X Fit two lifting lugs (i) (comprising of two parts (j) and (k) to the top chord. Secure each lifting lug
(i) with four bolts (l), eight washers (m) and four nuts (n).
(i) with four bolts (l), four distance sleeves (h) and eight washers (m) and four nuts (n).
1250 HC 40 / 49516 6 - 149

Mounting the jib guying
Warning!
Improper combination of the tie bars gor the jib guying can lead to accidents.
scribed.
Fig. 6-118 Mounting the jib guying

(a) Pin (e) Pin (i) Pin
(b) Cotter pin (2 piece) (f) Cotter pin (2 piece) (j) Pin
(c) Pin (g) Pin (k) Cotter pin (2 piece)
(d) Cotter pin (2 piece) (h) Cotter pin (2 piece) (l) Cotter pin (2 piece)
X Arrange, pin and secure tie bars and connection plates (For further information, see: chapter Jib
suspension ›Arrangement of tie bars‹ and see: Fig. 6-118) fitting, pinning and securing.
Description and
Pos. ID no. Utilisation ID no.

dimensions [mm]
(a) Pin 110x420x335 9710 357 01 Connection plate, tie bar 9573 827 01
(c) Pin 110x450x360 9710 358 01
Connection plate, jib 9573 830 01
(e) Pin 120x470x375 9975 662 01
(g) Pin 100x410x320 9975 880 01 Connection plate, tie bar 9573 811 01
Tab. 6-22 Pins used
6 - 150 1250 HC 40 / 49516

Description and
dimensions [mm]
(i) Pin 110x420x335 9975 880 01 9546 842 01
Connection plate for guying
(i) Pin 100x410x320 9975 880 01 9573 812 01
block
(j) Pin 100x495x405 9975 881 01 9546 844 01
Tab. 6-22 Pins used
1250 HC 40 / 49516 6 - 151

Preassembling jib section 2

Jib intermediate section -632
Jib head piece -641
Guying rods
Tab. 6-23 Assembly weights of jib section 2 for 82.1 m jib represented as an example

Jib head piece -641
Guying rods
Tab. 6-24 Assembly weights of jib section 2 for 76.3 m jib represented as an example

Jib head piece -641
Guying rods
Tab. 6-25 Assembly weights of jib section 2 for 64.7 m and 53.1 jib represented as an example

Jib head piece -641
Guying rods
Tab. 6-26 Assembly weights of jib section 2 for 41.5 jib represented as an example
6 - 152 1250 HC 40 / 49516


(a) Jib intermediate section

(b) Jib intermediate section
1250 HC 40 / 49516 6 - 153


(c) Jib intermediate section

(d) Jib intermediate section
6 - 154 1250 HC 40 / 49516


(e) Jib intermediate section
1250 HC 40 / 49516 6 - 155

Mounting the jib sections
Fig. 6-124 Preassembling jib section 2 (jib section 2 for 82.1 m jib length represented here as an ex-
ample)
(a) Jib heel piece (C036.020-632.000) (f) Cotter pin
(b) Jib intermediate section (C036.020-635.000) (g) Pin
6 - 156 1250 HC 40 / 49516

Fig. 6-124 Preassembling jib section 2 (jib section 2 for 82.1 m jib length represented here as an ex-
ample)
(c) Jib intermediate section (C036.020-633.000) (h) Cotter pin
(d) Jib intermediate section (C036.020-634.000) (i) Support (H = approx. 3.4 m)
(e) Pin
Note:
Ensure sufficient ground clearance (H = approx. 3.4 m) when fitting the jib sections together. The
trolley can then be pushed into the jib.
X Mount, pin and secure the jib sections which comply with the respective jib length (For further in-
formation, see: chap. Mounting the jib sections ›Arrangement of jib sections for jib‹).
Fig. 6-125 Mounting the jib head piece

(j) Jib intermediate section (C036.020-634.000) (n) Cotter pin
(k) Jib head piece (C036.020-641.000) (o) Pin
(l) Pin (p) Cotter pin
(m)
X Connect jib head piece (k) and jib intermediate section (j) to the top chords using a pin (l). Secure
the pin (l) with two cotter pins (n).
X Connect jib head piece (k) and jib intermediate section (j) to the lower chords using two pins (o).
Secure each pin (o) with a cotter pin (p).
1250 HC 40 / 49516 6 - 157

Fitting tie bar retainers and jib suspensions
Fig. 6-126 Fitting tie bar retainers

(a) Tie bar retainer (e)
(b) Bolt (f)
(c) Washer (g)
(d) Nut
X Fit two tie bar retainers (a) (comprised of two clamping pieces respectively) onto the top chord.
Secure each tie bar retainer (a) with two bolts (b), four washers (c) and two nuts (d).
6 - 158 1250 HC 40 / 49516

Fig. 6-127 Fitting the jib suspensions

(h) Distance sleeve (k) Jib suspension, part 2 (m) Washer
(i) Jib suspension, complete (l) Bolt (n) Nut
(j) Jib suspension, part 1
(i) with four bolts (l), eight washers (m) and four nuts (n).
(i) with four bolts (l), four distance sleeves (h) and eight washers (m) and four nuts (n).
1250 HC 40 / 49516 6 - 159

Mounting the jib guying
Warning!
Improper combination of the tie bars for the jib guying can lead to accidents.
scribed.
Fig. 6-128 Mounting the jib guying

(a) Pin 100x440x350 (c) Pin 100x410x320
(b) Cotter pin (d) Cotter pin
X Arrange, pin and secure tie bars and connection plates (For further information, see: chapter Jib
suspension ›Arrangement of tie bars‹ and see: Fig. 6-128) fitting, pinning and securing
Description and
dimensions [mm]
(a) Pin 100x440x350 9975 882 01 Connection plate, jib 9573 815 01
(c) Pin 100x410x320 9975 880 01 Connection plate, tie bar 9573 812 01
Tab. 6-27 Pins used
6 - 160 1250 HC 40 / 49516

6.8.7 Mounting jib section 1 to the slewing platform

Jib section 1 complete. see ›Specifications‹
Warning!
Improper assembly of jib section 1 can lead to accidents.
The weight of the sections being assembled may not exceed the maximum lifting capacity of the
auxiliary crane.

Slinging points for the jib have been predetermined and are marked accordingly.
Trolleys are secured against travelling.
Mounting the assembly ropes

Fig. 6-129 Mounting the assembly ropes (Example)

(a) Assembly rope, long (d) Connection plate, tower head
(b) Assembly rope, short (e) Pin
(c) Tie rod (f) Cotter pin
1250 HC 40 / 49516 6 - 161

X Connect the assembly rope (a) (58 m in length) to the tie rod (c) with pin (e). Secure the pin (e)
X Connect the assembly rope (b) (short) to the connection plate (d) with pin (e). Secure the pin (e)
Mounting jib section 1 to the slewing platform
Fig. 6-130 Mounting jib section 1 to the slewing platform (Example)

(a) Rope, auxiliary crane (d) Tower head (g) Locking washer
(b) Jib suspension (e) Pin (h) Bolt
(c) Jib section 1 (f) Axle support
X Hook the ropes of the auxiliary crane (a) into the jib suspensions and secure. (1)
Warning!
Risk of accident resulting from rotating jib section.
X Guide the jib section with ropes and prevent from rotating.
X Lift jib section 1 (c) and manoeuvre towards the tower head (d). (2)
Problem rectification
Jib section not suspended horizontally?
X Release the safety device on the trolleys and manoeuvre the trolleys by hand accordingly until the
jib section is suspended horizontally. Mark the new position of the trolleys and secure the trolleys
against travelling.
- or -
Set down the jib section once again. Reposition the jib suspensions accordingly, remove the old
markings and mark new slinging points.
6 - 162 1250 HC 40 / 49516

Warning!
Danger of falling from the slewing platform.
X Persons who remain on the slewing platform must wear a safety harness at all times and secure
the safety harness accordingly.
X Connect jib heel piece and slewing platform with two pins (e). (3)
X Secure two pins (e) with four axle supports (f). Secure each axle support (f) with two safety
washers (g) and two bolts (h).
6.8.8 Hooking jib section 1 into the guying
Danger!
Risk of crane toppling.
Improper hooking of the jib section into the guying can lead to accidents.
X Lift the jib section with auxiliary crane, avoiding diagonal pull of the slinging ropes, only so far
as to ensure that the tie bars can be pinned and secured.
Warning!
Risk of accident.
– Lift the jib guying only with the hoist gear.
– Lift the jib only with the auxiliary crane.
Fig. 6-131 Mounting the guying for jib section 1

(a) Assembly rope, long (c) Tie rod

(b) Jib section 1 (d) Connection plate
X Reeve the assembly rope (a) (long) in the tower head, connect with the hoist gear and secure.
X Allow the assembly rope (a) to unwind slowly and lift the jib guying (n). (1)
X Lift jib section 1 (b) only so far as to ensure that the tie rod (d) and the connection plate (k) can
be connected. (2)
1250 HC 40 / 49516 6 - 163

Fig. 6-132 Mounting the tie rod

(e) Tie rod (h) Cotter pin
(f) Connection plate (i) Assembly rope, long
(g) Pin
X Connect the tie rod (e) and connection plate (f) with a pin (g). Secure the pin (g) with two cotter
pins (h). (3)
X Check all connections of the jib guying and lower jib section 1 until it is suspended in the jib guying.
Note!
Jib section 1 must indicate a slight inclination (approx. 400 mm across the entire length).
Jib is hanging too far down or is positioned too steeply?
X Unpin the tie rod from the connection plate and select another borehole (!).
6 - 164 1250 HC 40 / 49516

X Ensure correct positioning of the jib section; readjust as necessary.
Unhook the lifting slings
Warning!
Improper unhooking of the auxiliary crane lifting slings can lead to accidents.
X Wear and use a safety harness, hook onto the handrail rope, secure and only walk out as far as
the jib slinging points. Do not extend any further towards max. radius as the crane has not yet
undergone proper ballasting.
X Unhook the slinging ropes

1250 HC 40 / 49516 6 - 165

6.8.9 Installing the A-ballast slab
Warning!
Improper assembly of the jib can lead to accidents.
After installing jib section 1 for the 82.1 m or 76.3 m jib length, one A-ballast slab of the counter-
weight must be installed precisely.
For further information, see: ›Static Data documentation‹.
Note
The weight of the A-ballast slab is 7.1 t.
Fig. 6-133 Installing A-ballast slab (7.1 t)

(a) A-ballast slab (b) Rope, auxiliary crane (c) Guide for ballast slab
After installing jib section 1 for the 82.1 m or 76.3 m jib length, install one A-ballast slab (a) at the rear at
the hoist gear into the opening of the counter-jib.
X Hook the rope of the auxiliary crane (b) into the A-ballast slab (a), lift the A-ballast slab (a) and
lower precisely into the guides (c).
6 - 166 1250 HC 40 / 49516

Mounting jib section 2 onto jib section 1

Jib section 2 complete. see ›Specifications‹
Mounting the assembly ropes
Warning!
Improper assembly of jib section 2 can lead to accidents.
The weight of the sections being assembled may not exceed the maximum lifting capacity of the
auxiliary crane.

The slinging points have been predetermined and are marked.
Fig. 6-134 Mounting the assembly ropes (Example)

(a) Assembly rope, long (d) Pin
(b) Assembly rope, short (e) Cotter pin
(c) Connection plate
X Connect assembly rope (b) (short) and assembly rope (a) (long) with connection plate (c) and se-
cure with two pins (d). Secure each pin (d) with two cotter pins (e).
1250 HC 40 / 49516 6 - 167

Mounting jib section 2 onto jib section 1
Fig. 6-135 Mounting jib section 2 onto jib section 1 (Example)

(a) Jib section 1 (f) Cotter pin (k) Erection rope
(b) Jib section 2 (g) Connection plate (l) Jib tie rods
(c) Pin (h) Pin (m) Mounting
(d) Cotter pin (i) Cotter pin (n) Connection plate
(e) Pin (j) Stay bar
X Hook the ropes of the auxiliary crane into the jib suspensions and secure. (1)
Warning!
Risk of accident resulting from rotating jib.
X Guide the jib with ropes and prevent from rotating.
X Lift jib section 2 (b) and manoeuvre towards the jib section 1 (a). (2)
6 - 168 1250 HC 40 / 49516

Jib section not suspended horizontally?
X Release the safety device on the trolleys and manoeuvre the trolleys by hand accordingly until the
jib section is suspended horizontally. Mark the new position of the trolleys and secure the trolleys
against travelling.
- or -
Set down the jib section once again. Reposition the jib suspensions accordingly, remove the old
markings and mark new slinging points.
Warning!
Danger of falling from the jib.
X Persons who remain on the jib must wear a safety harness at all times and secure the safety
harness accordingly.
X Connect jib section 2 (b) with jib section 1 (a) at the lower chords with two pins (c). Secure each
pin (c) with a cotter pin (d). (3)
X Pull the tie bars together using a tifor winch, connect with a connection plate (g) and secure with
two pins (e). Secure each pin (e) with two cotter pins (f). (4)
X Release the pin connection on the stay bar (j). (5)
Warning!
Tie bars may remain suspended at the fixtures or at the connection points during lifting.
X Observe the jib guying with utmost attention during the lifting procedure.
If the tie bars become snagged during the lifting procedure:
X Rectify any snagging by lifting / lowering the jib.
X Wind on the assembly rope (k) slowly and lift the jib guying (l). (6)
X Lift jib section 2 (b) only so far as to ensure that the jib guying and the tower head can be connect-
ed.
1250 HC 40 / 49516 6 - 169

6.8.10 Mounting the tie rod and hooking jib section 1 into the guying
Fig. 6-136 Mounting the tie rod (Example)

(a) Connection plate on the tower head (d) Cotter pin
(b) Connection plate for jib guying (e) Assembly rope, short
(c) Pin
X Connect the connection plate (a) on the tower head and the connection plate (b) of the jib guying
with a pin (c). Secure the pin (c) with two cotter pins (d).
X Check all connections of the jib guying and lower jib section 2 until it is suspended in the jib guying.
6 - 170 1250 HC 40 / 49516

Note!
Jib section 2 must indicate a slight inclination (approx. 400 mm across the entire length).
Jib is hanging too far down or is positioned too steeply?
X Unpin the tie rod from the connection plate and select another borehole (!).
X Ensure correct positioning of the jib section; readjust as necessary.
Unhook the lifting slings
Warning!
Improper unhooking of the auxiliary crane lifting slings can lead to accidents.
X Wear and use a safety harness, hook onto the handrail rope, secure and only walk out as far as
the jib slinging points. Do not extend any further towards max. radius as the crane has not yet
undergone proper ballasting.
X Unhook the slinging ropes
6.8.11 Installing the counterweight

Installing the counterweight, see chapter ›Static Data‹.
1250 HC 40 / 49516 6 - 171

6.8.12 IMounting the trolley travel ropes
Warning!
Improper assembly of the trolley travel ropes can lead to accidents.
X When working on the jib: Wear a safety harness at all times and ensure that the safety harness
is properly secured.
Warning!
Improper assembly of the trolley travel ropes can lead to accidents.
X Inspect the trolley travel ropes for damage prior to commencing assembly. For further informa-
tion, see: the chapter Maintenance and Inspection ›Ropes, rope pulleys and rope end fittings‹.
X Always ensure correct coursing of the ropes and correct reeving.
Fig. 6-137 Summary: Reeving the trolley travel ropes (Example)

(a) Rope reeving on the trolley travel gear (For (d) Rope reeving on the jib head section (For fur-
further information, see page: 6-173 ›Rope ther information, see page: 6-176 ›Rope reev-
reeving on the trolley travel gear‹) ing on the jib head section‹)
(b) Rope reeving on the jib intermediate sections (e) Rope end fitting on the trolley (For further
(For further information, see page: 6-174 information, see page: 6-177 ›Rope end fit-
›Rope reeving on the jib intermediate sec- ting on the trolley‹ and For further informa-
tions‹) tion, see page: 6-180 ›Rope end fitting on the
trolley‹)
6 - 172 1250 HC 40 / 49516

Fig. 6-137 Summary: Reeving the trolley travel ropes (Example)

(c) Rope reeving on the tensioning device (For (f) Rope reeving on the jib heel piece (For fur-
further information, see page: 6-175 ›Rope ther information, see page: 6-178 ›Rope reev-
reeving on the tensioning device‹) ing on the jib heel piece‹)
6.8.13 Rope reeving on the trolley travel gear

The trolley is secured on the jib heel piece against travelling.
Fig. 6-138 Rope reeving on the trolley travel gear (Example)

(a) Trolley travel gear (e) Bolt
(b) Rope storage drum (f) Trolley travel rope 2 „long“
(ø 16.0 mm / l = 170 m, ID no. 1017 5480)
(c) Rope clamp (g) Trolley travel rope 1 „short“
(ø 16.0 mm / l = 97 m, ID no. 1017 5479)
(d) Washer
X Secure the trolley travel ropes (f, g) on the outside of the rope storage drum (b) with three rope
clamps (c) respectively. Secure each rope clamp (c) with two bolts (e) and two washers (d).
1250 HC 40 / 49516 6 - 173

6.8.14 Rope reeving trolley travel rope 2 „long“

Trolley travel rope 2 „long“: ø 16.0 / l = 170 m ID no. 1017 5480
Rope reeving on the jib intermediate sections
Fig. 6-139 Rope reeving on the jib intermediate sections

(a) Cotter pin (b) Pin
X Remove the two cotter pins (a) and one pin (b). (1)
X Reeve the trolley travel rope.
X Insert pin (b) and secure pin (b) with two cotter pins (a).
6 - 174 1250 HC 40 / 49516

Rope reeving on the tensioning device
Fig. 6-140 Rope reeving on the tensioning device

(a) Cotter pin (d) Bolt
(b) Pin (e) Locking washer
(c) Protective covering (f) Washer
X Remove the six cotter pins (a) and three pins (b).
X Loosen the two bolts (d), two circlips (e) and two washers (f) and remove the protective covering
(c).
X Reeve the "long" trolley travel rope.
X Fit the protective covering (c) and secure with two bolts (d). Secure each bolt (d) with two circlips
(e) and two washers (f).
X Insert three pins (b). Secure each pin (b) with two cotter pins (a).
1250 HC 40 / 49516 6 - 175

Rope reeving on the jib head section
Fig. 6-141 Rope reeving on the jib head section

(a) Cotter pin (b) Pin
X Remove the two cotter pins (a) and one pin (b). (1)
X Insert pin (b) and secure pin (b) with two cotter pins (a).
6 - 176 1250 HC 40 / 49516

Rope end fitting on the trolley
Fig. 6-142 Rope end fitting "long" trolley travel rope and rope breakage safety device
(a) Cotter pin (c) Pin (e) Lever
(b) Washer (d) Safety catch retainer (f) Trolley travel rope 2 „long“:
Warning!
Risk of accident as a result of trolley not braking.
If the "long" trolley travel rope rips loose and the rope breakage safety device is not working, the
trolley could collide without braking against the cross member or the jib head section. This could
lead to serious injury of persons or significant damage to property.
X Fit the rope breakage safety device correctly and ensure proper functioning (see: Fig. 6-143)
X Remove the cotter pin (a), washer (b) and pin (c) and remove the safety catch retainer (d).
X Turn the lever (e) to the left into a horizontal position and retain in this position.
X Connect the safety catch retainer (d) and cable eye stiffener of the trolley travel rope (f) with a pin
(c). Secure the pin (c) with washer (b) and cotter pin (a).
X Ensure correct positioning and freedom-of-movement of the rope breakage safety device.
1250 HC 40 / 49516 6 - 177

Function: Rope breakage safety device
Fig. 6-143 Function: Rope breakage safety device

(a) Trolley travel rope not ripped loose: (b) Trolley travel rope ripped loose and rope safety
Rope breakage safety device not trig- breakage device triggered (trolley continues to the
gered. next cross member where it is halted).
6.8.15 Rope reeving trolley travel rope 1 „short“

Trolley travel rope 1 „short“: ø 16.0 / l = 97 m ID no. 1017 5479
Rope reeving on the jib heel piece
Fig. 6-144 Removing the cover for the rope guard

(a) Cover for rope guard (c) Locking washer
(b) Bolt (d) Washer
X Remove four bolts (b), each with a circlip (c) and washer (d).
X Remove the cover (a)
6 - 178 1250 HC 40 / 49516

Fig. 6-145 Rope reeving on the jib heel piece

(e) Cotter pin (f) Pin
X Remove the four cotter pins (e) and two pins (f). (1)
X Insert pin (f) and secure pin (f) with two cotter pins (e).
X Fit the cover (see: Fig. 6-144) for the rope guard.
1250 HC 40 / 49516 6 - 179

Rope end fitting on the trolley
Fig. 6-146 Rope end fitting "short" trolley travel rope and rope breakage safety device
(a) Cotter pin (c) Pin (e) Lever
(b) Washer (d) Safety catch retainer (f) Trolley travel rope 2 „short“:
Warning!
Risk of accident as a result of trolley not braking.
If the "long" trolley travel rope rips loose and the rope breakage safety device is not working, the
trolley could collide without braking against the cross member or the jib head section. This could
lead to serious injury of persons or significant damage to property.
X Fit the rope breakage safety device correctly and ensure proper functioning (see: Fig. 6-143)
X Remove the cotter pin (a), washer (b) and pin (c) and remove the safety catch retainer (d).
X Turn the lever (e) to the left into a horizontal position and retain in this position.
X Connect the safety catch retainer (d) and cable eye stiffener of the trolley travel rope (f) with a pin
(c). Secure the pin (c) with washer (b) and cotter pin (a).
X Ensure correct positioning and freedom-of-movement of the rope breakage safety device.
Function: Rope breakage safety device

For further information, see page: 6-178 ›Function: Rope breakage safety device‹.
6 - 180 1250 HC 40 / 49516

6.8.16 Applying tension to the trolley travel ropes
Fig. 6-147 Applying tension to the trolley travel ropes (Example)

(a) Mounting (e) Crank handle
(b) Tensioning device (f) Pressure screw
(c) Grip bolt (g) Nut
(d) Spring clip
Note
If the grip bolt (c) is stuck fast or can not be inserted, the tensioning device can be shifted vertically
(b) in the fixture (a).
X Adjust the tensioning device using the two pressure screws (f) in the fixture (a) until the tension-
ing device (b) is sitting correctly.
X Remove the spring clip (d) and the grip bolt (c). (1)
X To apply tension to the "long" trolley travel rope: Continue to actuate the crank handle (e) until
the "long" trolley travel rope is taut.
ª Tension is also applied to the „short“ trolley travel rope automatically.
X Insert the grip bolt (c) and secure the grip bolt (c) with a spring clip (d).
1250 HC 40 / 49516 6 - 181

The grip bolt (c) can not be inserted?
The boreholes of the fixture (a) and the tensioning device (b) do not align due to the hole-to-hole dis-
tance specified and an unfavourable elongation distance.
X To loosen the trolley travel rope or to relieve a little tension: Continue to actuate the crank handle
(e) until it becomes possible to insert the grip bolt (c).
6.8.17 Securing the trolley
Fig. 6-148 Securing the trolley against travelling (Example)

(a) Trolley (c) Pin
(b) Spring clip
X Manoeuvre the trolley to min. radius.

X Secure the trolley against travelling using two pins. Secure each pin with two spring clips.
6 - 182 1250 HC 40 / 49516

Mounting the hoist rope
6.9 Mounting the hoist rope
Warning!
Improper assembly of the hoist rope can lead to accidents.
X When working on the jib or on the tower: Wear a safety harness at all times and ensure that
the safety harness is properly secured.
Always close trapdoors following access.
Warning!
Improper assembly of the hoist rope can lead to accidents.
X Inspect the hoist rope for damage prior to commencing assembly. For further information, see:
the chapter Maintenance and Inspection ›Ropes, rope pulleys and rope end fittings‹.
X Always ensure correct coursing of the ropes and correct reeving.
1250 HC 40 / 49516 6 - 183

Fig. 6-149 Summary: Reeving the rope (2000 HC 60 - 65 m jib shown as an example)
(a) Hoist rope (d) Cylinder head screw (g) Rope deflection pulley, trolley
(b) Rope drum, hoist gear (e) Rope deflection pulley, (h) Rope deflection pulley, bottom
tower head hook block
6 - 184 1250 HC 40 / 49516

Fig. 6-149 Summary: Reeving the rope (2000 HC 60 - 65 m jib shown as an example)
(c) Rope clamp (f) Rope deflection pulley, (i) Twist compensator (fixed point,
slewing platform hoist rope)
Ensure that the following prerequisites have been guaranteed:

The hoist rope is secured on the outside of the rope storage drum with 5 rope clamps (c). Each rope
clamp (c) is secured with two cylinder head screws (d).
X Insert the power supply cable to the trolley travel gear.
6.9.1 Reeving the hoist rope in the tower head
Fig. 6-150 Reeving the hoist rope at the tower head

(a) Rope deflection pulley, tower head (c) Rope guard pin
(b) Hoist rope (d) Cotter pin
X Remove the two cotter pins (d) and two rope guard pins (d).
X Unwind the hoist rope (b) and reeve over the rope deflection pulley (a).
Caution!
Risk of accident as a result of incorrectly inserted rope guard pins.
Insertion of the rope guard pins can be implemented variably to suit different rope diameters.
X Insert the rope guard pins so that the distance from hoist rope to rope guard pin is kept to an
absolute minimum.
X Insert two rope guard pins (d) and secure with two cotter pins (d).
1250 HC 40 / 49516 6 - 185

6.9.2 Reeving the hoist rope in the jib heel piece
Fig. 6-151 Reeving the hoist rope at the slewing platform

(a) Hoist rope (d) Rope guard pin
(b) Cover for rope guard (e) Cotter pin
(c) Rope deflection pulley, jib heel piece

The trolley is secured with two pins against travelling, for further information see ›Securing the trol-
ley‹.
X Remove the two cotter pins (e) and one rope guard pin (d).
X Unwind the hoist rope (a) and reeve through the cover (b) via rope deflection pulley (c).
X Insert rope guard pin (d) and secure with two cotter pins (e).
6 - 186 1250 HC 40 / 49516

6.9.3 Reeving the hoist rope in the trolley
Fig. 6-152 Reeving the hoist rope in the trolley and bottom hook block (shown without jib)
(a) Rope deflection pulley, trolley (e) Cotter pin
(b) Hoist rope (f) Clamp piece
(c) Rope deflection pulley, bottom hook block (g) Bolt
(d) Rope guard pin (h) Trolley travel rope
X Remove two cotter pins (e) and one rope guard pin (d) from each of the rope deflection pulleys (d).
X Unwind the hoist rope (b) and reeve via six deflection pulleys (two rope deflection pulleys (a) for
each trolley and one rope deflection pulley (c) for each bottom hook block).
X Allow the hoist rope (b) to protrude approx. 1600 mm beyond the rope clamp (f) to ensure that the
wedge socket can be fitted.
X Fix the hoist rope (b) with clamp piece (f) and two bolts (g) .
X Insert one rope guard pin (d) to each of the four rope deflection pulleys (a). Secure each pin (d)
with two cotter pins (e).
1250 HC 40 / 49516 6 - 187

Fig. 6-153 Fitting the wedge socket

(i) Hoist rope (j) Wedge socket (k) Rope clamp
X Fitting the wedge socket (For further information, see page: 6-189 ›Fitting the wedge socket‹).
X Preparing the crane for 2-run or 4-run operation (for further information, see: the chapter
› Preparing the crane for 2-run or 4-run operation ‹)
6 - 188 1250 HC 40 / 49516

Fitting the wedge socket
Warning!
If the wedge socket is not fitted properly,
– the hoist rope could work itself loose.
– loads or crane parts are susceptible to falling.
X Select the applicable wedge socket for the respective rope diameter and fit properly in accord-
ance with size and configuration.
X Do not allow the wedge socket to become loaded on one side.
Ensure that the wedge socket, wedge and pin are checked prior to commencing assembly:
Do not use any parts which indicate cracks.
Only use original parts (without modifications).
Rectify any nicks or gouging on the wedge socket or pin by grinding until the surface are smooth
again (original dimensions may not be reduced by more than 10%).
Do not repair any damage by welding.
Wedge socket (configuration 1)
Fig. 6-154 Wedge socket (configuration 1)

(a) Wedge socket (d) Pin (g) Marking „permissible rope
(b) Cotter pin (e) Rope diameter“ (specifications in
mm)
(c) Wedge (f) Rope clamp
1250 HC 40 / 49516 6 - 189

Wedge socket (configuration 2)
Fig. 6-155 Wedge socket (configuration 2)

(h) Wedge socket (l) Cotter pin (p) Rope diameter too great
(i) Wedge (m) Rope clamp (q) Marking „permissible rope
(j) Pin (n) Rope diameter correct diameter“ (specifications in
mm)
(k) Rope (o) Rope diameter too small
Minimum length „L“ of rope end piece
Dimension „L“ (rope end piece)

Type of rope
at least minimum
6 to 8 chords standard ropes 6 x rope diameter 150 mm
Tab. 6-30 Minimum length „L“ of rope end piece
6 - 190 1250 HC 40 / 49516

Dimension „L“ (rope end piece)

Type of rope
at least minimum
Twist-free ropes 20 x rope diameter 150 mm
Tab. 6-30 Minimum length „L“ of rope end piece
6.9.4 Mounting the hoist rope at the twist compensator
Fig. 6-156 Mounting the hoist rope at the twist compensator

(a) Trolley (d) Twist compensator (f) Hinged pin
(b) Hoist rope (e) Pin (g) Washer
(c) Wedge socket
Caution!
The wedge socket on the hoist rope can be ripped out of its fixture.
X If the trolley is extended towards max. radius: Unwind the hoist rope without tension.
X Slowly extend the trolley (a) towards max. radius and at the same time unwind the hoist rope (b)
until the wedge socket (c) can be pinned with the twist compensator (d).
X Pin the wedge socket (c) and twist compensator (d) with pin (e). Secure the pin (e) with washer
(g) and hinged pin (f).
1250 HC 40 / 49516 6 - 191

Fig. 6-157 Releasing the rope clamp and securing in the operating position
(h) Bolt (i) Clamp piece, upper section (j) Clamp piece, lower section
X Release the clamp pieces (i, j), rotate around 90° and secure in the operating position with four
bolts (h).
X Retract the trolley towards min. radius and at the same time pull in the rope.
6 - 192 1250 HC 40 / 49516

Preparing crane for 4-fall / 2-fall operation
6.10 Preparing crane for 4-fall / 2-fall operation
Warning!
Risk of falling.
When working on the jib or on the tower:
Wear a safety harness at all times and ensure that the safety harness is properly secured.
Fig. 6-158 Prerequisites for preparation of 4-fall/2-fall operation

(a) Pin (b) Connecting strut (c) Locking device

The trolleys are connected with two connecting struts (b).
Trolleys are secured at min. radius and secured against travelling with two pins (a), for further infor-
mation, see ›Securing the trolley‹.
The bottom hook blocks are connected with the trolleys via four locking devices (c).
1250 HC 40 / 49516 6 - 193

6.10.1 4-fall operation
Fig. 6-159 Connect the bottom hook blocks with the assembly ropes and release the locking device
(a) Bottom hook block (c) Locking device
(b) Assembly rope (min. 5 m in length)
X Connect the bottom hook blocks (a) (to the rope guard sleeves) with the assembly rope (b) (min.
5 m in length) and secure. (1)
X Check hoist rope reeving and rope guard.
X Relieve tension in the bottom hook blocks by › hoisting upwards ‹ and release the four locking
devices (c). (2)
6 - 194 1250 HC 40 / 49516

Fig. 6-160 Lower the bottom hook blocks

(d) Bottom hook block 1 (f) Assembly rope (min. 5 m in length)
(e) Bottom hook block 2
X Lower the bottom hook blocks (d, e) by › hoisting downwards ‹. (3)

ª Bottom hook block 1 (d) is lowered by › hoisting downwards ‹. The second bottom hook block (e) is
pulled out of the trolley with the assembly rope (f).
1250 HC 40 / 49516 6 - 195

Fig. 6-161 Connecting the bottom hook blocks with the hooked lifting beam
(g) Bottom hook block (k) Bolt
(h) Hooked lifting beam (l) Washer
(i) Axle (m) Erection rope
(j) Axle support
X Lower both bottom hook blocks (g) completely. (4)

X Connect the two bottom hook blocks (g) using the two axles (i) to the hooked lifting beam (h). (5)
X Secure the two axles (i) with four axle supports (j). Secure each axle support (j) with two
washers (l) and two bolts (k). (6)
X Lift the hooked lifting beam (h) and remove the assembly rope (m).
6 - 196 1250 HC 40 / 49516

Fig. 6-162 Ensuring correct functioning of the load hooks

(n) Hook block
X Ensure correct functioning of the load hooks (n) (rotating, swinging, safety bow.
Fig. 6-163 Releasing the travel safety device on the trolley

(o) Trolley (q) Pin

(p) Spring clip
X Release the pin (q) of the travel safety device on the trolley (o) and secure with two spring
clips (p).
ª Both trolleys are connected with one another and can be manoeuvred freely.
1250 HC 40 / 49516 6 - 197

6.10.2 2-fall operation
Fig. 6-164 Loosening the locking device

(a) Bottom hook block 1 (c) Locking device
(b) Bottom hook block 2

X Relieve tension in bottom hook block 2 (b) by › hoisting upwards ‹ and release the two locking
devices (c). (1)
ª Bottom hook block 1 (a) remains locked.
6 - 198 1250 HC 40 / 49516

Fig. 6-165 Lowering the bottom hook block

(d) Bottom hook block 1 (e) Bottom hook block 2
X Lower the bottom hook block (d) by › hoisting downwards ‹. (2)

1250 HC 40 / 49516 6 - 199

Fig. 6-166 Connecting the bottom hook blocks with the load hook
(f) Bottom hook block (i) Axle support
(g) Hook block (j) Bolt
(h) Axle (k) Washer
X Lower the bottom hook block (f) completely. (4)

X Connect the bottom hook block (f) with the load hook (g) using the axle (h). (4)
X Secure the axle (h) with two axle supports (i). Secure each axle support (i) with two washers (k)
and two bolts (j). (5) LBC/en/01/Issued: 07.11
6 - 200 1250 HC 40 / 49516


(l) Hook block
X Ensure correct functioning of the load hook (l) (rotating, swinging, safety bow.
Fig. 6-168 Releasing the connecting strut on the trolley

(m) Connecting strut (p) Trolley 1
(n) Pin (q) Trolley 2
(o) Spring clip
X Remove the two spring clips (o) and two pins (n) on trolley 2 (q) and fold down the two connecting
struts (m) to the rear.
X Insert two pins (n). Secure each pin (n) with a spring clip (o).
ª Trolley 1 is secured against travelling - trolley 2 can be manoeuvred freely.
6.10.3 Converting from 4-fall to 2-fall operation / from 2-fall to 4-fall opera-
tion
For further information, see: the chapter Control and Operation › Converting from 4-fall to 2-fall operation /
from 2-fall to 4-fall operation ‹
1250 HC 40 / 49516 6 - 201

Installing the aircraft warning system and wind measuring system (optional)
6.11 Installing the aircraft warning system and wind

measuring system (optional)
Warning!
W
Danger of falling down while installing the aircraft-warning system and the anemometer.
X Always wear and use a safety harness when installing aircraft-warning system and anemometer.
6.11.1 Installing the aircraft-warning system
Fig. 6-169 Installing the aircraft warning system on the tower head
(a) Tower head (e) Washer (i) Bolt
(b) Aircraft-warning system (f) Lock washer (j) Washer

(c) Obstruction lights (g) Nut (k) Lock washer
(d) Bolt (h) Mounting (l) Nut
Depending on configuration of the crane (b) the aircraft warning system is installed:
– with pulse generator - flashing.
– in switching or continuous operation - continuously on.
X Bolt the mounting (h) and tower head (a) with two bolts (i) . Secure each bolt (i) with washer (j),
6 - 202 1250 HC 40 / 49516

retaining washer (k) and nut (l). (1)

X Bolt the obstruction beacon (c) and mounting (h) with two bolts (d). Secure each screw (d) with
washer (e), retaining washer (f) and nut (g). (2)
6.11.2 Dismantling the anemometer
Fig. 6-170 Installing the anemometer on the tower head

(a) Tower head (d) Anemometer (g) Lock washer
(b) Anemometer (e) Mounting (h) Nut
(c) Clamp bolt (f) Washer (i) Bolt
X Bolt the mounting (e) and tower head (a) with two bolts (i) . Secure each bolt (i) with washer (f),
retaining washer (g) and nut (h). (1)
X Attach the anemometer (d) to the mounting (e). (2)
X Fix the anemometer (d) with clamp bolt (c). (3)
1250 HC 40 / 49516 6 - 203

6.11.3 Setting the sensors (potentiometer)
Warning!
Incorrectly set sensors can impair functioning of the overload protection.
X Adjustment tasks are to be carried out by specialist personnel only.
X The crane may only be operated if the overload protection has been set correctly.
Note
The transmission ratio and the rotational direction of the sensor have been set at the factory.
X When replacing the sensor: Adopt the setting of the potentiometer on the old sensor and scale
the crane anew via EMS.
If unusual values are being displayed on the display, this may indicate incorrect setting of the sen-
sor.
X Check the setting on the sensor, if necessary readjust and scale the crane anew via EMS.
For further information regarding scaling, see: ›Operating instructions for the EMS‹.
Fig. 6-171 Key switch in switch cabinet S1

(a) Keypad „+H-KF10“ (b) Key switch for operating modes ›Release brake‹ in position
„Brake applied“

The key switch (b) for operating modes ›Release brake‹ is turned to position „Brake applied“.
6 - 204 1250 HC 40 / 49516

Hoist gear
The sensor (lowering depth sensor) on the hoist gear measures upward and downward movement of
the load hook and relays the measured values to the control. This data is evaluated by the control.
Setting the hoist gear sensor
Fig. 6-172 Setting the hoist gear sensor

(a) Potentiometer, hoist gear (c) Sensor, hoist gear (set rota- (e) Hoist gear
sensor tional direction ›right‹
(b) Screw plug (d) Rotational direction ›right‹
X Determining the rotational direction being set: Lift the load hook and observe the rotational direc-
tion of the rope drum.
Note:
Rotational direction ›right‹ corresponds with an anticlockwise rotation looking at the sensor.
Rotational direction ›left‹ corresponds with a clockwise direction looking at the sensor.
1250 HC 40 / 49516 6 - 205

Revolutions Rotational direction Switch position

220 right 1
300 right 2
220 left 5
300 left 6
Tab. 6-31 Switch allocation GP95-320
X Set the potentiometer using the values in the table (see: Tab. 6-31).
Trolley travel gear

The sensor on the trolley travel gear measures the forward and backward movement of the trolley and
relays the measured values to the control. This data is evaluated by the control.
Setting the trolley travel gear sensor
Fig. 6-173 Trolley travel gear sensor (Example)

(a) Potentiometer, trolley travel (c) Sensor, trolley travel gear (e) Sensor, trolley travel gear
gear sensor (set rotational direction ›left‹
(b) Screw plug (d) Rotational direction ›left‹ (f) Trolley travel gear
X Determining the rotational direction being set: Manoeuvre the trolley backward (towards the tow-
er) and observe the rotational direction of the rope drum.
6 - 206 1250 HC 40 / 49516

Note:
Rotational direction ›right‹ corresponds with an anticlockwise rotation looking at the sensor.
Rotational direction ›left‹ corresponds with a clockwise direction looking at the sensor.
Revolutions Rotational direction Switch position

50 right 1
75 right 2
150 right 3
50 left 5
75 left 6
150 left 7
Tab. 6-32 Switch allocation GP95-160
X Set the potentiometer using the values in the table (see: Tab. 6-32).
1250 HC 40 / 49516 6 - 207

6.11.4 Setting the overload protection system
Warning!
Improper setting of the overload protection system can cause the crane to topple.
The adjustment tasks may only be carried out by properly qualified personnel.
The crane may only be operated when the overload protection system has been correctly set.
The overload protection system must be activated when exceeding the permissible load.
Warning!
When carrying out adjustment tasks on the tower head, there is a danger of crushing and a danger
of being drawn into machinery when working around rope pulleys and ropes.
X Do not perform any tower crane movements until the person carrying out the adjustment tasks
gives a clear indication to do so.
Fig. 6-174 Key switch in switch cabinet S1

(a) Keypad „+H-KF10“ (d) Key switch for operating modes ›Assembly/
(b) Keypad „+A-KF10“ Working mode/Scaling‹ in position „Working
mode“
(c) Key switch for operating modes ›Release (e) Key switch for operating modes ›Teach/125% -
brake‹ in position „Brake applied“ Overload‹

The key switch (d) for operating modes ›Assembly/Working mode/Scaling‹ is turned to position
„Working mode“.
The key switch (c) for operating modes ›Release brake‹ is turned to position „Brake applied“.
6 - 208 1250 HC 40 / 49516

Fig. 6-175 Load moment sensor

(a) Adjusting screw (b) Sensor, overload protection
Setting the moment overload protection system

X For further information, see: chap. ›Technical data‹ and ›Manual for LITRONIC - Tower crane‹.
X Checking the overload protection setting.
Setting the constant overload protection

X Check the overload protection setting.
Monitoring of load motor speed

X Check the overload protection setting.
1250 HC 40 / 49516 6 - 209

6.11.5 Preparing for initial start-up

X If the slewing gear is mounted with fluid coupling: set the selector switch ›Erection / Operation‹ to
›Operation‹.
-or-
If the slewing gear is mounted with frequency converter: implement parameter entry at the ›Slew-
ing gear‹ frequency converter. For further information, see: Appendix.
X Check the oil level in the fluid couplings, correct as required. For further information, see: Chap.
›Maintenance and Inspection‹.
X Check the settings of hoist gear brake, travel gear brake and trolley travel gear brake, re-adjust as
required. For further information, see: Chap. ›Repair‹.
X Carry out the pre-start checks and start up the crane. For further information, see: Chap. ›Opera-
tion‹.
6 - 210 1250 HC 40 / 49516

Climbing the crane
6.12 Climbing the crane

The standard climbing equipment is prepared for installation. For further information, see: Chap.
›Installing the tower with climbing equipment‹.
X Climb the crane. For further information, see: Appendix. ›Top-climbing crane application‹.
1250 HC 40 / 49516 6 - 211

Climbing the crane
6 - 212 1250 HC 40 / 49516

7 Climbing the crane
For further information, see: Appendix Information booklet ‹Climbing the crane›
1250 HC 40 / 49516 7-1

Climbing the crane Instruction Manual
7-2 1250 HC 40 / 49516

Instruction Manual Operation
8 Operation
This chapter has been completed for the crane operator. The instructions detailed here will describe
how the crane can be operated safely and cost-effectively. First you will obtain information
concerning safety during operation of the crane. You will then obtain information concerning actual
operation of the crane. A summary of all operating elements and their utilisation has also been
provided. The operation section describes how the crane can be safely started up and shut down.
The final section includes details which will assist you in the event of any operational faults occurring.
1250 HC 40 / 49516 8-1

Operation Instruction Manual
Notes on operational safety
8.1 Notes on operational safety
8.1.1 Who is permitted to operate the crane?

The crane should be operated only by reliable persons who are at least 18 years old and who are
familiar with the crane and have been instructed as to the possible accident risks involved.
8.1.2 Under which conditions may the crane be operated?

Ensure that no obstacles are present within the working or travel area.
Ensure that all necessary protective measures to safeguard public transport have been undertaken
around the building site.
Operating the crane in windy conditions
Warning!
Risk of accidents as a result of excessive wind speeds
Should wind speeds exceed 20 m/s (72 km/h, wind force 8), there is a risk of the crane toppling.
Please note that unexpected wind speeds far exceeding 20 m⁄s could occur as a result of sudden
gusts.
X Discontinue crane operation immediately if wind speeds exceed 20 m/s (72 km/h, wind force 8).
X Discontinue crane operation immediately if gusts exceed 20 m/s (72 km/h, wind force 8).
Exception: -cranes in the LM 2 range
Warning!
Risk of accidents as a result of excessive wind speeds
Should wind speeds exceed 13.8 m/s (50 km/h, wind force 6) during crane operation with
-cranes in the LM 2 range, there is a risk of the crane toppling. Please note that un-
expected wind speeds far exceeding 13.8 m⁄s could occur as a result of sudden gusts.
X Discontinue crane operation immediately if wind speeds exceed 13.8 m/s (50 km/h, wind
force 6).
X Discontinue crane operation immediately if gusts exceed 13.8 m/s (50 km/h, wind force 6).
8.1.3 For the contractor:

The contractors are responsible for safe operation of the crane. Ensure that all necessary measures
have been taken to prevent danger.

Designation of persons who are authorised to operate the crane must be confirmed in writing.
Only experienced persons may be authorised to secure the loads.
All notes concerning safety and danger, as well as the operating instructions, must be on-hand in their
entirety and fully legible.
Ensure that the valid local guidelines for accident-prevention are understood and observed.
8-2 1250 HC 40 / 49516

Ensure that only authorised persons access the crane.

The crane must be inspected by specialists preceding initial start-up or following fundamental alter-
ations.
The crane may only be operated if all protective and safety devices are available and fully functional.
The safety devices (limit switches) may not be bridged or readjusted.
8.1.4 For the crane operator:

Operation of a crane demands an elevated sense of responsibility. Malpractice during the operation
of a crane can lead to serious injury. Yourself and other persons could suffer serious injury, or even
fatalities as a consequence.
Which requirements must be met before you are entitled to

operate the crane?
You must be over 18.
You have received instruction for operation of the crane and proven your proficiency to the building
contractor.
The contractor must have authorised you for operation of the crane in writing.
You must have read and fully understood the instruction manual, in particular the chapter concerning
notes on safety and operation.
You must have read and fully understood the valid local guidelines for accident-prevention.
X Carry out a visual inspection before each start-up for damage and faults. The crane may only be
operated when in a technically safe, sound condition.
ª Discernible damage and faults must be reported immediately to the person responsible.
ª Shut down and secure the crane immediately.
Before starting up the crane, make sure that the following conditions have been met:
All protective and safety devices are in place and fully functional.
All handles, handrails, platforms, landings and ladders on the crane are free from dirt, snow and
ice.
No persons are endangered in any way.
Wear your personal protective equipment:
– Safety helmet
– Safety boots.
– Safety harness (e.g. in case of power failure, for travelling the trolley).
1250 HC 40 / 49516 8-3

8.1.5 Operating instructions
Danger!
Negligence of the following operating instructions can cause immediate serious injury. Yourself and
other persons could suffer serious injury, or even fatalities. All liability claims become null and void
with improper operation of the crane.
Use of the crane to dislodge loads which are stuck fast is prohibited. (1)
X Lift free-standing loads only.
Swinging or pendulous movements of the load is prohibited. (2)
X Maintain a calm handling of the load.
Improper slinging of the load is prohibited. (3)
X Secure the load correctly. Only experienced persons should be authorised to secure the loads.
Horizontal displacement of not freely suspended loads is prohibited. (4)

X Lift the load first, then move it horizontally.
Exceeding the crane's permissible lifting capacity is prohibited. (5)
X The overload protection devices must not be used to switch off the hoist gear or trolley travel gear.
X Do not use the crane as scales.
X The overload protection in the hoist gear may not be rendered obsolete by adding weights.
8-4 1250 HC 40 / 49516

X Select the load in accordance with the lifting capacity diagram.

Allowing the hook to rest on the load or on the ground is prohibited. (6)
X Keep the hoist rope taut. Avoid slack rope.
Increasing a suspended load is prohibited. (7)
Diagonal pull is prohibited. (8)
X Before lifting the load: The trolley must always be positioned vertically or centrally above the load.
The carriage of persons with the load is prohibited. (9)
Moving a load without visual contact/signalman is prohibited. (10)

X Always maintain visual contact with the load, or organise the aid of a signalman. Ensure a clear
understanding with the signalman.
Leaving the control stand whenever a load is suspended from the hook is prohibited. (11)
X Always supervise the control stand when a load is suspended.
Operation of the crane in poor visibility is prohibited. (12)
X Visibility must be sufficient to view the entire working area.
Installing advertisement boards, making changes, installing or modifying anything without

permission from the manufacturer is prohibited. (13)
Welding work on loads suspended from the hook without suitably insulated lifting slings is
prohibited. (14)
1250 HC 40 / 49516 8-5

Abrupt drop of the load is prohibited without first obtaining the manufacturer's authorisation.
(15)
When travelling with the crane, it is prohibited to manoeuvre the trolley, to lift and lower the
load or to slew the crane. (16)
8.1.6 Safe distance to obstacles in the immediate vicinity
Warning!
Danger of crushing from moving crane parts.
The safe distance between moving crane parts (e.g. rail-going crane base) and obstacles in the im-
mediate vicinity must be at least 0,5 m.
X If it is not possible to maintain the safe distance, cordon off the danger area.
Fig. 8-1 Safe distance to obstacles in the immediate vicinity

8-6 1250 HC 40 / 49516

8.1.7 Safe distance between tower cranes
Fig. 8-2 Safe distance between cranes at least 2 m and electronic operating-range limiting system
(a) Electronic operating-range limiting system (ABB) (b) Obstacle (e. g. building)
8.1.8 Safe distance to overhead electric lines
Danger!
Contact with overhead electric lines can lead to fatal injury of the crane operator and persons in the
immediate vicinity of the crane.
X Maintain a safe distance from live overhead electric lines in accordance with DIN 57105 /
VDE 0105. Ask the power supply company to inform you of the voltage level.
X If it is not possible to maintain the safe distances, the overhead electric lines must be de-ener-
gized. This condition must be guaranteed for the duration of the work being carried out.
1250 HC 40 / 49516 8-7

Fig. 8-3 Maintain distance to live overhead electric lines
Nominal voltage Minimum distance

up to 1kV 1m
more than 1 kV up to 110 kV 3m
if nominal voltage is not known 5m
Tab. 8-1 Minimum distances to live overhead electric lines
8.1.9 Measures to be taken if contact is made with live

overhead electric lines
Fig. 8-4 Contact with live overhead electric lines
X Do not leave the tower crane.

X Do not touch the steel construction.
X If possible, move the crane out of the hazard zone.
X Warn others against approaching and touching the crane.
8-8 1250 HC 40 / 49516

X Arrange to have the power switched off in the contacted/damaged line.

X Do not leave the tower crane until the contacted/damaged line has been safely de-energized.
8.1.10 Weathervaning
Warning!
Toppling of the crane.
If the jib does not slew in the direction of the wind, the crane could topple.
The slewing brake must be released after switching off the crane.
The crane must be able to slew freely in the direction of the wind.
X Before shutting down: Set the crane to weathervaning. For further information see chapter:
›Shutting down and stopping the crane‹.
Fig. 8-5 Crane slews in the direction of the wind

1250 HC 40 / 49516 8-9

8.1.11 Safety plates
Warning!
Avoid incomplete or illegible safety plates, in order that persons may be forewarned against possible
dangers. Serious accidents could be resulted.
X Check that the safety plates are complete.
X Ensure that the safety plates are in a legible condition at all times.
X Replace any missing or illegible plates.
Fig. 8-6 Safety plates (example 2000 HC)

(a) Danger resulting from electrical energy (d) Note
(b) Danger of falling! Wear a safety harness (e) Accident prevention Prohibition
plate A
(c) Accident prevention Prohibition plate B
8 - 10 1250 HC 40 / 49516
Fig. 8-7 Safety signs on the switching station (example 2000 HC)
(f) Danger of falling! Wear a safety harness (g) Electrical voltage
1250 HC 40 / 49516 8 - 11
8.1.12 Information plates
Fig. 8-8 Information plates

(a) Sign, noise level [dbA] (c) Load capacity plate, rear side
(b) Load capacity plate, front side (d) Type identification plate
X Check that the information plates are complete.

X Replace any missing or illegible plates.
8 - 12 1250 HC 40 / 49516
Control and operating elements
8.2 Control and operating elements
8.2.1 A summary of all operating elements
Fig. 8-9 A summary of operating elements

(a) EMS-display (optional) (c) Radio remote-control desk (optional)
(b) Control stand in cab (d) ›Electrical free jib slewing‹ control box
1250 HC 40 / 49516 8 - 13
8.2.2 Radio remote-control desk (optional)
Fig. 8-10 Radio remote control desk

(a) Control lever ›Slewing gear/ (f) Push-button ›Control On‹ (k) Locking switch ›Emer-
Trolley travel gear‹ gency Stop‹
(b) EMS-display (optional) (g) Lamp ›Battery charging sta- (l) No function
tus‹
(c) ›Hoist gear / Travel gear (h) Selector switch ›Radio (m) Push-button ›Lighting of
control lever‹ remote control On/Off‹ display‹
(d) Push-button ›Positioning‹ (i) Selector switch ›Radio fre- (n) Push-button ›Control Off‹
quency‹
(e) Push-button ›Horn‹ (j) No function (o) ›Apply slewing gear brake
pushbutton‹
Functions on the radio remote control desk
Function Actuations on the control desk

Switching on the control circuits X Press pushbutton (f).
again ª All crane movements can be performed immediate-
ly.
The control was previously switched off
by pressing the ›Control Off‹ push-but-
ton.
Switching on the control circuits X Switch on the main switch.
The control was previously switched off X Press push-button (f).

via the main switch. ª All crane movements can be performed after 30 sec-
onds.
Switching off the control circuits X Press push-button (n).
ª All brakes are applied except for the slewing brake.
Switching off the control circuits in X Press the ›Emergency-Stop‹ locking switch (k).
the event of an emergency ª All brakes are applied.
Tab. 8-2 Radio remote-control desk functions
8 - 14 1250 HC 40 / 49516

Switching on the control circuits X Release the ›Emergency-Stop‹ locking switch (k) by
again following the event of an emer- turning.
gency
X Press push-button (f).
Activating the deadman control X Release the control levers.
Inductive deadman control on the con-
trol levers.
Applying the slewing brake X Press push-button (o).
ª The slewing brake is applied.
The brake is only designed to hold the
jib in the desired position, in particular
against the wind. The slewing move-
ment is stopped by applying counter-
current.
Releasing the slewing brake X Move the control lever (a).
Tab. 8-2 Radio remote-control desk functions
1250 HC 40 / 49516 8 - 15
8.2.3 Control stand in the cabin (optional)
Control desk
Fig. 8-11 Control desk in the cabin - control panel on the left and on the right
(a) Push-button ›Windscreen (h) Push-button ›Horn‹ (o) Push-button ›Positioning‹
washer‹
(b) Push-button ›Horn‹ (i) Push-button ›Control Off‹ (p) Control lever ›Slewing gear/
Trolley travel gear‹
(c) ›Switch over to load curve (j) Control knob ›Thermostat‹ (q) ›Hoist gear / Travel gear
LM2‹ pushbutton control lever‹
(d) Pushbutton 1st gear (k) Lamp ›Frequency con- (r) Selector switch ›Heating/
verter ready for operation‹ Ventilation‹
(e) Pushbutton 3rd gear (l) Push-button ›Cabin lighting‹ (s) Locking switch ›Emergency
Stop‹
(f) Pushbutton 3rd gear (m) Without function (t) Selector switch ›Wind-
screen wiper‹
(g) Push-button ›Control On‹ (n) Push-button ›Applying the
slewing brake‹
8 - 16 1250 HC 40 / 49516
Functions of the control desk in the cab

Switching on the control circuits X Press pushbutton (g).
again ª The pushbutton lights up.
ª All crane movements can be performed immediate-
ly.
by pressing the ›Control Off‹ push-but-
ton.
Switching on the control circuits X Switch on the main switch.
The control was previously switched off X Press pushbutton (g).
via the main switch. ª The pushbutton lights up.
ª All crane movements can be performed after 30 sec-
onds.
ª Lamp (k) lights up.
Switching off the control circuits X Press the pushbutton (i).
ª The push-button goes out.
Switching off the control circuits in X Press the ›Emergency-Stop‹ locking switch (s).
the event of an emergency ª All brakes are applied.
Switching on the control circuits X Release the ›Emergency-Stop‹ locking switch (s).
again following the event of an emer-
X Press pushbutton (g).
gency
ª The pushbutton lights up.
ª All crane movements can be performed after 30 sec-
onds.
ª Lamp (k) lights up.
Activating the deadman control X Release control lever (p) or (q)
Inductive deadman control on the con-
trol levers.
Applying the slewing brake X Press the key (n).
The brake is only designed to hold the
jib in the desired position, in particular
against the wind. The slewing move-
ment is stopped by applying counter-
current.
Releasing the slewing brake X Deflect control lever (p) or (q) .
ª Slewing gear brake is released.
Tab. 8-3 Functions on the control desk in the cabin
1250 HC 40 / 49516 8 - 17
Operating the crane operator's seat
Fig. 8-12 Crane operator's seat

(a) Adjusting height of the seat (g) Air intake for ventilation (m) Adjustable head rest
(b) Adjustment of seat height (h) Terminal box with 230 V (n) Armrest
and seat inclination plug socket
(c) Seat rotation in exiting posi- (i) Armrest height adjustment (o) Longitudinal adjustment for
tion armrest
(d) Adjustment of seat inclina- (j) Back rest inclination (p) Longitudinal adjustment of
tion seat
(e) Adjustment of seat length (k) Adjustment for lumbar sup- (q) Heater
via control desk port
(f) Side desks inclination (l) Inclination adjustment for
adjustment armrest
8 - 18 1250 HC 40 / 49516
Operating heating and ventilation
Fig. 8-13 Heating and ventilation

(a) Control insert (d) Ventilator stage 1 (g) Selector switch Heating/
Ventilation
(b) Selector switch (e) Heating output 2 kW (h) Temperature regulator
(c) Ventilator stage 2 (f) Heating output 4 kW (i) Lever, Fresh air / Recircu-
lated air flap
The heating times can be set individually for each day of the week. Duration of the shortest switching
unit is 13/4 h.
Activating the heating automatically

X Set the ›Heating/Ventilation‹ selector switch (g) to 0 ›Heating‹.
X Position the control insert (a) of the timer to the respective time period.
X Set the selector switch (b) to ›Automatic‹ (central switch position).
X Select the room temperature via the temperature regulator (h).
ª The heating is automatically switched on if the room temperature drops below the set value.
Heating completely switched off

X Set the ›Heating/Ventilation‹ selector switch (g) to 0.
- or -
Set the selector switch (b) on the timer to ›completely off‹ (switch down).
Operating the heating without timer (as required)

X Set the selector switch (b) on the timer to ›continuously on‹ (switch up).
X Use the ›Heating/Ventilation‹ selector switch (g) to select the heating output (stage I: 2 kW; stage
II: 4 kW).
X Select the room temperature via the temperature regulator.
ª The heating is automatically switched on if the room temperature drops below the set value.
1250 HC 40 / 49516 8 - 19
Activating the ventilation

X Set the ›Heating/Ventilation‹ selector switch (g) to ventilation stage I or II.
X To obtain fresh air: Position the lever (i) for the flap for fresh air and air admission downwards.
X To obtain air admission: Position the lever (i) for the flap for fresh air and air admission upwards.
EMS-display in the cab (optional)

For further information, see: Operating manual Electronic monitoring system EMS.
Fig. 8-14 EMS-display in the cabin

(a) Date display (e) Wind display (i) Bright/dark control for LCD-
display
(b) Diagnostic message (f) Mask display (j) Cursor control
(c) Time display (g) Display masks selection (k) Display Hook block reeving
keys
(d) LCD-display (h) Function keys
8 - 20 1250 HC 40 / 49516
8.2.4 Electrical free jib slewing / Emergency-Stop control box
Fig. 8-15 Electrical free jib slewing / Emergency-Stop control box

(a) ›Free jib slewing pushbut- (b) ›Free jib slewing lamp‹ (c) ›Emergency-Stop‹ locking
ton‹ switch
Functions on the Electrical free jib slewing / Emergency-Stop control box
Function Actuations on the control box

Activating free jib slewing X Hold pushbutton (a) pressed until the lamp lights up.
ª The slewing brake is locked in the released position.
by pressing the ›Control Off‹ push-but- X Press the ›Emergency Stop‹ locking switch.
ton.
Deactivating free jib slewing X Press the ›Control On‹ push-button on the radio re-
mote control or on the control stand in the cabin.
ª The locking of the slewing brake is released.
Tab. 8-4 Functions of the Electrical free jib slewing control box
1250 HC 40 / 49516 8 - 21
Air-conditioning unit (not featured as standard)
Operating elements:
1. The thermostat features a temperature range
(2)
of 18.5 °C in the cooling position (1) and up to
32.5 °C in the heating position (2). The
thermostat controls the ON/OFF sequence of
the compressor unit in cooling operation.
(1)
(3)
2. The selector switch (3) controls the blower
speed of the unit, heating and cooling
operation and the operating mode of the
blower.
Cooling operation:
1. Set the thermostat (10.B.1) in the position which corresponds with your comfort
requirement.
2. Set the selector switch (10.B.2):
a.: Max. cooling (switch position 3) = Greatest degree of cooling and dehumidifying
b.: Medium cooling (switch position 2) = Average degree of cooling and dehumidifying
c.: Min. cooling (switch position 1) = Minimum degree of cooling and dehumidifying
(night-time operation)
During cooling
Room temperature
Cooling Blower on
on
For circulation
Room temperature
During cooling
Cooling Blower on
off
The compressor of the air-conditioning unit switches itself on or off in correlation with the
required degree of cooling, ensuring that the desired temperature level set at the
thermostat is maintained.
Comment: The blower of the air-conditioning unit runs continuously to circulate air within
the cab and to maintain a constant temperature. It does not switch itself on and off in
correlation with the compressor.
8 - 22 1250 HC 40 / 49516
Blower operation:
Blower
If you would like to circulate air
within the cab without using the
heater, select one of the three (1) (1)
blower speeds.
The blower then runs continuously
as prescribed and circulates air Blower
on
within the cab.
Heater operation:
1. Set the selector switch to the "Slow heating operation" position (2).
- Blower and fan heater run continuously at slow speed.
Heater
operation
Room temperature Heating
on
(2)
Blower
on
Room temperature Heating

Heater off
operation
(2)
Blower
on
Comment:
- The electrical fan heater can not substitute the heater in the cab in cold weather. It
has only been provided for the purpose of preheating air on cold days or early
mornings.
- In the event that the available fan heater has not yet been installed, and is selected
only later, the blower runs in "Slow" operation.
1250 HC 40 / 49516 8 - 23
Switching off:
Set the selector switch to the 0 position.
Switch off
Comment:
When the air-conditioning unit is switched on and a cooling requirement has been
selected for the thermostat, the blower and compressor are started simultaneously.
Following manual shutdown of the air-conditioning unit, either with the selector switch or
via the thermostat, always wait at least 2-3 minutes before switching the air-conditioning
unit back on again. This will enable the cooling pressure to stabilise in the air-
conditioning unit, and the compressor can be switched back on again
Cooling on
2 minutes
Cooling Cooling
on off
Cooling on
3 minutes
8 - 24 1250 HC 40 / 49516
Operation
8.2.5 Slewing
Note
– The further the control lever is deflected from the neutral position, the quicker the crane will ro-
tate. When the control lever is moved towards the neutral position, the drive unit is slowed down.
Use the slowest speed in order to reach the exact stopping position.
– The influences from wind and load will be compensated by the control system.
– The control system prevents the crane from vibrating and the load from swinging.
Fig. 8-16 Slewing

(a) Push-button ›Applying the slewing brake‹ (c) Control lever ›Slewing gear/Trolley travel gear‹
(b) Radio remote control desk (d) Control desk in the cabin
Slewing movement to the right

X Move the control lever (c) to the right. (1)
X Just before reaching the stopping position: Move the control lever (c) to the slowest speed step.
X In this step, continue slewing the crane until the slewing movement is stopped. Then return the
control lever (c) to the "NEUTRAL" position. (2)
ª The slewing brake is applied after approx. 20 seconds.

The slewing movement can be stopped faster by applying counter-current (by moving the control le-
ver sensitively through the "NEUTRAL" position to the opposite direction to reverse the slew. motors).
Slewing movement to the left

X Move the control lever (c) to the left. (3)
X For further information see: Slewing movement to the right
1250 HC 40 / 49516 8 - 25
Holding the jib in position, in particular against the wind

The slewing movement must be stopped.
The control lever (c) must be returned to the "NEUTRAL" position.
X Press the push-button (a). (4)
ª The slewing brake is applied immediately.
8.2.6 Manoeuvring the trolley
Note
The further the control lever is deflected from the neutral position, the quicker the trolley is moved.
By returning the control lever towards the "NEUTRAL" position, the drive unit is slowed down auto-
matically. Thus, applying counter-current is not required.
Fig. 8-17
(a) Radio remote control desk (b) Control lever ›Slewing gear/ (c) Control desk in the cabin
Trolley travel gear‹
Trolleying-out
X Move the control lever (b) forward. (1)
Stopping the trolley

X Return the control lever (b) to the "NEUTRAL" position. (2)

ª The trolley travel gear brake is applied.
Trolleying-in
X Move the control lever (b) backward. (3)
8 - 26 1250 HC 40 / 49516
8.2.7 Lifting and lowering the hook
Note
The further the control lever is deflected from the neutral position, the quicker the load hook is lifted or low-
ered. The speed can be reduced by pressing the push-button (a) on the control lever to 1/4. The load can
thus be lifted and lowered with considerably more precision. Use this possibility when positioning the load.
As long as the push-button (a) remains pressed, the hoist gear brake remains released. Even when the
control lever is in the neutral position.
Fig. 8-18 Lifting and lowering the hook

(a) Radio remote control desk (c) Control lever ›Hoist gear‹ (d) Control desk in the cabin
(b) Push-button ›Positioning‹
Lifting the hook

X Move the control lever (c) backward. (1)
Stopping the hook

X Return the control lever (c) to the "NEUTRAL" position. (2)
ª The hoist gear brake is applied.
Lowering the hook

X Move the control lever (c) forward. (3)
Reducing the speed to 1/4

X Press the push-button (a) on the control lever (c) and hold pressed.
Caution!
If the push-button (a) is released when the control lever is in a deflected position, the speed is in-
creased instantaneously. This reduces the working life of the drive units.
X Before releasing the push-button: Return the control lever to the "NEUTRAL" ("ZERO") position.
1250 HC 40 / 49516 8 - 27
8.2.8 Travelling with the crane
Danger!
Lifting and lowering of the load, as well as slewing during crane travelling, can cause the crane to
tip with certain crane configurations. For further information see: ›Corner pressures, foundation
loadings and ballast data‹.
If in doubt, refrain from lifting and lowering of the load, as well as slewing during crane travelling.
Fig. 8-19 Crane travelling

(a) Radio remote control desk (b) Control lever ›Hoist gear‹ (c) Control desk in the cabin
Travelling the crane forwards

X Move the control lever (b) to the right. (1)
Stopping the crane

X Move the control lever (b) sensitively through the "NEUTRAL" to the opposite direction (applying
counter-current). (2)
- or -
Return the control lever (b) to the "NEUTRAL" position.
ª The crane comes slowly to a standstill.
Travelling the crane backwards

X Move the control lever (b) to the left. (3)
The brake of the travel gear is applied automatically after a short time. It serves as a holding brake
only.
8 - 28 1250 HC 40 / 49516
Operation
8.3 Operation
8.3.1 Pre-start checks

The protective measures against dangerous electrical shocks have been undertaken.
The maintenance and inspection tasks in accordance with the maintenance and inspection chart
have been carried out.
Switchgears (switch cabinets) are dry and are free of condensation.
The nominal voltage is available at the site junction box.
Central ballast and counter-ballast are complete.
If the slewing gear is mounted with fluid coupling, the selector switch ›Erection / Operation‹
in switchgear cabinet S1 must be set to ›Operation‹.
If the slewing gear is mounted with frequency converter, parameter entry must be implemen-
ted. For further information, see: Appendix for parameter entry at the ›Slewing gear‹ frequency
converter.
All safe distances are maintained.
The slewing area is free of obstacles.
The travel lane is free of obstacles.
Checking the bolt connections

All bolt connections are correctly tightened. In particular on the ball slewing ring and on the tower
connections. For further information see: Appendix Information booklet, Prestressed high-tensile
bolt connections.
Checking the ropes and rope pulleys

All ropes are correctly reeved.
All ropes are running correctly in the rope pulleys.
All ropes are well-greased.
The rope pulley grooves are free from hardened grease.
The ropes are undamaged.
All ropes are evenly wound onto their rope drums.
1250 HC 40 / 49516 8 - 29
Operation
8.3.2 Starting up the crane
Fig. 8-20 Starting up the crane

(a) Radio remote control desk (d) Isolating switch, slipring assembly
(b) Control desk in the cabin (e) Site junction box
(c) Main switch (f) Rail clamp

The pre-start checks are carried out.
The ›Emergency Stop‹ locking switches have been released.
X In case of rail-going crane: Release the rail clamps (f). (1)
Caution!
Moisture or condensation in the switchgears can cause damage to the assemblies of the electrical
equipment.
X Avoid moisture or condensation in switchgears (switch cabinets).
X Before switching on the voltage for the first time, or following long periods out of opera-
tion or in storage: inspect the switch cabinets for the presence of moisture or condensation.
X If moisture is found to be present in the switchgears (switch cabinets), this must be removed be-
fore starting up the crane (e.g. by preheating).
X Connect the main power supply: (2).

Set the isolating switch (d) on the slipring assembly to the 1 position.
- or -
8 - 30 1250 HC 40 / 49516
Operation
Connect the main power supply cable at the site junction box (e). (2)
X Turn the main switch (c) to 1 ›Operation On‹. (3)
X Switch on the crane control circuits on the radio remote control desk (a) -or- on the control desk
(b). (4)
Checking drive units and brakes for correct operation
Warning!
Faulty drive units and brakes can lead to serious accidents.
Should any malfunctions be detected during the functional inspection, the crane should not be op-
erated under any circumstances. The malfunction must be reported without delay to the person in
charge.
X Carry out functional checks every day.
Checking the hoist gear
Fig. 8-21 Functional check of the hoist gear
X Move the ›Hoist gear‹ control lever forward and backward.

ª The hoist gear brake is released.
ª The hook is lowered or raised.
X Return the control lever to the "NEUTRAL" ("ZERO") position.
ª The hoist speed is reduced.
ª The hoisting movement is stopped.
The load must be held in this position.
Note
During crane operation, the hoist gear brake air gap is supervised. If the air gap exceeds a specified
value, the lamp ›Checking the hoist gear brake‹ on the control desk in the cabin lights up. In addition,
the horn sounds when the hook is lowered. The crane can be operated for the moment.
X Inform the responsible person in charge.
1250 HC 40 / 49516 8 - 31
Operation
Checking the trolley travel gear
Fig. 8-22 Functional check of the trolley travel gear
X Move the ›Slewing gear/Trolley travel gear‹ control lever forward and backward.
ª The trolley travel gear brake is released.
ª The trolley moves forward or backward.
ª The trolley speed is reduced.
ª The trolley stops.
Checking the slewing gear
Fig. 8-23 Functional check of the slewing gear
X Move the ›Slewing gear/Trolley travel gear‹ control lever to the left and to the right.
ª The slewing brake is released.
ª The jib rotates into the determined direction.
ª The slewing speed is reduced.
ª The slewing movement is stopped.
Even with stormy wind (wind force 8), the jib must be held in this position.
8 - 32 1250 HC 40 / 49516
Operation
Checking the crane travel gear
Fig. 8-24 Functional check of the crane travel gear
X Move the ›Hoist gear‹ control lever to the right and to the left.
ª The travel gear brake is released.
ª The crane moves into the determined direction.
ª The crane travel speed is reduced.
ª The travel gear brake is applied.
ª The crane stops.
1250 HC 40 / 49516 8 - 33
Operation
8.3.3 Shutting down the crane
Bringing the crane into the basic position
Fig. 8-25 Bringing the crane into the basic position
X Set down and remove any suspended load. (1)

X Raise the hook block to the maximum hoisting height. (2)
X Trolley-in to the minimum radius. (3)
X Ensure that the crane has complete freedom of movement when shut down and that all safe dis-
tances are maintained. (4)
Free jib slewing
Warning!
If the jib can not rotate in the wind, the crane could tip.
X Before shutting down: Activating free jib slewing.
Fig. 8-26 Free jib slewing
8 - 34 1250 HC 40 / 49516
Operation
Shutting down and stopping the crane with radio remote control operation
Fig. 8-27 Shutting down and stopping the crane with radio remote control operation
(a) Radio remote-control (d) ›Electrical free jib slewing / Emergency-Stop‹ control
box at the tower base
(b) Locking switch ›Emergency Stop‹ (e) Locking switch ›Emergency Stop‹
(c) ›Free jib slewing active‹ lamp

Both control levers are at "NEUTRAL" ("ZERO") position.
All ›Emergency Stop‹ locking switches have been released.
X Switch off the control circuits. (1)
X Activating the "free jib slewing": Press the ›free jib slewing‹ pushbutton and hold pressed until the
lamp (c) lights up. (2)
ª The slewing brake is locked in the ›released‹ position.
X Press the ›Emergency-Stop‹ locking switch (e)and turn the main switch in switchgear cabinet S1
to 0 ›Operation Off‹. (3)
The following equipment remain in operation:
– Aircraft-warning system
– Cabin heating
– Switchgear cabinet heating
– Crane lighting
1250 HC 40 / 49516 8 - 35
Operation
Shutting down and stopping the crane with cabin control stand operation
Fig. 8-28 Shutting down and stopping the crane with cabin control stand operation
(a) Locking switch ›Emergency Stop‹ (d) Locking switch ›Emergency
Stop‹
(b) ›Free jib active‹ lamp (e) Main switch on switchgear cabi-
(c) ›Free jib slewing / Emergency-Stop‹ control box in the net S1
slewing platform

Both control levers are at "NEUTRAL" ("ZERO") position.
All ›Emergency Stop‹ locking switches have been released.
X Switch off the control circuits. (1)
X Activating free jib slewing: Press the ›free jib slewing‹ pushbutton and hold pressed until the lamp
(b) lights up. (2)
ª The slewing brake is locked in the ›released‹ position.
X Press the ›Emergency Stop‹ locking switch (d) and turn the main switch (e) in switchgear cabinet
S1 to 0 ›Operation Off‹. (3)
The following equipment remain in operation:
– Cabin heating
– Crane lighting
8 - 36 1250 HC 40 / 49516
Operation
Actuating the free jib slewing manually
Fig. 8-29 Activating and deactivating the free jib slewing manually
(a) Rubber plug (d) Manual operation ›Brake released‹
(b) Manual operation ›Brake applied‹ (e) Hand-operated brake release lever
(c) Rubber plug (f) Locking ›Brake released‹
In the event of power failure: Activating the free jib slewing manually at all six slewing gears
X Remove the rubber plug (c).
X Push the hand-operated brake release lever (e) upwards to the stop and hold in this position.
X Press the ›Release brake‹ (d) manual actuation as far as the stop and hold pressed.
ª The locking ›Brake released‹ (f) is pushed under the hand-operated brake release lever.
X Release the hand-operated brake release lever.
X Release the ›Brake released‹ (d) manual actuation
ª The brake remains locked in the released position.
X Reinstall the rubber plug (c).
In the event of power failure: Deactivating the free jib slewing manually at all six slewing gears
If power supply is available, free jib slewing is deactivated automatically as soon as the control is ac-
tivated and the ›Slewing gear‹ control lever is operated.
Manual deactivation is only necessary in the event of a power failure:
X Remove the rubber plug (a).
X Push the hand-operated brake release lever (e) upwards to the stop and hold in this position.
1250 HC 40 / 49516 8 - 37
Operation
X Press the ›Brake applied‹ (b) manual actuation as far as the stop.
X Release the hand-operated brake release lever.
ª The brake is applied.
X Reinstall the rubber plug (a).
Securing the crane
Fig. 8-30 Securing the crane

(a) Isolating switch (b) Site junction box (c) Rail clamp
X In case of travelling crane, apply the rail clamps (c). (1)

X Disconnect the main power supply: (2).
Disconnect the main power supply cable at the site junction box (b).
- or -
Set the isolating switch (a) on the slipring assembly to the 0 position.
After the main power supply cable has been disconnected, the following equipment are switched off:
– Cabin heating
– Crane lighting
Secure the crane against unauthorised reconnection.

X Lock the site junction box or the isolating switch.
X Lock the cabin.
8 - 38 1250 HC 40 / 49516
Operation
8.3.4 Setting down the load in the event of power failure
Fig. 8-31 Releasing the hoist gear brake in the event of power failure
(a) Lever (b) Seat valve (c) Hydraulic aggregate
In the event of power failure, the hoist gear brake is applied automatically. In order that the load can
be set down, the brake on the hydraulic aggregate (c) must be released manually.
X Insert the lever (a) into the guide. (1)
X Press the seat valve (b) and hold pressed. (2)
X Continue to pump steadily using the lever (a) . (3)
ª The brake is released and the load is lowered.
X After setting down the load: Release the seat valve (b). (4)
ª The brake is applied.
1250 HC 40 / 49516 8 - 39
4-fall / 2-fall operation
8.4 4-fall / 2-fall operation
Warning!
Danger of falling.
When working on the jib or on the tower:
Wear a safety harness at all times and ensure that the safety harness is properly secured.
8.4.1 Converting from 4-fall to 2-fall operation
Fig. 8-32 Securing the trolley against travelling

(a) Trolley (c) Pin
(b) Spring clip
X Manoeuvre the trolley to min. radius.

X Secure the trolley against travelling using two pins. Secure each pin with two spring clips.
ª Trolley 1 is connected with trolley 2 - Trolleys 1 and 2 are secured against travelling.
8 - 40 1250 HC 40 / 49516
Fig. 8-33 Setting down the hooked lifting beam

(d) Hooked lifting beam (h) Axle support
(e) Hook block (i) Bolt
(f) Bottom hook block (j) Washer
(g) Axle (k) Erection rope
X Lower the hooked lifting beam (d) by › hoisting downwards ‹. (1)
Warning!
Danger of crushing as a result of the hooked lifting beam tipping.
If the load hook has not been swung completely into the hooked lifting beam, the hooked lifting beam
could tip.
X It must therefore be ensured that the load hook has been completely swung in and that the
hooked lifting beam is sitting safely on the ground.
X Lower the hooked lifting beam (d) completely and swing in the load hook (e). (2)
1250 HC 40 / 49516 8 - 41
Caution!
Risk of accident if the bottom hook blocks are not connected.
If the bottom hook blocks are not connected via an assembly rope, the bottom hook block may get
pulled in and collide wildly with the trolley.
X Connect the bottom hook blocks with the assembly rope.
ª Bottom hook block 2 is also pulled up with the assembly rope as lifting is initiated.
X Connect the bottom hook blocks (f) (to the rope guard sleeves) with the assembly rope (k) (min.
X Remove the eight bolts (i), eight washers (j) and four axle supports (h). (4)
X Remove the two axles (g). (5)
Fig. 8-34 Connecting the bottom hook block with the load hook
(l) Bottom hook block 1 (p) Axle support
(m) Bottom hook block 2 (q) Bolt
(n) Hook block (r) Washer

(o) Axle (s)
X Connect bottom hook block 2 (m) with the load hook (n) via the axle (o). (6)
X Secure the axle (o) with two axle supports (p). Secure each axle support (p) with two washers (r)
and two bolts (q). (7)
X Lift bottom hook blocks 1 (l) and 2 (m) (8)
8 - 42 1250 HC 40 / 49516

(t) Hook block
X Ensure correct functioning of load hook (t) (rotating, swinging, safety bow). (8)
Converting the trolley to 2-fall operation
Fig. 8-36 Releasing the connecting strut on the trolley

(a) Connecting strut (d) Trolley 1
(b) Pin (e) Trolley 2
(c) Spring clip
X Remove the two spring clips (c) and two bolts (b) on the trolley 2 (e) and fold the two connecting
struts (a) to the rear. (1)
X Insert two pins (b). Secure each pin (b) with a spring clip (c).
ª Trolley 1 (d) is secured against travelling - Trolley 2 (e) can be manoeuvred freely.
1250 HC 40 / 49516 8 - 43
Fig. 8-37 Connecting the bottom hook block with the trolley
(f) Bottom hook block 1 (i) Trolley 2
(g) Trolley 1 (j) Locking device
(h) Bottom hook block 2
X Lift the bottom hook blocks (f, h) by › hoisting upwards ‹. (2)

X Connect bottom hook block 1 (f) and the trolley 1 (g) with two locking devices (j). (3)
ª Bottom hook block 1 is secured - Bottom hook block 2 is freely manoeuvrable.
8 - 44 1250 HC 40 / 49516
8.4.2 Converting from 2-fall to 4-fall operation
Hinweis
– Trolley 1 must be secured against travelling (f). For further information see: Chap. Fig. 8-32 Se-
curing the trolley against travelling
– Each pin (d) must be secured with two linch pins (e).
Fig. 8-38 Securing the trolley against travelling

(a) Trolley 2 (d) Pin
(b) Connecting strut (e) Spring clip
(c) Trolley 1 (f) Trolley 1 is secured with on pin (f) against
travelling
X Manoeuvre trolley 2 (a) towards min. radius until it becomes possible to connect both
trolleys (a, c) with one another.
X Remove the two spring clips (e) and two pins (d) on the trolley 2 (a) and fold the two connecting
struts (b) forwards.
X Insert two pins (d). Secure each pin (d) with a spring clip (e).
ª Trolley 1 is connected with trolley 2.
1250 HC 40 / 49516 8 - 45
Fig. 8-39 Connect the bottom hook blocks with the assembly ropes and release the locking device
(g) Bottom hook block (i) Locking device
(h) Assembly rope (min. 5 m in length)
X Connect the bottom hook blocks (g) (to the rope guard sleeves) with the assembly rope (h) (min.
X Relieve tension in the bottom hook blocks by › hoisting upwards ‹ and release the four locking
devices (i). (2)
8 - 46 1250 HC 40 / 49516
Fig. 8-40 Lowering the bottom hook blocks and dismantling the load hook
(j) Bottom hook block 2 (n) Axle
(k) Bottom hook block 1 (o) Washer
(l) Assembly rope (min. 5 m in length) (p) Bolt
(m) Hook block (q) Axle support
X Lower the bottom hook blocks (j, k) by › hoisting downwards ‹. (3)

ª Bottom hook block 2 (k) is lowered by › hoisting downwards ‹. Bottom hook block 1 (j) is pulled
out of the trolley by the assembly rope (l).
Warning!
Danger of crushing as a result of the load hook tipping.

If the load hook has not been swung in completely, the load hook could tip.
X It must therefore be ensured that the load hook has been completely swung in and that it is sitting
safely on the ground.
X Lower both bottom hook blocks (k, j) completely and swing in the load hook (m). (4)
X Remove the four bolts (p), four washers (o) and two axle supports (q). (5)
X Remove the axle (n). (6)
1250 HC 40 / 49516 8 - 47
Fig. 8-41 Connecting the bottom hook blocks with the hooked lifting beam
(r) Bottom hook block (v) Bolt
(s) Hooked lifting beam (w) Washer
(t) Axle (x) Erection rope
(u) Axle support
X Connect the two bottom hook blocks (r) with the hooked lifting beam (s) via the two axles (t). (7)
X Secure the two axles (t) with four axle supports (u). Secure each axle support (u) with two
washers (w) and two bolts (v). (8)

X Lift the hooked lifting beam (s) and remove the assembly rope (x).
8 - 48 1250 HC 40 / 49516

(y) Hook block
X Ensure correct functioning of the load hooks (n) (rotating, swinging, safety bow.
Converting the trolley to 4-fall operation

Fig. 8-43 Releasing the travel safety device on the trolley

(a) Trolley (c) Pin
(b) Spring clip
X Release the pin (c) of the travel safety device on the trolley (a) and secure with two spring
clips (b).
ª Both trolleys are connected with one another and can be manoeuvred freely.
1250 HC 40 / 49516 8 - 49
Operational faults
8.5 Operational faults
Observation Cause Remedy
Adjust the air gap.

Braking action of slewing gears, Air gap too great
By authorised personnel only!
travel gears and hoist gears di-
minishing Replace the brake disc.
Brake disc worn
The Emergency Stop Release the Emergency Stop

switch is locked switch
Electrical free jib slewing can not
The control lever is not at
be activated Move the control lever to the
"NEUTRAL" ("ZERO") po-
The ›free jib slewing‹ lamp on the "NEUTRAL" ("ZERO") position.
sition.
control box does not light up.
The air gap on the slewing Adjust the air gap.
brake is too great By authorised personnel only!
Adjust the air gap.

The ›Hoist gear brake faulty‹ Air gap too great
lamp lights up and the horn
sounds Lining on hoist gear brake Replace the brake rotor.
rotor worn By authorised personnel only!
Tab. 8-5 Operational faults
8 - 50 1250 HC 40 / 49516
Instruction Manual Maintenance and inspection
9 Maintenance and inspection
This chapter has been compiled for maintenance personnel designated by the operating company.
The maintenance and inspection chart provides a summary of all necessary maintenance and in-
spection tasks. The maintenance and inspection deadlines can be planned precisely using the inter-
val specifications.
1250 HC 40 / 49516 9-1

Maintenance and inspection Instruction Manual
Notes on safety for maintenance
9.1 Notes on safety for maintenance
9.1.1 Safety via regular maintenance

Ensure that all specified maintenance and inspection tasks are carried out. Failure to carry out main-
tenance and inspection can impede safe operation of the crane considerably. The operating company
is solely responsible for any damage caused as a result of failure to carry out maintenance or inspec-
tion.
9.1.2 Who is permitted to carry out maintenance and inspection?

The maintenance personnel must be designated by the operating company. Maintenance of the
crane requires a specialist knowledge of crane technology. The operating company is solely respon-
sible for any damage caused as a result of improper maintenance.
9.1.3 Safety measures

– Switch off the crane and secure against incorrect or unauthorised restart.
– If there is any danger of falling objects: Cordon off the danger area or secure the area with warning
signs.

– Safety helmet
– Protective gloves
– Safety boots
– Safety harness when working above head height.
9.1.5 Which additional guidelines must be observed?

– Local accident-prevention guidelines.
9.1.6 Which dangers are resulted from the crane?

– Danger of crushing around the entire area of the crane.
– Danger resulting from electrical energy.

– Danger resulting from hydraulic energy.
9-2 1250 HC 40 / 49516

9.1.7 Notes on safety for maintenance tasks on the brakes
- Essentially, all maintenance tasks on the brakes can be carried out with the
crane erected!
- Maintenance and repair tasks may only be carried out by qualified, specialist
personnel.Refer to the notes on safety in the following maintenance
instructions!
- Refer also to the information regarding maintenance and repair in the enclosed
operating instructions from the supplier (see the chapter "Accessories")!
- A spacious maintenance or repair area must be cordoned off as required!
Access to this area is prohibited to unauthorised persons!
- Ensure before carrying out any maintenance tasks on the crane:

o No load on the hook
o Secure the respective crane drives against unintentional movement:
When carrying out maintenance tasks on the trolley travel gear
brake: Secure the trolley.
When carrying out maintenance tasks on the hoist gear brake.
Secure the load hook. Thus: Pin the bottom hook block with the
upper hook block and reeve to 4-run.
o Switch off the main switch and mount the corresponding warning
signs to warn against unintentional restart.
o Allow the drives and aggregates to cool sufficiently.
Before commencing any maintenance tasks, disconnect power

and pressure to the hydraulic system!
Escaping pressurised oil can lead to accidents and cause burns!
- Do not use any mechanical aids to block the brakes!

- The spring force of the respective braking cylinder has been set to
nominal force at the factory and can not be changed!
Braking cylinders may not be opened!
1250 HC 40 / 49516 9-3

Notes on safety for maintenance tasks on the brakes
- Check the brakes / braking systems outside of the maintenance

intervals wherever:
- overspeed of the braking discs and/or impermissible lengthy braking
times occur.
- the brakes or systems have not been operated for lengthy periods.
- leaks occur.
9-4 1250 HC 40 / 49516

9.1.8 Fundamental notes on maintenance for brakes
Daily functional inspection of all drives!

Example: Hoist gear brake
For spring-loaded brakes (trolley travel gear and slewing gears):

- If the braking effect decreases, check the air gap and the brake disc! (Description
on the following pages)
- If the air gap maximum value has been reached, readjust the air gap!
- If the brake disc minimum value has been reached, replace the brake disc!
Prerequisites for electrically-released spring-loaded brakes:

- The drives may not be permitted to start up! Disconnect the drive motor!
- Do not disconnect the power supply to the brakes!
- Do not touch voltage-carrying parts!
- After carrying out the checks: Switch off the power and reconnect the
drive motor.
- Ensure that the friction lining of the brake disc and the friction surfaces are
free of oil and grease at all times!
- Fastening screws:
- Tightening torques must be complied with!
- Check regularly! No loose bolts!
- The braking moment for the respective drive has been set at the factory!
Do not adjust the adjusting ring for the braking moment!
When carrying out the replacements (spare-parts) check the setting of
the braking moment!
(Checking is only possible for adjustable brakes)
Example of brake description: BFK 458-12E for (A)djustable
BFK 458-12N for (N)on-adjustable
- Do not readjust the adjustment nuts for manual release!
Always remove the hand-operated brake release lever!

- Install original spare-parts only!
- After carrying out maintenance tasks always perform a check of all
functions!
1250 HC 40 / 49516 9-5

Fundamental notes on maintenance for brakes
For hydraulic braking systems (hoist gear):

Requirements:
- Shut down the crane! See chapter 5.
- Refer to the "Notes on safety for maintenance tasks on the hydraulic
braking systems"! See following pages to obtain a description.
Fastening bolts:
- Tightening torques must be complied with!
- Check regularly! No loose bolts!
After carrying out the maintenance tasks, always perform a functional

inspection!
Essential maintenance instructions for hydraulic braking systems!
9-6 1250 HC 40 / 49516

9.1.9 Essential maintenance instructions for hydraulic braking systems
- Check all cylinders, lines, hoses and the tank regularly for leaks
and for any discernible exterior damage. Rectify this damage
immediately!
- Dispose of old fuels and lubricants in an orderly manner!
- Observe the "Safety regulations for hydraulic hoselines"!

(ZH 1/74)
- The oil quality must be adhered to!
Use prescribed oil types only, see lubricant chart
Oil change:
Comprehensive testing and oil analyses have shown that contaminated oil
causes premature wear of aggregates.
This contamination could have the following consequences:
- Contamination penetrating parts when carrying out repairs.
- Wear of hydraulic components.
- Penetration of dust and moisture via the ventilation and bleed filters.
- Topping up of lost quantities with unsuitable oil.
- Penetration of dirt particles via cylinder rods.
Until now, varying change intervals have been specified.
Every 2000 operating hours, however, at the latest after 2 years, it is
imperative that the hydraulic oil is changed.
This oil change depends first and foremost on the actual condition of the oil
(viscosity, degree of purity etc.). These factors are dependent upon the
respective application of the crane.
This means that an oil change carried out in compliance with the previously
specified change intervals could be performed too early, as well as too late.
The new type of hydraulic oil change, as stipulated by the
"Wear-Check lubricant analysis"
allows potentially considerable extensions of the oil change intervals.
For reference or user information, as well as guidelines pertaining to
the "Wear-Check lubricant analysis", see the chapter "Accessories"
1250 HC 40 / 49516 9-7

Maintenance and inspection chart
9.2 Maintenance and inspection chart
The maintenance and inspection chart gives a summary of all maintenance and inspection tasks. A
description of these tasks can be obtained on the following pages. The general plan can be used as
a check-list and as verification that the work has been carried out.
Maintenance and inspection intervals Tasks to be carried out

Every three months
Every six months
10000h / 2 years*
Special intervals
2000h / 2 years*
by maintenance personnel
by specialist personnel
Once a year
Monthly
Weekly
* the earlier time is definitive

Daily
Complete crane
all grease nipples
Tower
3 weeks after initial visual inspection

assembly, with each Grease the tower connections after each dismantling,
installation at least after three years.
Hoist gear
Check functioning of the hoist gear brake
Lubrication
Analysing / changing gear oil
Check the oil level on the hydraulic power unit
Analysing / changing hydraulic fluid of hydraulic power

unit
as required Cleaning tasks
Slewing gear
Check functioning of the slewing gear brake
Lubrication tasks on the slewing gear

Trolley travel gear
Check functioning of the trolley travel gear brake
Lubrication tasks on the trolley travel gear motor
Tab. 9-1 Maintenance and inspection chart
9-8 1250 HC 40 / 49516

Maintenance and inspection chart
Every three months

Every six months
10000h / 2 years*
Special intervals
2000h / 2 years*
by maintenance personnel
by specialist personnel
Once a year
Monthly
Weekly
* the earlier time is definitive

Daily
Roller slewing ring
Prior to each Lubrication tasks on the ball track

assembly
Prior to each Lubrication tasks on the gear teeth

assembly
Prior to each Inspection tasks at the ball slewing ring:

assembly Check the gear backlash
3 weeks after initial Inspection tasks at the ball slewing ring:

assembly, with each Check high-tensile bolt connections
installation
Electrical devices
Check the switch cabinet
Upper hook block, bottom hook block and load hook
Prior to each Check upper hook block, bottom hook block and load
assembly hook
Ropes, rope pulleys and rope mounting
See chapter Lubricate ropes
See chapter Check ropes at hoist ropre drum
See chapter Check ropes
See chapter Check rope pulleys
See chapter Check rope end fittings
Cabin
Prior to each Check the hinges on the front windshield and roof
assembly hatch
Tab. 9-1 Maintenance and inspection chart
1250 HC 40 / 49516 9-9

Inspection tasks
9.3 Inspection tasks
Should one or more of the following criteria occur, the drive unit must be examined by specialist
personnel and repaired:
– The gears or other drive components are leaking (contamination indicates a leak).
– The visible shaft connections (e.g. flexible couplings, dowel shaft or spline shaft connections) be-
tween individual drive components (e.g. electric motor, coupling, gear, brake, drum) indicate wear
or damage.
– Unusually large clearance (backlash) indicates a defect (e.g. worn shaft-hub connections, worn
gear teeth, worn couplings, loose connections etc.) in the drive train (e.g. electric motor, coupling,
gear, brake, drum).
– Unusual noises are audible.
– An unusual degree of heat is evident.
– The general condition (corrosion, dirt) gives the impression of concealed faults.
– Fastening bolts are loose, cracked or faulty.
– The brake lining is worn or damaged.
– The prescribed, recurring inspections by skilled and specialist personnel have not been carried
out (documented in the crane test record book).
– The maintenance and repair tasks prescribed in the operating instructions have not been carried
out (documented, for example, in the crane test record book).
– Determined faults have been neglected over lengthy periods of time without being remedied.
– The electrical installation (cable entries, cable attachments) indicates damage or signs of ageing.
– Operating conditions are extreme (e.g. multi-shift operation, continuous operation with maximum
load), in other words, the operating conditions far exceed the conditions originally taken as a basis
for the design of the drive units (tower cranes for building sites).
This list has been compiled to provide exemplary criteria for the condition-related maintenance of
tower crane drive units. This list does not assume any liability as to completeness.
9 - 10 1250 HC 40 / 49516
Hoist gear
9.4 Hoist gear
Hoist gear type: 3-speed frequency converter hoist gear of the VZ-serie
9.4.1 Checking correct functioning of the hoist gear brake

Interval: Daily
Fig. 9-1 Functional check of the hoist gear brake
X Move the "Hoist gear" control lever forward or backward.

ª The hoist gear brake is released.
ª The hook is lowered or lifted.
ª The hook stops.
Warning lamp ›Check hoist gear brake‹ is lit on the control desk? The horn sounds during lowering?
Braking action is failing?
Too great an air gap or the lining of the brake rotor is worn.
X Check air gap and brake rotor (By specialist personnel only!). For further information, see:
Chap. ›Repair - hoist gear brake‹
9.4.2 Inspection tasks on the hoist gear

X Inspecting the telescope power supply lines for wear.
X Check the oil level regularly (see: Fig. 9-3 / see: Fig. 9-4).
X Check backlash.
For further information, see: Chap. ›Inspection tasks‹
9.4.3 Lubrication tasks at the hoist gear

Interval: Every 10000 h
1250 HC 40 / 49516 9 - 11
Hoist gear
Bearings featuring sealing washers have been lubricated for their entire service life and are mainte-
nance-free.
Clean anti-friction bearings featuring sealing washers with benzine and fill with new grease. Fill the
bearing and the empty space in the housing to approx. 30 to 50% with grease.
9.4.4 Inspecting the telescope power supply lines for wear

Interval: weekly
Fig. 9-2 Inspecting the telescope power supply lines for wear
(a) Telescope power supply lines for wear (b) Marking „Maximum permissible wear“

The crane has been shut down (master switch ›Off‹) and is secured against unintentional restart.
The master switch is locked in the ›Off‹ position.
X Inspect the telescope power supply lines for wear, replace as necessary.
9 - 12 1250 HC 40 / 49516
Hoist gear
9.4.5 Analysing / changing gear oil

Interval: Every 2000 h, but no longer than every 2 years
For further information see: Chap. ›Analysing hydraulic oil / gear oil‹
Note
Only change the gear oil when the oil is at operating temperature. If necessary, operate the hoist
gear before shutting the crane down. The gear oil should be changed immediately following shut-
down.
The oil-change intervals can be reduced if operation is being carried out under tough conditions:
– Due to high air humidity.
– Due to an aggressive environment (solvent, dust).
– Due to severe deviations in temperature.
Caution!
The gears can become damaged if unsuitable lubricants are used.
X Used prescribed oil types only.
X Do not mix lubricants.
For further information, see: chap. ›Lubricants, filling amounts‹.
Changing oil at the spur gear

Part No.: 9396 605 01 / Drawing No.: GET 450 JX 427-100.000
Fig. 9-3 Changing oil at the spur gear

(a) Oil inspection glass (d) Oil filler plug / screw plug
(b) Drainage outlet (e) Drain plug
1250 HC 40 / 49516 9 - 13
Hoist gear
Fig. 9-3 Changing oil at the spur gear

(c) Oil filling inlet (f) Sealing ring

X Place a suitable collecting pan (min. 25 l capacity) below the drain outlet (b).
X Unscrew the oil filler plug / bleed screw (d) .
X Unscrew the drain plug (e) and drain the oil.
X Scavenge the gear with the same oil type.
X Check the sealing ring (f) of the drain plug (e) for wear and replace as necessary.
X Screw in the drain plug (e) again.
X Fill in new oil. For further information, see the chapter: ›Lubricants, filling quantities‹.
X Screw in the oil filler plug / bleed screw (d) again.
Changing oil at the angular gear

Part No.: 9692 000 01 / Drawing No.: GET 4600 MW 401-100.000
Part No.: 9706 420 01 / Drawing No.: GET 4600 MW 404-100.000
Fig. 9-4 Changing oil at the angular gear

(a) Oil inspection glass (d) Oil filler plug / screw plug
(b) Drainage outlet (e) Drain plug
(c) Oil filling inlet (f) Sealing ring

9 - 14 1250 HC 40 / 49516
Hoist gear

X Place a suitable collecting pan (min. 100 l capacity) below the drain outlet (b).
X Unscrew the oil filler plug / bleed screw (d) .
X Unscrew the drain plug (e) and drain the oil.
X Check the sealing ring (f) of the drain plug (e) for wear and replace as necessary.
X Screw in the drain plug (e) again.
X Screw in the oil filler plug / bleed screw (d) again.
1250 HC 40 / 49516 9 - 15
Hoist gear
9.4.6 Checking the brake callipers

Interval: weekly
Checking for correct fastening
Fig. 9-5 Checking fastening of the brake callipers

(a) Knurled screw (d) Nut
(b) Cover plate (e) Locknut
(c) Bolt

The measures required for preparations prior to repair have been taken (for further information,
see: Chap. ›Preparing for repair tasks‹).
X Check the brake callipers are properly installed on the brake housing. For further information, see:
Chap. ›Repair‹.
9 - 16 1250 HC 40 / 49516
Hoist gear
Checking brake linings, brake disc and brake pads

X Checking brake linings, brake disc and brake padsFor further information, see: Chap. ›Repair‹.
Checking the air gap
Fig. 9-6 Checking the air gap

(a) Hexagon tappet (c) Brake cylinder
(b) Contact surface, hexagon tappet (d) Brake lever groove base

X Check the air gap between contact surface of hexagon tappet (b) and brake lever groove base (d).
ª The air gap is 6-8 mm. For further information, see: Chap. ›Repair‹.
Checking the hexagon tappet

X Make sure that the hexagon tappet is seated properly in the brake lever groove base.
X Make sure that the hexagon tappet is seated properly in the brake cylinder.
The hexagon tappet must not be able to be pulled out of the brake cylinder.
X For further information, see: Chap. ›Repair‹.
1250 HC 40 / 49516 9 - 17
Hoist gear
X
The hexagon tappet can be pulled out of the brake cylinder?
If the hexagon tappet can be pulled out of the brake cylinder, it is broken. The automatic adjustment
is not working.
X Replace the brake cylinder with hexagon tappet.
9.4.7 Analysing / replacing the hydraulic oil

Interval: Every 2000 h, at least every
For further information, see: chap. ›Analysing hydraulic oil / gear oil‹
Note
Only change the hydraulic oil when the oil is still warm from operation. If necessary, manoeuvre the
hoist gear before shutting down. Change the gear oil immediately following shutdown.
The oil change intervals can be shortened if operation is being carried out in difficult conditions:
– Due to high humidity.
– Due to aggressive environments (solvents, dust).
– Due to excessive fluctuations in temperature.
Caution!
The hydraulic system can sustain damage if unsuitable lubricants are used.
X Use prescribed oil types only.
9 - 18 1250 HC 40 / 49516
Hoist gear
Checking the oil level
Fig. 9-7 Checking the oil level at the hydraulic aggregate

(a) Hydraulic aggregate (b) Breather filter with oil dipstick (filling inlet)

The crane is shut down (main switch ›Off‹) and secured against unintentional start-up. The main
switch is locked in the ›Off‹ position.
X Unscrew the breather filter with oil dipstick (b), allow the hydraulic oil to drain and wipe off the oil
dipstick (b). (1)
X Screw in the breather filter with oil dipstick (b) (2)
X Unscrew the breather filter with oil dipstick (b), allow the hydraulic oil to drain and read off the oil
level. (3)
X Screw in the breather filter with oil dipstick (b) (4)
1250 HC 40 / 49516 9 - 19
Hoist gear
Changing the hydraulic oil
Fig. 9-8 Oil change in the hydraulic aggregate

(a) Hydraulic aggregate (d) Drain plug
(b) Breather filter with oil dipstick (filling inlet) (e) Sealing ring
(c) Drain outlet

The crane is shut down (main switch ›Off‹) and secured against unintentional start-up. The main
switch is locked in the ›Off‹ position.
X Position a suitable collecting basin (min. 6 l capacity) beneath the drain outlet (c).
X Unscrew the breather filter with oil dipstick (b). (1)
X Unscrew the drain plug (d) and drain the oil. (2)
X Scavenge the gear using the same type of oil.
X Check the sealing ring (e) of the drain plug (d) for wear; replace as necessary.
X Screw in the drain plug (d) again. (3)
X Fill in new oil. For further information, see: chap. ›Lubricants, filling amounts‹.
X Screw in the breather filter with oil dipstick (b) again. (4)
9 - 20 1250 HC 40 / 49516
Hoist gear
9.4.8 Cleaning tasks
Fig. 9-9 Cleaning the ventilation grid
X Clean the ventilation grid on the motor from the outside.

1250 HC 40 / 49516 9 - 21
Slewing gear
9.5 Slewing gear
Type of slewing gear: DRW 200 AZ 403, DRW 200 AZ 404

Type of slewing gear: DRW 210 AZ 401, DRW 210 AZ 402
9.5.1 Check functioning of the slewing gear brake

Interval: Daily
Note
Braking action of the slewing gear brake is best checked with wind forces of between 3 and 8.
Fig. 9-10 Checking functioning of the slewing gear brake
X Manoeuvre the control lever „slewing gear/trolley travel gear“ to the left or to the right.
ª The slewing gear brake is released and the slewing platform turns to the left or to the right
ª Rotary motion of the slewing platform stops after 5 to 7 sec.
The slewing gear brake is applied after approx. 10 sec.
ª The slewing gear brake holds the slewing platform, and thus the jib, in position.
Too great an air gap or the lining of the brake rotor is worn.
Chap. ›Repair - slewing gear brake‹
9.5.2 Inspection tasks at the slewing gear

X Check the oil level regularly.
X Check backlash.
For further information, see: Chap. ›Inspection tasks‹
9 - 22 1250 HC 40 / 49516
Slewing gear
9.5.3 Lubrication tasks on the slewing gear

Interval: Every 10000 h
nance-free.
Clean anti-friction bearings featuring sealing washers with benzine and fill with new grease. Fill the

Interval: Every 2000 h, but no longer than every 2 years
For further information see: Chap. ›Analysing hydraulic oil / gear oil‹
Note
Only change the gear oil when the oil is at operating temperature. If necessary, turn the slewing plat-
form before shutting down. The gear oil should be changed immediately following shut-down.
The oil-change intervals can be reduced if operation is being carried out under tough conditions:
Caution!
The gears can become damaged if unsuitable lubricants are used.
X Used prescribed oil types only.
1250 HC 40 / 49516 9 - 23
Slewing gear
Fig. 9-11 Changing oil in the slewing gear transmission (Example: Slewing platform
for crane 2000 HC)
(a) Oil inspection glass (e) Oil drain hose
(b) Sealing ring (f) Butzen (BUZ 18-L)
(c) Oil filler plug / Bleed screw (g) Fitting (G 18-PL)
(d) Oil filling inlet

The crane has been shut down (Master switch ›Off‹) and has been secured against unintentional
restart (master switch is locked in the ›Off‹ position).
Note
It is difficult to access the Oil drain hose with the crane assembled. We recommend therefore, that
the oil-change intervals be arranged so that oil-change can be carried out from the ground (e.g. prior
to assembly or following disassembly).
X Place a suitable collecting pan (min. 20 l capacity per slewing gear) beneath the oil drain plug (e).
X Unscrew the oil filler plug / bleed screw (c) .
X Unscrew the threaded union (g) at the oil drainage hose (e), remove the lug (e) and drain the oil.
X Screw the lug (e) and the threaded union (g) back onto the oil drainage hose (e).
X Screw in the oil filler plug / bleed screw (c) again.
9 - 24 1250 HC 40 / 49516
Slewing gear

1250 HC 40 / 49516 9 - 25
Trolley travel gear
9.6 Trolley travel gear
Trolley travel gear type: KAW 200 KY 001
9.6.1 Checking functioning of the trolley travel gear brake

Interval: daily
Fig. 9-13 Functional check of the trolley travel gear brake
X Move the "Slewing gear/Trolley travel gear" control lever forward or backward.
ª The trolley travel gear brake is released.
ª The trolley moves forward or backward.
ª The trolley stops.
Too great an air gap or brake lining is worn.
Chap. ›Repair - trolley travel gear brake‹
9.6.2 Inspection tasks at the trolley travel gear

X Check the oil level regularly.
X Check backlash.
For further information, see: Chap. ›Inspection tasks‹.
9.6.3 Lubrication tasks on the trolley travel gear motor

Interval: every 10000 h
nance-free.
9 - 26 1250 HC 40 / 49516
Trolley travel gear
Clean anti-friction bearings without sealing washer with benzine and fill with new grease. Fill the

Interval: every 2000 h, at least every 2 years
For further information, see: Chap. ›Analysing hydraulic oil / gear oil‹
Warning!
Risk of burns due to hot gearbox and gear oil.
X Before starting operations, let the gearbox cool down.
X Unscrew the oil-level plug and the drain plug carefully.
Note
Only change the gear oil when the oil is at operating temperature. If necessary, operate the trolley
travel gear before shutting the crane down. Change the gear oil immediately following shutdown.
The oil change intervals can be shortened if operation is being carried out in difficult conditions:
– Due to high humidity.
– Due to aggressive environments (solvents, dust).
– Due to excessive fluctuations in temperature.
Caution!
The gearbox can become damaged if unsuitable lubricants are used.
X Use prescribed oil types only.
1250 HC 40 / 49516 9 - 27
Trolley travel gear
Fig. 9-14 Changing oil in the trolley travel gearbox

(a) Bleed screw (e) Drain outlet (h) Oil-level hole
(b) Sealing ring (f) Drain plug (i) Required oil level
(c) Oil-levell plug (g) Sealing ring (j) Oil
(d) Sealing ring

The crane has been shut down (main switch ›Off‹) and is secured against unintentional start-up.
The main switch is locked in the ›Off‹ position.
X Position a suitable receptacle beneath the oil-level plug (c).
X Position a suitable collecting vessel (min. 12 l capacity) beneath the drain outlet (e).
X Unscrew the oil-level plug (c) and the bleed screw (a). (1)
X Unscrew the drain plug (f) and allow the oil to drain. (2)
X Flush out the gearbox using the same type of oil.

X Check the sealing ring (g) of the drain plug (f) for wear; replace as necessary.
X Screw in the drain plug (f) again.
X Fill in new via the bleed hole to the lower edge of the oil-level hole (h) . For further information,
see: chap. ›Lubricants, filling amounts‹.
X Check the sealing rings (b, d) of bleed screw (a) and oil-level plug (c) for wear; replace as neces-
sary.
9 - 28 1250 HC 40 / 49516
Trolley travel gear
X Screw in the bleed screw (a) and the oil-level plug (c) again.

1250 HC 40 / 49516 9 - 29
Roller slewing ring
9.7 Roller slewing ring
9.7.1 Lubrication tasks on the roller track

Interval: Prior to each erection and then every three months
Fig. 9-16 Lubrication points on the ball track (example for crane 2000 HC 60)
Note
The manual lubrication tasks no longer apply when operation is being carried out with a centralized
lubrication system (optional). The batching quantity, however, must be checked regularly. For fur-
ther information, see: Operating instructions ›Centralized lubrication system‹ in the appendix.
X Determine the amount of grease required for the year. For further information, see: chap. ›Lubri-
cants, filling amounts‹.
X Deduct approx. 200 cm3 of the overall grease required for the year for the gear teeth.
X Divide the remaining quantity of grease by four (interval: every three months).
X Calculate the number of strokes of the handpump per grease nipple. Ensure that the amount per
stroke complies with the details specified by the manufacturer of the hand pump.
X Apply the calculated amount of grease into the grease nipple using the hand pump, at the same
time slowly turning the crane.
Note
Change the grease completely
– prior to, and following, lengthy breaks in operation.
– in particular prior to, and following, the winter break.
X To change the lubricating grease: Turn the crane slowly and continue to lubricate until grease is
exuded from under the lip-type seals.
9 - 30 1250 HC 40 / 49516
Roller slewing ring
9.7.2 Lubrication tasks on the gear teeth

Interval: Prior to each erection and then every week
Danger!
Exposed running spur gears.
Loose items such as clothing, hair and jewellery can become snagged in the spur gears. This can
result in body parts being drawn into machinery and crushed, causing serious injury or death.
X Ensure when carrying out lubrication tasks, that no loose items can be drawn into machinery.
Warning!
Danger of falling when lubricating the spur gear.
X Lubrication tasks should be carried out from the maintenance platform only. Do not leave the
maintenance platform.
Note
The manual lubrication tasks no longer apply when operation is being carried out with a centralized
lubrication system (optional). The batching quantity, however, must be checked regularly. For fur-
ther information, see: Operating instructions ›Centralized lubrication system‹ in the appendix.
The tooth flanks must indicate a sufficient film of lubricant at all times. Excessive applications of lu-
bricating grease must be subsequently removed.
Fig. 9-17 Lubricating the gear teeth
X Apply lubricating grease to the entire spur gear, at the same time turning the slewing platform step
by step.
1250 HC 40 / 49516 9 - 31
Roller slewing ring
9.7.3 Inspection tasks at the roller slewing ring

Interval gear backlash: Prior to each erection
Interval high-tensile bolt connections: 3 weeks after initial erection, with each installation and
at least once a year
Fig. 9-18 Gear backlash and high-tensile bolt connection

(a) Pinion, slewing gear (b) High-tensile bolt connection
Note
It is difficult to access the pinion on the slewing gear with the crane assembled. We recommend
therefore, that the inspection (and any necessary adjustment) be arranged so that inspection can
be carried out from the ground (e.g. prior to assembly).
X Check the gear backlash using the feeler gauge and then check the teeth designated with „+“
(cross). (1)
Note
Permissible gear backlash: 0.3 - 0.4 mm.
9 - 32 1250 HC 40 / 49516
Roller slewing ring
Gear backlash too great or insufficient ?
X Readjust the gear backlash. (by specialist personnel only!)
X Check the high-tensile bolt connections (b) over the entire ball slewing ring. (2)
For further information, see: Information brochure ›High-tensile bolt connections‹.
1250 HC 40 / 49516 9 - 33
Electrical system
9.8 Electrical system
9.8.1 Check the switchgear cabinet

Interval: Weekly
Danger!
Electrical energy.
Contact with voltage-carrying parts within the switchgear cabinet can cause fatal electric shocks.
X Disconnect the mains before commencing any tasks at the switchgear cabinets: Position the iso-
lating switch on the slipring assembly to 0 „Mains disconnected“.
Fig. 9-19 Switchgear cabinets S1 and S2
Checking the contactors

The switch contacts must remain coarse. Only replace the contact pieces when the silver lining has
all but been burnt away and the contact holders are visible.
A black colouring of the contacts is not necessarily an indication of damage, therefore the contacts
should never be filed.
Following a short circuit: Check the switch contacts. Excessive burning, or even a fusing of the con-
tacts, could occur.
Check the connecting bolts
Caution!
Clamp bolts which have fallen out could cause dangerous electrical faults.
X Tighten the connecting bolts on the clamping strip and control units securely.
9 - 34 1250 HC 40 / 49516
Electrical system
Replacing resistors
Caution!
Loose bolt connections lead to scale formation and disruptions. The motors could sustain damage
as a result.
X Ensure secure fastening of the bolt connections.
9.8.2 Checking the limit switches

Interval: Weekly
Fig. 9-20 Checking the limit switches
Ensuring correct functioning

X Check the limit switches for correct functioning: Rollers and push-buttons must be clean and fea-
ture easy freedom-of-movement.
X Check covers and seals for correct seating and secure fastening.
Electric cables
X Ensure that cable glands are fitted correctly: Cable glands must be fastened securely and fixed
with a locknut.
X Check the cable: Cables should not indicate any kinks or damage (cracks, etc).
1250 HC 40 / 49516 9 - 35
Upper and bottom hook block and load hook
9.9 Upper and bottom hook block and load hook
Warning!
Risk of the hook block falling as a result of damaged parts.
If the hook nuts, load hook (load hook threads, hook heights, hook catch widths) or safety items are
worn or corroded, it is possible that the hook block might break and fall. This could in turn cause
serious injury to personnel.
X Replace worn or corroded hook nuts, load hook threads or safety items (hook nuts and load
hooks may only ever be replaced as one unit).
9.9.1 Inspecting the upper hook block, bottom hook block and load hook
Interval: Prior to erection and then once a year
Note
The inspections must be performed by a specialist personnel.
The type of inspection and result, as well as the remedying of any determined defects, must be doc-
umented in the test book of the crane.

The crane has been shut down (main switch ›Off‹) and has been secured against unintentional
restart (main switch is locked in the ›Off‹ position).
Fig. 9-21 Inspecting the upper hook block, bottom hook block and load hook
(a) Upper hook block (c) Bottom hook block (e) Load hook
(b) Rope pulley (d) Cross-head (f) Hook catch
9 - 36 1250 HC 40 / 49516
X Ensure that all fastening parts (pins, cotter pins, bolting assemblies …) have been assembled cor-
rectly.
X Check the rope pulleys (b) (for further information, see: Chap. ›Inspections at the rope pulleys‹).
X Grease all moving parts (bearing …).
X Ensure freedom-of-movement of the load hook (e).
The load hook has seized or is extremely stiff when rotated?
X Check the connection from the cross-head to the load hook (For further information see: Chap.
9.9.2 Check the load hook to cross-head connection.
X Check the hook catch (f) for correct functioning and easy-freedom-of-movement.
X Check the connection from the bottom hook block (c) to the cross-head (d) (pins, cotter pins, bolt-
ed assemblies…) for correct assembly and freedom-of-movement.
X Check the connection from the cross-head (d) to the load hook (e) (For further information see:
Chap. 9.9.2 Check the load hook to cross-head connection.
X Check the load hook (e) (For further information see: Chap. 9.9.3 Inspecting the load hook.
1250 HC 40 / 49516 9 - 37
9.9.2 Check the load hook to cross-head connection

Interval: Once a year
Note

Fig. 9-22 Checking the load hook to cross-head connection

(a) Bolt (d) Hook nut (g) Load hook
(b) Lock washer (e) Cover ring (h) Cross-head
(c) Fitting key (f) Ball bearing (i) Designation panel, load
hook identification plate
X Check the load hook identification plate (i) (For further information see: Chap. 9.9.3 Inspecting the
load hook).
X To check the axial play (A) of the hook nut (d): Dismantle the load hook (g) and screw on the hook
nut (d) again.
X Move the hook nut (d) upwards and downwards. At the same time, measure the path of motion
using a dial gauge.
ª The path of motion is the axial play (A) of the hook nut (d) (permissible axial play see: Tab. 9-2).
X Check the thread of the hook nut (d) and load hook (g), as well as the shank of the load hook (g)
for corrosion, and replace as necessary.

X Install the load hook again and grease all moving parts.
9 - 38 1250 HC 40 / 49516
Axial play (in mm)
Load hook
Load hook Permissible axial play (A) Thread
No.
Lah 010 … RSN 08 0,13 M 24
Lah 020 … RSN 1.6 0,14 M 30
threads
Metric
Lah 030 … RSN 2.5 0,15 M 36
Lah 050 … RSN 4 0,16 M 42
Lah 063 … RSN 5 0,16 M 45
Lah 080 … RSN 6 0,10 Rd 50x6
Lah 100 … RSN 8 0,10 Rd 56x6
Lah 125 … RSN 10 0,10 Rd 64x8
Lah 160 … RSN 12 0,10 Rd 72x8
Round threads
Lah 200 … RSN 16 0,20 Rd 80x10
Lah 250 … RSN 20 0,20 Rd 90x10
Lah 320 … RSN 25 0,20 Rd 100x12
Lah 400 … RSN 32 0,20 Rd 110x12
Lah 500 … RSN 40 0,20 Rd 125x14
Lah 630 … RSN 50 0,30 Rd 140x16
Lah 800 … RSN 63 0,30 Rd 160x18
Tab. 9-2 Load hook configurations

1250 HC 40 / 49516 9 - 39
9.9.3 Inspecting the load hook

Interval: Prior to erection and then once a year
Note
If inspection can not be carried out with the load hook installed, the load hook must be removed.

Fig. 9-23 Inspecting the load hook

(a) Designation panel, (b) Designation panel, load
dimension „y, y1, y2“ hook identification plate
Note
The load hooks can only be differentiated between via the identification „Lah …“ on the identification
plate or via the identification „RSN …“ or RFN …“ on the hook itself.
For further information regarding the load hook, see DIN 15 401 (single hook) or DIN 15 402 (dou-
ble hook), for load hook identification, see DIN 15 404 and for load hook inspection, see
DIN 15 405.
X Check the load hook identification (b) (in the identification panel (b) the manufacturer's trademark,
9 - 40 1250 HC 40 / 49516
load hook number, material and batch number, as well as the DIN 15 401 (single hook) or
DIN 15 402 (double hook) is are embossed.
Inspecting the load hook for deformation

Load hook in accordance with DIN 15 401 and DIN 15 402 up to load hook no. 5:
X Measure hook catch width, dimension „a2“.
Load hook in accordance with DIN 15 401 and DIN 15 402 upwards of load hook no. 6:
Note
The maximum permissible dimension „y“ (for double load hooks „y1 / y2“) is imprinted on the load
hook in the designation panel (a).
X Measure the hook catch width, dimension „y“ (for double load hooks „y1 / y2“).
Measured hook catch width „a2“ or „y“ (for double load hooks „y1 / y2“) is more than 10% greater
than the maximum permissible dimension ?
(maximum permissible dimension „a2“ see: Tab. 9-3 or maximum permissible dimension „y1 / y2“
see: Load hook designation panel (a))
X Replace the load hook.
Inspecting the load hook for surface cracks

X Position the surface of the load hook so that any cracks will be instantly recognisable.
X Check the surface using a method specifically suited for this purpose.
Cracks have been determined on the surface of the load hook?
X Remedy any cracks via grinding until the surface is once again free of dents. At the same time,
the permissible tolerances should not be exceeded.
Welding on the load hook is absolutely prohibited!
Inspecting the load hook for wear

X Measure the load hook „h2“ (for double load hooks „h“).
Measured hook height „h2“ (for double load hooks „h“) is more than 5% less than the minimum
permissible dimension ?
(minimum permissible dimension, see: Tab. 9-3)

X Replace the load hook.
Welding on the load hook is absolutely prohibited!
1250 HC 40 / 49516 9 - 41
(Double load hook)

(Single load hook)
(Single & double load hook)
h2 (single load hook)
h (Double load hook)

Load hook
y, y1, y2
Load hook Threads
No.
a2
a2
Lah 010 … RSN 08 38 30 - 37 33 m24
Lah 020 … RSN 1.6 45 36 - 48 43 m30
Lah 030 … RSN 2.5 50 40 - 58 50 m36
Lah 050 … RSN 4 56 45 - 67 60 m42
Lah 063 … RSN 5 63 50 - 75 67 m45
Lah 080 … RSN 6 71 56 85 75 Rd 50x6
Lah 100 … RSN 8 80 63 95 85 Rd 56x6
are imprinted on the load hook.

(for double load hooks y1, y2)“
Lah 125 … RSN 10 90 71 Maximum dimensions „y, 106 95 Rd 64x8
Lah 160 … RSN 12 100 80 118 106 Rd 72x8
Lah 200 … RSN 16 112 90 132 118 Rd 80x10
Lah 250 … RSN 20 125 100 150 132 Rd 90x10
Lah 320 … RSN 25 140 112 170 150 Rd 100x12
Lah 400 … RSN 32 160 125 190 170 Rd 110x12
Lah 500 … RSN 40 180 140 212 190 Rd 125x14
Lah 630 … RSN 50 200 160 236 212 Rd 140x16
Lah 800 … RSN 63 224 180 265 236 Rd 160x18
Tab. 9-3 Permissible load hook deviations

9 - 42 1250 HC 40 / 49516
Ropes, rope pulleys and rope end fittings
9.10 Ropes, rope pulleys and rope end fittings
9.10.1 Lubrication tasks on the ropes

Interval: every 200 operating hours
Fig. 9-24 Lubricating the ropes
Regular lubrication increases life-expectancy of the ropes. Regreaseing must be undertaken more
regularly when working under special conditions (e.g. extreme climates, sea water).
Graphite-based lubricant must be used for multi-layer windings (Lebus drums).
Ensure that the following prerequisites have been met before carrying out regreasing:
The ropes have been cleaned.
Excess lubricant has been completely removed.
The lubricant being subsequently applied is compatible with the lubricant which is already coated
on the rope.
1250 HC 40 / 49516 9 - 43
9.10.2 Rope inspections on the hoist rope drum

Interval: Daily
Note
Checking the winding action of the hoist rope on the

hoist rope drum
In order that winding errors („carving“ into underlying rope layers or loop-formation in underlying rope
layers), and thus damages to the rope as a direct result thereof can be avoided, a daily inspection of
the winding action is absolutely necessary. Likewise, the hoist rope should be regularly wound on and
wound off as a precautionary measure. See the following instructions for further information.
Fig. 9-25 Possible winding errors

(a) „Carving“ into underlying (b) Loop-formation in underly-
rope layers ing layers
Fig. 9-26 Winding on the pretensioned hoist rope
9 - 44 1250 HC 40 / 49516
Winding on the pretensioned hoist rope

X Wind off the hoist rope - until three safety windings remain on the rope drum.
X Wind on the hoist rope with approx. 10% of the maximum load.
Fig. 9-27 Winding on the hoist rope without tension
Warning!
W
Danger of crushing when feeding the hoist rope.

X Wear safety gloves.
X Do not intervene between hoist rope and hoist rope drum.
Winding on the hoist rope without tension

X Wind off the hoist rope - until three safety windings remain on the rope drum.
X Wind on and feed the hoist rope in stage 1.
1250 HC 40 / 49516 9 - 45
Checking the hoist rope on the hoist rope drum for flattening
The hoist rope in the crossover section (A) of the rope layers being wound on is subjected to in-
creased stress. As a rule, the rope can then be repositioned twice.
Repositioning the rope

X Inspect the rope for flat sections.
The hoist rope does not yet indicate any wire strand fractures.
The wires in the outer strands have been flattened to a maximum half the thickness of the wire.
X Shorten and reposition the rope by approx. half the diameter of the hoist rope drum.
The outer strands have been excessively flattened? The hoist rope indicates wire strand fractures?
X Remove the rope.
9 - 46 1250 HC 40 / 49516
9.10.3 Inspections on the ropes

Interval: Prior to assembly and at regular intervals in order that any damage can be deter-
mined in good time
Note
Shorter inspection intervals are imperative:
– in the first weeks following reeving of a new rope.
– after being subjected to extraordinary stresses.
– with suspected, non-visible damage.
An inspection is also necessary:
– before starting up the crane following lengthy periods of inactivity.
– following any accident or event of damage which occurred in connection with the ropes.
Inspecting the ropes to see if they are due to be taken down
Fig. 9-28 Particularly susceptible rope sections (using the 154 EC-HM as an example)
When inspecting the ropes, pay particular attention to the rope sections which are guided over rope
pulleys or rope drums and which are located next to rope end fittings.
X Follow closely the onset of any changes which may become evident in the behaviour of the ropes.
X Should there be any doubt regarding operational safety of a rope on the crane: Remove the rope.
Note
Only use ropes which comply with the specifications in the Liebherr rope list. For further information,
see: Chap. 2.2 Components.
Regular monitoring of the ropes maintains operational safety.
1250 HC 40 / 49516 9 - 47
The ropes on the crane must be taken down if they indicate
Corkscrew-type deformation exceeding more

than 1⁄3 of the rope diameter
Basket-like distortion
The emergence of hairpin-shaped wires or

groups of wires from the rope (loop-formation)
Loosening of the rope structure (e.g. due to cor-

rosion and wear)
-
Reduction of the rope diameter by 10 % of the
rope's nominal diameter with simultaneous oc-
currence of corrosion and/or wear
-
Reduction of the rope diameter by 15 % of the
rope's nominal diameter with simultaneous oc-
currence of corrosion and/or wear
Constriction (e.g. resulting from a damaged

rope layer)
Crushing or bending resulting from mechanical

influences
Tab. 9-4 Criteria for the determining when ropes on the crane must be removed
9 - 48 1250 HC 40 / 49516
The ropes on the crane must be taken down if they indicate
Kinks or other permanent distortions
- Rupturing of a strand
- Several ruptures of the wire rope
- Reaching of the maximum number of wire frac-
tures (see following table)
Tab. 9-4 Criteria for the determining when ropes on the crane must be removed
Number of visible wire strand frac-

Number of load- tures for removal of the rope in a
bearing wires in section of the rope measuring
Structure Lang's lay Crosslay
the outer
strands 6 x rope diame- 30 x rope diam-
ter eter
Non-rotating hoist ropes
PC Starlift x 112 5 10
PC Powerlift x 126 6 11
PC Eurolift x 126 3 6
PD D 915 C x 105 2 5
PD D 1315 C x 105 2 5
PD D 915 CZ x 105 2 5
PD D 1315 CZ x 105 2 5
PD D 1318 CZ x 126 3 6
PD D 1918 Z x 126 6 11
PD D 2118 C x 126 3 6
PD D 3615 C x 105 2 5
PD D 1918 Z/So x 126 6 11
PV 403 x 75 2 3
Perfekt TK 12 x 105 5 10
Ropes which are not non-rotating
(flat-/pull-back-/luffing-/
assembly-/adjusting-/retaining ropes)
PC Alphalift x 152 6 13
PC Durolift x 152 6 13
PC Stratolift x 152 6 13
PC Turbolift x 208 9 18
PC Turboplast x 208 9 18
PD S 417 x 152 6 13
Tab. 9-5 Removal of wire ropes as a result of wire strand fractures
1250 HC 40 / 49516 9 - 49
Number of visible wire strand frac-

Number of load- tures for removal of the rope in a
bearing wires in section of the rope measuring
Structure Lang's lay Crosslay
the outer
strands 6 x rope diame- 30 x rope diam-
ter eter
PD S 505 x 152 6 13
PD S 506 x 152 6 13
PD S 625 x 114 5 10
PD SKZ 8 x 208 9 18
PD P 825 x 152 6 13
PD PZ 371 > 14 mm Ø x 208 9 18
PC 8 FK x 152 6 13
PC 8 FKV x 208 9 18
PC FKX x 190 8 16
P 331 x 171 7 14
P 335 x 171 7 14
P 336 x 190 8 16
P 550 x 288 12 24
PN 42 x 42 2 4
PN 114 x 114 5 10
PN 115/7 x 114 5 10
PN 116/7 x 114 5 10
PN 216/7 x 216 9 18
PN 222 x 222 10 19
PV 288/7 x 288 12 24
DIN 3066 FE x 222 10 19
Perfekt 612 W x 114 5 10
Perfekt BS 812 F x 152 6 13
Tab. 9-5 Removal of wire ropes as a result of wire strand fractures
X Check ropes for above-mentioned distortions and wire strand fractures.

X If rope damage is determined: Remove the rope.
X Should there be any doubt regarding operational safety of a rope on the crane: Remove the rope.
- or -
Consult professional personnel for further assessment.
X For special rope damages: Determine the cause of the damage and rectify before reeving a new
rope. Damages and signs of abrasion to structural parts could be used for reference.
9 - 50 1250 HC 40 / 49516
9.10.4 Inspections at the rope pulleys

mined in good time
Note

The crane has been shut down (master switch ›Off‹) and has been secured against unintentional
Fig. 9-29 Checking the rope pulley
Dimension Meaning
A Groove depth
D Rope nominal diameter
D1 Diameter for the bottom of the groove
D2 Overall diameter of the rope pulley
R Groove radius
Vmax Maximum permissible wear

Tab. 9-6 Dimensions and their meanings
The value D1 can be obtained in the spare-parts list. In the designation of the rope pulley, the first two
positions following the point specify the diameter for the bottom of the groove D1 in cm. For example
if the rope pulley features a designation Ser 10.38, the diameter for the bottom of the groove is D1 =
38 cm, and if the rope pulley features a designation Ser 8.28, the diameter for the bottom of the rope
pulley is D1 = 28 cm.
1250 HC 40 / 49516 9 - 51
Inspecting the mounting of the rope pulley

X Turn the rope pulley. (1)
ª The rope pulley must indicate easy freedom of movement.
The rope pulley does not indicate easy-freedom-of-movement?
X Replace the mounting of the rope pulley or the entire rope pulley.
Check for wear at the rope pulley

X Check whether the rope pulley indicates a depressed rope profile in the bottom of the groove. (2)
The rope pulley indicates a depressed rope profile in the bottom of the groove?
X Replace the rope pulley.
X Calculate groove radius R and check using a radius gauge. (3)
Note
The groove radius is at least R = 0.53 x D (example: For a nominal rope diameter D = 20 mm, the
groove radius is R = 10.6 mm.)
X Carry out an inspection for wear (1st method). (4)

- or -
Carry out an inspection for wear (2nd method).
Inspection for wear (1st method)

X Obtain the diameter for the bottom of the groove D1 from the spare-parts list.
X Calculate the maximum permissible wear Vmax: Vmax = 0.15 x D.
X Calculate the minimum permissible diameter for the bottom of the groove D1min: D1min = D1 -
2Vmax.
X Measure the actual value of the diameter for the bottom of the groove D1ist.
X If D1ist < D1min: Replace the rope pulley.
Note
Example: Rope nominal diameter D = 20 mm, diameter for the bottom of the groove D1 = 38 cm.
X Calculate the maximum permissible wear Vmax: Vmax = 0.15 x D = 0.15 x 20 mm = 3 mm.
X Calculate the minimum permissible diameter for the bottom of the groove D1min: D1min = D1 -
2Vmax = 380 mm - 2 x 3 mm = 374 mm.
The minimum possible diameter for the bottom of the groove in this example is D1min = 374 mm. If
the actual value of the diameter for the bottom of the groove measured is less than the minimum
permissible groove diameter D1min, the rope pulley must be replaced.
Inspection for wear (2nd method)

X Obtain the diameter for the bottom of the groove D1 from the spare-parts list.
X Measure the overall diameter D2 of the rope pulley.
X Calculate the original value of the groove depth A (condition when delivered): A = (D2 - D1) : 2.
9 - 52 1250 HC 40 / 49516
X Calculate the maximum permissible wear Vmax: Vmax = 0.15 x D.

X Calculate the maximum permissible groove depth Amax: Amax = A + Vmax.
X Measure the actual value of the groove depth Aist.
X If Aist > Amax: Replace the rope pulley.
9.10.5 Inspections at the rope end fittings

mined in good time
Note

The crane has been shut down (master switch ›Off‹) and has been secured against unintentional
Checking the wedge socket (configuration 1)
Fig. 9-30 Wedge socket (version 1)

(a) Clamping bracket, rope clamp (c) Flanged nut, rope clamp (e) Wedge socket element
(b) Clamping jaw, rope clamp (d) Key (f) Rope clamp
X Ensure correct assembly of the wedge socket. (1)

X Check the rope clamps for (a) secure seating. (2)
X Check the clamping bracket (a) for dents and chinks. (3)
X Check the wedge socket element (e) for dents and chinks. (4)
1250 HC 40 / 49516 9 - 53
Dents and chinks have been determined on the clamping bracket and wedge socket element?
X Remedy the dents and chinks by grinding until the surfaces are once again smooth.
The permissible tolerances = original dimensions - max. 10 % however may not be exceed-
ed.
Welding of the wedge sockets is absolutely prohibited!
X Check the wedge (d) for dents and chinks. (5)
Dents and chinks have been determined on the wedge?
X Replace the wedge.
Checking the wedge socket (configuration 2)
Fig. 9-31 Wedge socket (version 2)

(a) Clamping bracket, rope clamp (c) Flanged nut, rope clamp (e) Wedge socket element
(b) Clamping jaw, rope clamp (d) Key (f) Rope clamp
X Ensure correct assembly of the wedge socket. (1)

X Check the rope clamps for (a) secure seating. (2)
X Check the clamping bracket (a) for dents and chinks. (3)
X Check the wedge socket element (e) for dents and chinks. (4)
9 - 54 1250 HC 40 / 49516
Dents and chinks have been determined on the clamping bracket and wedge socket element?
X Remedy the dents and chinks by grinding until the surfaces are once again smooth. The permis-
sible tolerances = original dimensions - max. 10 % however may not be exceeded.
Welding of the wedge sockets is absolutely prohibited!
X Check the wedge (d) for dents and chinks. (5)

´
Dents and chinks have been determined on the wedge?
X Replace the wedge.
1250 HC 40 / 49516 9 - 55
Checking the twist compensator

Interval: Prior to assembly and then once a year
Note
When using a non-rotating hoist rope, the twist compensator must be freely rotatable.
When using a hoist rope which does not rotate freely, the twist compensator must be fixed securely.
Fig. 9-32 Checking the twist compensator (different configurations represented within the example)
X Ensure correct assembly of the wedge socket (see: Fig. 9-30 and Fig. 9-31). (1)
X Connection of rope to twist compensator: Check the pin, cotter pin, hinged pin, … for correct
assembly. (2)
X Grease all moving parts (bearing…). (3)

X Connection twist compensator to jib head section: Check correct assembly and easy-freedom-of-
movement of pin, axle support, bolting assembly…. (4)
X Check all threads for corrosion and signs of wear.
9 - 56 1250 HC 40 / 49516
Fig. 9-33 Securing the twist compensator with hoist ropes which do not rotate
X To secure the twist compensator (for hoist ropes which do not rotate): Screw in the screw until it
is no longer possible to turn the twist compensator. (1)
X Lock the screw with a nut. (2)
Inspecting the rope clamp connections on the rope drums

Interval: Prior to assembly and then once a year
Fig. 9-34 Checking the rope clamp connections on the rope drums (hoist gear represented as an
example)
(a) Rope clamp connection (b) Rope drum
1250 HC 40 / 49516 9 - 57
X Check fastening of the rope clamp connections at the rope drums for secure seating.
Checking all other rope connections

mined in good time
Fig. 9-35 Check the rope connections (different configurations represented within the example)
X Check fastenings and safety devices of all connecting parts (e.g. pins, axle support, cotter pins,
spring plugs and distance washers) for correct assembly and secure seating.
9.10.6 Cleaning the ropes
Fig. 9-36 Cleaning the ropes

Note
When cleaning the ropes, remove excess grease completely from the rope, otherwise newly applied
grease will not be able to permeate the rope.
X Clean the ropes with a brush if necessary.
9 - 58 1250 HC 40 / 49516
9.10.7 Cleaning the rope pulleys
Fig. 9-37 Cleaning the rope pulleys
X Remove excess grease from the rope pulleys.

1250 HC 40 / 49516 9 - 59
Operator’s cab
9.11 Operator’s cab
Interval: Once a year
Note
The lubrication intervals can be reduced if operation is being carried out under tough conditions:
9.11.1 Lubrication tasks at the front windshield
Note
New hinges on the front windshield are designed without grease nipples and do not require lubricat-
ing.
X Nevertheless, correct functioning of the hinges must be checked regularly.
Fig. 9-38 Hinges on the front windshield

(a) Hinge (b) Front windshield
X Ensure correct functioning of the hinges (a) on the front windshield (b).
The hinges (a) are stiff ?
X Lubricate the hinges (a).
9 - 60 1250 HC 40 / 49516
Operator’s cab
9.11.2 Lubrication tasks at the roof hatch
Fig. 9-39 Hinges on the roof hatch

(a) Hinges (b) Roof hatch
X Ensure correct functioning of the hinges (a) on the roof hatch (b).
The hinges (a) are stiff ?
X Lubricate the hinges (a).
1250 HC 40 / 49516 9 - 61
Operator’s cab
Maintenance: Air conditioner
Air filters:
Periodically remove the return air filters located above the removable panels in the air
box. Wash filters with soap and warm water, let dry and then reinstall (Fig. 9.C)
- Never run the air conditioner without return air filters in place !
- Frost formation on cooling unit: Under certain conditions, frost may from on
the evaporator coil. If this should occr, inspect the filter and clean if dirty. Make
sure air louvers are not obstructed. Air conditioners have a greater tendency to
frost when the outside temperature is relatively low. This may be prevented by
adjusting the thermostat control knob to a warmer setting (counterclockwise).
Should frosting continue, operate on low, med., or high FAN setting until the
cooling coil is free of frost.
Air box installation:
A. Remove the two return air grills and filters which are shipped loose the air box.
(Abb.9.A)
B. Slide the front end of the air box over the shafts of the thermostats and
selector switch. (Fig.9.B)
9 - 62 1250 HC 40 / 49516
Operator’s cab
Maintenance: Air conditioner
C. Install the four screws through legs in air box into the prepunched holes in the
ceiling temlate. NOTE: There are three optional mounting holes for which no
screws are provided. (Fig.9.C)
D. Install the return air grills and filters by simply pushing them into place.
(Fig.9.D)
E. Install the two knobs provided on the ends of the thermostat and selector
switch shafts.
F. The power supply to the air contitioner may now be turned ON.
1250 HC 40 / 49516 9 - 63
Analysing hydraulic oil / gear oil
9.12 Analysing hydraulic oil / gear oil
Extensive examinations and oil analyses have proven that contaminated oil will lead to premature
wear of aggregates.
This contamination may be caused by any one of the following:
– Dirt sticking to parts being reassembled following repair.
– Wear of hydraulic components / gear components.
– Dirt and moisture entering via the ventilation and aeration filters.
– Topping up oil deficits with unsuitable oil.
– Infiltration of dirt particles via cylinder rods.
Until now, the hydraulic oil / gear oil had to be changed every 2000 operating hours, and at least every
2 years. Necessity of the oil-change is largely dependent on the condition of the oil (viscosity, degree
of contamination etc.). These factors will depend on the respective application of the crane. This
means that oil-changes were carried out either too early or too late in accordance with the previously
prescribed change intervals.
The new method of the hydraulic oil / gear oil change, in accordance with the "Wear-Check lubricant
analysis" offers the following advantages:
– Oil-change intervals can be extended considerably wherever required, in accordance with appli-
cation conditions, and safely adapted effectively and economically.
– Servicing costs are reduced, the life-expectancy of the aggregates is increased and the purchas-
ing costs and disposal costs for lubricants are minimised.
– Any damage to the hydraulic system / gear system can be avoided.
– Unexpected machine failure, as well as shut-down and consequences thereof, are prevented.
– The environment is conserved as a result of reduced and controlled disposal.
Liebherr recommend the oil-change intervals for the hydraulics and the gears to be carried out in
compliance with the "Wear-Check lubricant analysis" as an alternative to the intervals used thus
far.
Customers can therefore obtain the following analysis kits from Liebherr:
– Individual analysis kit (Part No. 8145660)
– 6-piece analysis kit (Part No. 7018368 03)
– 6-piece bio-analysis kit (Part No. 7026088 03)
– 12-piece analysis kit (Part No. 7018369)
– Hand pump (Part No. 8145666 03) (only required once)
For further information see: Chap. 9.12.3 Taking a sample with the hand pump
If the Liebherr customer is in possession of one of these analysis kits, they may naturally take an oil
sample when the inspection interval is reached (see the corresponding aggregate description in the
chapter "Maintenance and inspection"), or in accordance with the specifications resulted in the last
laboratory report, and forward it to Wear-Check.
The customer will then be informed of the results obtained from the analysis (For further information
see: Chap. 9.12.4 Evaluating the laboratory report) via post, e-mail or fax two or three days after the
sample has arrived in the form of over 20 individual results.
For further information, see:
– www.wearcheck.com
– www.wearcheck.de
9 - 64 1250 HC 40 / 49516
9.12.1 Analysis kit
Fig. 9-40 Example: Contents of a 6-piece analysis kit

(a) Sample form (c) Extraction hose (e) Sampling container
(b) Courier bag (d) Courier envelope
9.12.2 Filling out the sample form

Fig. 9-41 Example: Sample form

(a) WC number with barcode (b) Machine / sample data (c) Address details
1250 HC 40 / 49516 9 - 65
Note
Do not change the labelling of a sample once it has been allocated.
The examination results are stored in a database and are printed out and interpreted on the respec-
tive laboratory report with the same sample labelling for subsequent tests .
X Enter all required data (for further information, see: www.wearcheck.de under menu item „Sample
delivery note“).
9.12.3 Taking a sample with the hand pump
Fig. 9-42 Taking a sample with the hand pump

(a) Hose (d) Hand pump (g) Hand pump (complete).
(b) Knurled screw (e) Sampling container (h) Oil filling inlet
(c) Seal (f) Cover, sampling container
Note
All oils featuring a viscosity of ISO 680 or SAE 60 or SAE 140 or less ,as well as all other liquids,
can be pumped cleanly and easily into the sampling container using the handpump.

The oil is at operating temperature.
The oil sample is taken a few minutes following shut-down (observe the recommended guidelines
for service intervals or sample extraction intervals).

The oil sample is always taken from the same point and always using the same method.
The oil sample is never taken from the filter, but rather in front of the filter, wherever possible.
The oil sample is taken shortly after an oil-change or following topping up with a large quantity of
oil.
Only clean and dry sampling containers are used for filling the oil sample into; preferably, imme-
diately into the "original" from the analysis kit.
X Ensure cleanliness of the hand pump (d), if necessary, clean with a clean rag.
9 - 66 1250 HC 40 / 49516
X Cut a new hose (a) to the required length with an angle of 45°.
- or -
Use the same hose (a) as was previously used to for the same oil type again, after cleaning and
rinsing thoroughly.
X Loosen the knurled screw (b) on the hand pump (d) until it is possible to push in the hose (a).
X Push in the hose (a) (the end of the hose should protrude approx. 1 cm into the receptacle) and
tighten the knurled screw (b).
X Unscrew the lid (f) of the sampling container (e) and screw the sampling container (e) onto the
hand pump (d).
Note
Clean the area around the point where the sample was extracted thoroughly.
Avoid contamination of the hose.
X Insert the end of the hose (canted at an angle of 45°) through the oil filling inlet (h) or the vent for
the hydraulic tank / gear tank only so far into the oil that it does not touch the base of the tank or
the oil pan.
Note
When pumping, always hold the hand pump (d) so that the sampling container (e) is positioned ver-
tically.
X Continue pumping until the sampling container (e) has been filled to approx. 1 cm below the rim.
X Unscrew the sampling container (e) and tightly screw on the lid (f).
X Fill out the sample delivery pump completely (For further information see: Chap. 9.12.2 Filling out
the sample form).
X Pull the adhesive label featuring the WC-number and the barcode from the sample delivery note
and stick it onto the sampling container.
ª It is thus instantly recognisable which sampling container belongs to which sample delivery note.
Note
Only use the "Wearcheck" courier envelope provided.
The courier envelope is filled with shredded waste paper to soak up the oil sample should a leak in
the sampling container occur.
X Put the sampling container and the original sample delivery note (copy or detached sample doc-
ument is withheld by the sender) into the "Wearcheck" courier envelope and close only with the
envelope clip (saves on charges).
X Send the sample as a trade sample.
1250 HC 40 / 49516 9 - 67
9.12.4 Evaluating the laboratory report
Fig. 9-43 Example: Laboratory report

(a) Symbol identification: Values within the per- (f) Laboratory values regarding wear, con-
missible tolerances tamination, oil condition, additives and
additional tests
(b) Symbol identification: Values compared with (g) Basic data of the sample
(a) slightly increased. Observe the notes in the
text field.
(c) Symbol identification: Value is outside of the (h) Machine data
tolerance range. It is imperative that the notes
in the text field are observed.
(d) Text field with notes (i) Address field
(e) Laboratory values from previous examinations (j) Sample description
Using the symbol identification (a, b, c), it is possible to determine from the result whether the oil must
be changed or whether the oil currently being used is still okay.
The determined numerical values are denoted in the text field (d). Evaluation does not only take the
condition of the oil sample into consideration, but also the respective machine type. The comments
tell you whether the condition of the hydraulic system / gear system is okay or whether continued
operation will result in damage being caused.
9 - 68 1250 HC 40 / 49516
Lubricant chart for Liebherr cranes
9.13 Lubricant chart for Liebherr cranes
9.13.1 Notes in general
Note:
Intervals for changing the oil and the lubricant
The oil-change intervals are dependent upon the respective gear types.
It should be noted that special lubricants are required for certain gears.
Flushing
If the drained oil indicates heavy contamination, we recommend flushing the gearboxes before re-
filling them. The same oil type should be used for scavenging to prevent the oil from thinning. Ben-
zine and petrol are not permissible.
Procedures are described in the 'Maintenance' chapter in the operating instructions of the respec-
tive crane.
X Follow the details in the instruction manual (for further information see: Chap. ›Maintenance and
inspection‹.)
9.13.2 Lubricant requirements
Outside Type Liebherr

Lubricating points Specification
temperature ISO VG / SAE Lubricants
Liebherr Hydrau-
up to -25 °C ISO VG 32-68 DIN 51524 T3 / HVLPD lic HVI
Part No. 10356791
Liebherr Hydrau-
Spur gear (electro- ISO VG 32-68
up to -25 °C 1) + 3) + 4) DIN 51 524 T3 / HVLPD HC lic Plus
magnetic shift)
Part No. 10356303
ISO 6743T4 / HEPR
quickly biodegradable Liebherr Hydrau-
ISO VG 15-46 in accordance with CEC-L-33-A-93
up to -40 °C 1) + 3) + 4) lic Plus Arctic
Part No. 10356825
Liebherr Hydrau-
up to -25 °C ISO VG 32-46 DIN 51524 T2 / HVLP lic 37
Part No. 10675471
Hydraulic brakes DIN 51 524 T3 / HVLPD HC Liebherr Hydrau-
ISO VG 15-46 ISO 6743T4 / HEPR
quickly biodegradable
in accordance with CEC-L-33-A-93
Part No. 10356825
Tab. 9-7 Lubricant requirements
1250 HC 40 / 49516 9 - 69

Liebherr Hydrau-
up to -25 °C ATF Dexron II D lic Gear ATF
Part No. 10356828
Oil-hydraulic sys- Liebherr Hydrau-
tems up to -20 °C ISO VG 32-68 DIN 51524 T3 / HVLPD lic HVI
Part No. 10356791
Fluid couplings Liebherr Hydrau-
(as transmission ele- ISO VG 32-68
up to -25 °C 1) + 3) + 4) DIN 51 524 T3 / HVLPD HC lic Plus
ment in gears) Part No. 10356303
ISO 6743T4 / HEPR
quickly biodegradable Liebherr Hydrau-
ISO VG 15-46 in accordance with CEC-L-33-A-93
Part No. 10356825
Liebherr Gear
ISO VG 100 /
up to -25 °C DIN 51517 T3 CLP / API GL 4 Plus 20W-40
SAE20W-40
Part No. 10356831
Liebherr Syntoge-
ISO VG 100 / DIN 51517 T3 CLP-HC / API
Spur gears up to -40 °C ar Plus 75W-90
SAE75W-90 GL 5
Part No. 10356826
(mechanically shiftable
and not shiftable) ISO VG 220 / Liebherr Gear Ba-
up to -25 °C DIN 51517 T3 CLP / API GL 5 sic 90LS
SAE85W-90
Part No. 10356829
up to -40 °C ISO VG 220 1) DIN 51517 T3 / CLP-HC —
2)
up to -40 °C ISO VG 220 DIN 51517 T3 / CLP-PG —
1)
up to -40 °C ISO VG 320 DIN 51517 T3 / CLP-HC —
Worm gear unit 2)
up to -40 °C ISO VG 320 DIN 51517 T3 / CLP-PG —
Anti-friction bear- Liebherr Universal
up to -25 °C NLGI 2 DIN 51502 / KPF 2 N-25
ings, bushings, roller Lithium-grease
grease 9900
bearings Part No. 10358949
Liebherr Universal
Slewing ring (ball up to -60 °C NLGI 1 DIN 51 502 / KPFHC 1 N-60 grease Arctic
track) Part No. 10358948
Liebherr Spray
DIN 51502 / MPF 00 G-40 paste
Part No. 10358950
up to -25 °C
Liebherr Universal
Lubricant and
Open gear wheels DIN 51502 / KPF 2 N-25 grease 9900
preservative
Part No. 10358949
Liebherr Universal
up to -60 °C DIN 51 502 / KPFHC 1 N-60 grease Arctic
Part No. 10358948
Liebherr WR-Lube
Adhesive lubri-
Ropes up to -40 °C — SC
cant
Part No. 10173371

Liebherr Special
High-tensile bolt con-
up to -40 °C — — screw paste 5)
nections
Part No. 10171336
Liebherr Tele-
scopic grease
Telescopic tower up to -40 °C NLGI 2 DIN 51502 / KP 2 K-30
9613 Plus
Part No. 10358947
9 - 70 1250 HC 40 / 49516

1)
HC / Synthetic hydrocarbon ( PAO ) also at low temperatures
2)
PG / Polyglycol (not to be mixed with mineral oils or synthetic oils)
3)
HEPR / Synthetic hydrocarbon / synthetic ester
4)
HEES / Synthetic ester (please consult Liebherr services)
5)
TI 690a/2008 must be observed
Note:
Please contact your Liebherr service partner to obtain additional information or to place orders.
Liebherr-Lubricant-Hotline
+ 49 (0) 7354/80-6060
lubricants@liebherr.com
1250 HC 40 / 49516 9 - 71
Lubricants, fluid capacities
9.14 Lubricants, fluid capacities
Note
Additonal details and notes regarding lubricants can be obtained in the chap. ›Lubricant chart for
Liebherr cranes‹.
Designation Medium Specification Classification Quantity
Hoist gearbox:
WIW 300 VZ 427
Spur gear hydraulic flu-

HLPD 32 ISO VG 32 20,0 l
GET 450 JX 427 id
Angular gear Lubricating ISO VG 100

CLP 100 95,0 l
GET 4600 MW 401 oil SAE 80
Brake hydraulic flu-

HLPD 32 ISO VG 32 8,0 l
BRE 3300 BY 404 id
Lubricating ISO VG 100

CLP 100 19,5 l
Trolley travel gearbox oil SAE 80
DRW 200 AZ 403 NLGI 2
DRW 200 AZ 404 Lubricating
Lithium-based 0,75 kg
grease
grease
Travel gearbox
Synthetic oil CLP PG 220 ISO VG 220 10,0 l
KAW 200 KY 001
Roller track roller slew-

NLGI 2
ing ring (centralised lubri- Lubricating KPE 2 K-30 7000,0 cm3
Lithium-based
cation system: container grease DIN 51 825 per year
grease
capacity 8 l)
roller slewing ring tooth

NLGI 2
system (centralised lubri- Lubricating KPE 2 K-30 1500,0 cm3
Lithium-based
cation system: container grease DIN 51 825 per year
grease
capacity 4 l)
Rope end fittings
Tab. 9-8 Filling amounts

9 - 72 1250 HC 40 / 49516
Instruction Manual Repair
10 Repair
This chapter has been compiled exclusively for authorised, skilled personnel.
1250 HC 40 / 49516 10 - 1
Repair Instruction Manual
Notes on safety for repair
10.1 Notes on safety for repair
10.1.1 Who may carry out repair tasks?

Repair tasks may only be carried out by skilled personnel authorised by Liebherr. Do not attempt any
repair tasks with which you are not familiar. If necessary, request the assistance of Liebherr service
technicians.
10.1.2 Safety measures

– Switch off the crane and secure against incorrect or unauthorised restart.
– If there is any danger of falling objects: Cordon off the danger area or secure the area with warning
signs.

– Safety helmet
– Protective gloves
– Safety boots
– Safety harness for tasks on the crane
10.1.4 Which additional guidelines must also be noted?

– Local guidelines for accident-prevention
10.1.5 Which dangers can be resulted from the crane?

– Danger of crushing around the entire crane
– Danger resulting from electrical energy
– Danger resulting from hydraulic energy
10.1.6 Restarting the crane following repairs and modification work

The crane may only be restarted following repair work if the contractor or a representative of his au-
thorises operation to be recommenced.
Before this authorisation is granted, the contractor must ensure that

– that all tasks have been carried out to completion
– that the entire crane is once again in an operationally-safe condition
– all personnel who were involved in carrying out the repair tasks have left the crane
10 - 2 1250 HC 40 / 49516
Hoist gear brake
10.2 Hoist gear brake
Brake type: BRE 3300 BY 404
10.2.1 Preparing for repair tasks
Fig. 10-1 Preparations prior to repair
X Set down and remove any suspended load. (1)

X Raise the load hook to maximum hook height and manoeuvre the trolley to minimum reach. (2)
X Change over to 4-run operation (for further information, see: Operation › 4-run / 2-run operation ‹).
X Connect two bottom hook blocks and two trolleys with four locking devices. (3)
X Fit the rope clamp on the tower head. (4)
X Relieve tension in the hoist rope. (5)
X Shut down the crane (main switch to 0 ›Off‹ and secure against unintentional activation. Lock the
main switch in the ›Off‹ position). (6)
1250 HC 40 / 49516 10 - 3
Hoist gear brake
10.2.2 Components of the hydraulic brake
Fig. 10-2 Components of the hydraulic brake

(a) Terminal box (e) Brake housing
(b) Breather filter with oil dipstick (filling inlet) (f) Brake callipers
(c) Pressure line (g) Hydraulic aggregate
(d) Brake cylinder (h) Terminal box
10 - 4 1250 HC 40 / 49516
Hoist gear brake
Components of the brake callipers
Fig. 10-3 Components of the brake callipers

(a) Brake lever (cylinder side) (k) Fastening nut (tightening torque 130 Nm)
(b) Brake lever (opposite side) (l) Locking washer
(c) Return springs (m) Brake cylinder
(d) Fastening bolts (n) Pressure connection
(e) Brake shoe (o) O-ring
(f) Parallel guide rod (p) Safety plug
(g) Brake block (q) Nut (SW 19)
(h) Brake disc (r) Protective cap
(i) Wear indicator (embedded in the (s) Condensed water borehole (must be pointing down
brake block) at all times)
(j) Tappet (t) Lower bleed screw
10.2.3 Setting values
Thickness A of brake lining [mm] Thickness B of brake disc [mm]

minimum remaining useful thickness minimum new
2 12 14 mm
Tab. 10-1 Values for BRE 3300 BY 404
1250 HC 40 / 49516 10 - 5
Hoist gear brake
Fasteners Tightening torque [Nm]

Fastening nut on the tappet 130
Fastening screws on the housing (brake calliper) 87
Tab. 10-2 Tightening torque BRE 3300 BY 404
10.2.4 Checking brake lining and brake disc
Fig. 10-4 Checking brake lining and brake disc

(a) Knurled screw (c) Brake block
(b) Cover plate (d) Brake disc

All measures required for preparations prior to repair have been taken (For further information,
see: chap. 10.2.1 Preparing for repair tasks).
X Loosen the knurled screw (a) and remove the cover plate (b).
X Measure the remaining useful thickness (see: Tab. 10-1) of the brake blocks (c).
X If the minimum value of the brake block has been reached: Replace the brake blocks (c). For
further information, see: chap. 10.2.5 Replacing the brake blocks.

X Thickness (see: Tab. 10-1) of the brake disc (d). (2)
X If the minimum value of the brake disc is reached: Replace the brake disc (d) (to be carried out by
Liebherr service technicians only).
10 - 6 1250 HC 40 / 49516
Hoist gear brake
10.2.5 Replacing the brake blocks
Note
Brake blocks require replacing in the event of:
– the horn sounding during lowering in stage 1.
– the warning lamp lighting up on the control panel.
X The brake blocks must be replaced at the very latest 40 operating hours after receiving the war-
ning
- or -
if the residual useful thickness measures 2 mm or less.
Fig. 10-5 Releasing the brake

(a) Sealing cover (d) Protective cap
(b) Locking pin (e) Screw connection
(c) Nut

All measures required for preparations prior to repair have been taken (For further information,
see: chap. 10.2.1 Preparing for repair tasks).
X Actuate the „HS1M“ switch for manual bleeding of the brake to position 2 (HOIST GEAR BRAKE
RELEASED) in the switching station.
X Remove the cover plate (For further information, see: chap. 10.2.4 Checking brake lining and bra-
ke disc).
X Remove the protective cap (d) and unplug the safety plug (b).
Warning!
Tensioned spring! Do not loosen the screw connections (e)!
X The brake cylinder may only be opened by the manufacturer.
X Turn the nut (a) against the sealing cover (a) until the brake is retained in the released position.
X This action is to be carried out on both brake callipers.
ª Only then may the brakes be released completely.
1250 HC 40 / 49516 10 - 7
Hoist gear brake
Removal and replacement
Fig. 10-6 Disconnecting the brake calliper from the brake housing
(f) Screw connection (g) Brake calliper
X Loosen the three screw connections (f) and disconnect the brake calliper (g) from the brake hou-
sing.
Fig. 10-7 Replacing the brake blocks

(h) Brake block (j) Terminal box
10 - 8 1250 HC 40 / 49516
Hoist gear brake

(i) Retainer plate (k) Connecting cable for the wear indicator
X Bend back the retainer plate (i) of the brake blocks (h) over the brake shoe. (1)
X Remove the brake block (h) and disconnect the connecting cable (k) of the electrical wear indica-
tor in the terminal box (j). (2)
X Press the new brake block into the recess in the brake shoe and secure by bending around the
retainer plate. (3)
X Connect the connecting cable (k) for the wear indicator as described in the connection chart (see:
Fig. 10-7). (4)
Installation and setting
Lubricate the bearing points and the contact surfaces

The following contact surfaces have been treated with molybdenum-based lubricant paste or copper
paste:
– Bearing points of the brake lever
– Contact surfaces of the hexagonal tappet on the brake lever (opposite side)
– Guide of hexagonal tappet in the brake cylinder
Fig. 10-8 Lubricate the bearing points and the contact surfaces
(a) Bearing points of the brake lever (c) Guide of hexagonal tappet in the brake cylinder
(b) Contact surfaces of the hexagonal tappet

on the brake lever (opposite side)
X When replacing the brake blocks, check freedom-of-movement of the brake lever. If necessary,
lubricate the bearing points.
1250 HC 40 / 49516 10 - 9
Hoist gear brake
Installation and setting

(a) Return spring (c) Hexagonal tappet
(b) Brake lever (d) Brake cylinder
X Remove the return springs (a) and push the brake lever (b) apart. (1)
X Turn the hexagon tappet (c) in a clockwise direction as far as the stop in the brake cylinder (d). (2)
Fig. 10-10 Fitting the brake calliper in the brake housing

(e) Brake calliper (g) Nut
(f) Bolt (h) Lock nut
X Fit the brake calliper (e) in the brake housing using three screws (f). Secure each screw (f) with a
10 - 10 1250 HC 40 / 49516
Hoist gear brake
nut (g) (observe the tightening torque (see: Tab. 10-2)) and lock the lock nut (h). (3)
Fig. 10-11 Setting the brake lever

(i) Brake lever (l) Bearing surface, hexagon tappet
(j) Hexagonal tappet (m) Brake lever flute base
(k) Brake cylinder (n) Return spring
Note
To ensure that the brake can be set properly, the brake blocks must be sitting on the brake disc.
X Push the brake lever (i) apart. (4)

X Unscrew the hexagon tappet (j) out of the brake cylinder (k) until a gap of 6 mm has been opened
up between the bearing surface (l) of the hexagon tappet and the brake lever flute base (m). (5)
X Align the hexagon of the tappet parallel to the groove.
X Hook in the return springs (n). (6)
1250 HC 40 / 49516 10 - 11
Hoist gear brake
Fig. 10-12 Apply the brake

(o) Sealing cover (q) Nut
(p) Locking pin (r) Protective cap
X Turn the nut (q) back into the start position and insert the locking pin (p).
X Fit the protective cap (r).
X This action is to be carried out on both brake callipers.
ª Only then is the brake fully applied
X Actuate the „HS1M“ switch for manual bleeding of the brake to position 1 (HOIST GEAR BRAKE
OPERATION) in the switching station.
X Change over the load hook from 4-run to 2-run operation (for further information, see: Operation
› 4-run / 2-run operation ‹).
Warning!
Risk of injury if the brakes have not been installed properly.
If the brake has not been properly fitted, the hydraulic system could lose pressure and the braking
action could diminish.
X Actuate the brake continuously and ensure secure fastening and sealing of all screws, nuts and
connections, tighten the connections as required.
X Mount the cover plate and secure with knurled screw (see: Fig. 10-4).
10 - 12 1250 HC 40 / 49516
Slewing gear brake
10.3 Slewing gear brake
Brake type: BFK 458-18 E
10.3.1 Preparations prior to repair
Fig. 10-13 Removing the fan cover

(a) Slewing gear brake (c) Nut
(b) Hand-operated brake release lever (d) Fan cover

restart. The main switch is locked in the ›Off‹ position.
Free jib slewing is not activated.
Easy access to the slewing gear brake (a) can be obtained by removing the fan cover (d).
X Unscrew the hand-operated brake release lever (b). (1)

X Unscrew the four nuts (c). (2)
Caution!
X Do not damage the fan cable when removing the fan cover (d).
X Remove the fan cover (d) from above. (3)
1250 HC 40 / 49516 10 - 13
Slewing gear brake
10.3.2 Adjusting data
Air gap A Thickness B of the brake disc with lining

minimum maximum minimum when new
0.7 mm 1.2 mm 10 mm 13 mm
Tab. 10-3 Values for air gap and brake disc BFK458-18 E
Fastening screws Tightening torque [Nm]

23
Tab. 10-4 Tightening torque BFK 458-18 E
Jib length [m] Max. possible braking moment [Nm] Setting value D [mm]
1)
41.5 - 81.0 120 0,4
Tab. 10-5 Setting dimension for braking moment BFK 458-18 E
1)
When replacing the brake (spare part) or at initial start-up of the brake, the braking moment (pre-
adjusted at the factory to 100 Nm) must be re-adjusted (For further information see: Chap. ›Adjusting
the braking moment‹).
10.3.3 Checking the air gap and the brake disc
Fig. 10-14 Checking the air gap and the brake disc
(a) Sleeved screw (c) Armature disc (d) Magnet piece
(b) Brake disc

the measures for preparing for the repair tasks have been carried out. For further information, see:
10 - 14 1250 HC 40 / 49516
Slewing gear brake
chap. 10.3.1 Preparations prior to repair

X Measure the air gap A (see: Tab. ›Values for air gap and brake disc‹) with feeler gauge around all
sleeved screws (a) (between armature disc (c) and magnetic piece (d)). (1)
X If the maximum value of the air gap is reached: Adjust the air gap to the permissible minimum va-
lue. For further information, see: chap. 10.3.4 Adjusting the air gap.
X Measure the thickness B (see: Tab. ›Values for air gap and brake disc‹) of the brake disc (b) using
the calliper gauge. (2)
X If the minimum value of the brake disc is reached: Replace the brake disc. For further information,
see: chap. 10.3.5 Replacing the brake disc.
10.3.4 Adjusting the air gap
Fig. 10-15 Adjusting the air gap

(a) Fastening screw (b) Sleeved screw

X Loosen the six fastening screws (a). (1)
X By adjusting the sleeved screw (b), set the air gap A (see: Tab. ›Values for air gap and brake disc‹)
around all sleeved screws (b) to minimum value. (2)
1/ of a turn of the sleeved screw reduces the air gap by approx. 0.15 mm.
6
X Screw in all fastening screws (a) again. At the same time, observe the correct tightening torque
1250 HC 40 / 49516 10 - 15
Slewing gear brake
(see: Tab. ›Tightening torque‹).

X Check the air gap A (see: Tab. ›Values for air gap and brake disc‹) around all sleeved screws (b).
For further information, see: chap. 10.3.3 Checking the air gap and the brake disc.
X Ensure correct functioning of the brake.
10.3.5 Replacing the brake disc
Fig. 10-16 Removing the hood and the rotary encoder

(a) Hood (d) Rotary encoder (g) Washer
(b) Screw (e) Clamp bolt
(c) Washer (f) Screw

10 - 16 1250 HC 40 / 49516
Slewing gear brake
Note
The wind release device remains installed on the brake coil body.
Note
The rotary encoder is a sensitive component.
X Please ensure during assembly / disassembly that the rotary encoder does not sustain damage.
X Unscrew the three screws (b) and remove the three washers (c).
X Remove the fan cover (a) from above. (1)
X In order to disconnect the rotary encoder (d) from the shaft: Loosen the clamp bolt (e). (1)
X Unscrew the two fastening screws (f) and remove the two washers (g). (2)
Fig. 10-17 Replacing the brake disc

(h) Fastening screw (j) Free jib slewing (l) Brake disc
(i) Brake coil body (k) Shaft (m) Hub
X Loosen the six fastening screws (h). (3)

X Remove the brake coil body (i) with free jib slewing (j). (4)
X Remove the brake disc (l) from the hub (m) and re-install the new brake disc. (5)
Assembly is carried out in reverse order.
X Screw in all fastening screws (h) again. At the same time, observe the correct tightening torque
1250 HC 40 / 49516 10 - 17
Slewing gear brake
(see: Tab. ›Tightening torque‹).

X Check the air gap A around all sleeve screws (For further information, see: chap. 10.3.3 Checking
the air gap and the brake disc).
10.3.6 Adjusting the microswitch

The microswitch serves the air control. The microswitch is pre-set at the factory. Readjustment is usu-
ally only necessary following a replacement or repair.
Fig. 10-18 Adjusting the microswitch on the slewing gear brake

(a) Manual operation ›Brake released‹ (c) Microswitch (e) Screw
(b) Hand-operated brake release lever (d) Fastening screw (f) Nut

the measures for preparing for the repair tasks have been carried out.For further information, see:
X Check the air gap A around all sleeve screws (For further information, see: chap. 10.3.3 Checking
the air gap and the brake disc).
X Screw in the hand-operated brake release lever (b) and activate the free jib slewing manually (for
further information, see: chap. ›Crane operation - Manual actuation of the free jib slewing‹). (1)
X Screw in the screw (e) precisely to the switch point towards the microswitch (c).
X When the switch point has been reached: Screw in the screw (e) another 60° towards the mic-
roswitch (c).
X Lock the screw (e) with the nut (f). Ensure at the same time, that the position of the screw (e) does
not shift.
X Secure the nut (f) and fastening screws (d) using locking paint.
X Check as to whether the switch point is still passed over.
X Manually deactivate the free jib slewing (for further information, see: chap. ›Crane operation - Ma-
nual actuation of the free jib slewing‹).
10 - 18 1250 HC 40 / 49516
Slewing gear brake
10.3.7 Adjusting the braking moment

When replacing the brake (spare part) or at initial start-up of the brake, the braking moment (pre-ad-
justed at the factory to 100 Nm) must be re-adjusted.
Fig. 10-19 Adjusting the braking moment

(a) Hook wrench (b) Adjusting ring
X Measure the setting dimension D with the feeler gauge.

X Turn the adjusting ring (b) with the hook wrench (a) until the required setting imension D (see: Tab.
›Setting dimension for braking moment‹) has been reached.
ª The adjusting ring (b) must engage.
The braking moment changes 1.6 Nm per notch.
1250 HC 40 / 49516 10 - 19
Trolley travel gear brake
10.4 Trolley travel gear brake
Brake type: BM 15 HR
Fig. 10-20 Preparations prior to repair
X Set down the load.

X Raise the load hook to the minimum hook level. (1)
X Trolley-in to the minimum radius. (2)
X Shut down the crane (master switch to 0 ›Off‹). (3)
10 - 20 1250 HC 40 / 49516
Trolley travel gear brake Type BM 15 HR (Order No. 5020 306 01; 1017 0274) Sheet 1 of 3
for trolley travel gears: KAW 160 KV 015; KAW 170 KY 006; KAW 200 KY 001 / KY 002
Check for correct operation every day!
Braking moment
stop ! adjusted
at the factory!
50 Nm
if the braking effect decreases!
Check the brake disk, air gap

and play of the manual release!
Trolley travel gear
brake applied!
Trolley travel gear Adjusting nuts
Manual release for air gap !
Fastening
pins !
„B“
2.0 mm
„B“ „A“
Brake disk with Air gap
lining (mm) (mm) „A“
new
min. min. max. Check at
lining
all
10.0 14,2 0.3 1.2 adjusting
nuts.
Push the sealing

ring aside.
If the maximum value of the air gap is reached - adjust it !

If the minimum value of the brake disk is reached - replace it !
1250 HC 40 / 49516 10 - 21
Trolley travel gear brake: Adjusting the air gap Sheet 2 of 3
Adjusting the air gap !
5 2.0 mm
Reset the
adjusting nuts.
Push the sealing

ring aside.
Reposition the sealing ring (the
condensate hole must point down).
"A" = 0.3 mm (minimum value)
Measure at all adjusting nuts.
Check for correct

operation!
If the minimum value of the brake disk is reached - replace it !
10 - 22 1250 HC 40 / 49516
Trolley travel gear brake: Replacing the brake disk Sheet 3 of 3
Secure the trolley

against rolling away!
Pull off the brake coil body and the brake disk.
Fit the new brake disk

(observe the gear teeth). Remove the nuts.
Push the sealing
ring aside.
2.0 mm
Refit the brake coil body.
Measure at
all adjusting
nuts.
Check for
correct
operation!
Tighten the adjusting nuts
and adjust the air gap.
"A" = 0.3 mm (min.)
Reposition the sealing ring (the
condensate hole must point down).
1250 HC 40 / 49516 10 - 23
Free jib slewing
10.5 Free jib slewing
If the free jib slewing is not functioning properly, it might have been incorrectly set.
Fig. 10-21 Removing the fan cover

(a) Slewing gear brake (c) Nut
(b) Hand-operated brake release lever (d) Fan cover

restart. The main switch is locked in the ›Off‹ position.
Removing the fan cover (e) allows easy access to the slewing gear brake (a).
X Unscrew the hand-operated brake release lever (b). (1)
X Unscrew the four nuts (c). (2)
Caution!
X Do not damage the fan cable when removing the fan cover (d).
X Remove the fan cover (d) from above. (3)
10 - 24 1250 HC 40 / 49516
Free jib slewing
10.5.2 Adjusting data
Air gap A Air gap C

minimum maximum minimum maximum
0.7 mm 1.2 mm 0.35 mm 0.39 mm
Tab. 10-6 Air gap values for free jib slewing
10.5.3 Checking the air gap
Fig. 10-22 Checking the air gap

(a) Manual operation ›Brake released‹ (c) Sleeved screw (e) Magnet piece
(b) Hand-operated brake release lever (d) Armature disc

Activating manual free jib slewing

X Screw in the manually operated brake release lever (b).
X Push the hand-operated brake release lever (b) upwards to the stop and secure in this
position. (1)
X Push the manual actuation ›release brake‹ (a) up to the stop and hold pressed. (2)
ª The ›Brake released‹ locking is pushed under the hand-operated brake release lever (b).
1250 HC 40 / 49516 10 - 25
Free jib slewing
X Release the hand-operated brake release lever (b).

X Release the ›release brake‹ manual actuation (a)
ª The brake remains locked in the released position.
Checking the air gap

X Measure the air gap C (see: Tab. 10-6) with the feeler gauge around all sleeved screws (between
the armature disc (d) and magnet piece (e)). (3)
The air gap C is outside of the tolerances?
X Manually deactivating the free jib slewing.
X Check the air gap A around all sleeved screws, adjust as necessary (for further information, see:
chap. ›Slewing gear brake - Checking the air gap and the brake disc‹).
X Measure the air gap C again, adjust as necessary (For further information, see: chap. 10.5.4 Ad-
justing the air gap).
10.5.4 Adjusting the air gap
Fig. 10-23 Adjusting the air gap C

(a) Tie bar (b) Nut

X Activate the free jib slewing manually (For further information, see: chap. 10.5.3 Checking the air
gap).
X Loosen the nut (b) on the two tie bars (a). (1)
10 - 26 1250 HC 40 / 49516
Free jib slewing
X With equilateral adjustment of the tie bars (a), adjust the air gap C (see: Tab. 10-6) to the minimum
value. (2)
X Lock the two tie bars (a) with nut (b). (3)
X Check the air gap C (see: Tab. 10-6) around all sleeved screws. For further information, see: chap.
10.5.3 Checking the air gap. (4)
X Check functioning of the free jib slewing and the brake.
1250 HC 40 / 49516 10 - 27
Ropes
10.6 Ropes
10.6.1 Transporting ropes
Fig. 10-24 Transporting the ropes correctly
Caution!
Damage to the rope.
X Do not allow the rope to come into direct contact with a load hook or the fork of a fork-lift truck.
X Lift and transport the reel using a rod which has been inserted through the bore of the reel. (1)
- or -
Lift and transport the rope pulleys using wide, textile lifting straps. (2) LBC/en/01/Issued: 07.11
10 - 28 1250 HC 40 / 49516
Ropes
10.6.2 Storing the ropes
Fig. 10-25 Storing the ropes

the storage area is clean, cool and dry
only store the ropes on top of palettes and avoid contact with the ground.
the ropes are covered if stored outside. avoid the formation of condensation via the insertion of
an intermediate layer made of sacking
the ropes are protected against strong sunlight. Otherwise the lubricant in the ropes will liquify and
rip off.
10.6.3 Unwinding the rope from the reel
Caution!
The ropes will become distorted, as well as develop kinks and bends, if the rope is unwound from
the reel from a sidewards angle.
X Before unwinding the rope, mount the reel onto a turntable or stand.
1250 HC 40 / 49516 10 - 29
Ropes
Fig. 10-26 Unwinding the ropes
10.6.4 Rewinding the ropes from the reel onto the rope drum
Fig. 10-27 Rewinding the rope
Caution!
Damage to the rope as a result of rewinding from the reel onto the rope drum!
X Only rewind the rope under very light tension (1…2 % of the minimum rupture force of the rope).
X Ensure that the rope retains the preferred direction of bending.

X Do not drag the rope over sharp-edges. Protect points where abrasion may occur using wood.
X Do not drag the rope along the ground.
X Only brake the reel at the reel flange using a board.
X Rewind the rope under light tension (1…2 % of the minimum rupture force of the rope) from the
10 - 30 1250 HC 40 / 49516
Ropes
reel onto the rope drum. When rewinding, the rope must retain the preferred direction of bending.
X Brake the reel at the reel flange using a board.
10.6.5 Preparations prior to reeving of the rope and reeving the rope
Only use ropes which comply with the specifications in the Liebherr rope list. If ropes are used which
do not comply with the specifications in the Liebherr rope list, sound operation of the crane can no
longer be guaranteed. Reeve the ropes in accordance with the rope reeving diagrams. For further
information, see: Chap. Erection.
If non-twist ropes are used: Non-twist ropes should only be run with fixed points at both ends.

the crane has been shut down (crane control „Off“ and master switch „Off“)
the rope drum and rope pulleys rotate lightly in the bearing
The rope diameter fits perfectly in the grooves in the rope pulleys and the rope drum (the radius
of the groove on the rope drum and rope pulleys totals at least R = 0.53 mm x rope nominal
diameter).
The rope pulleys do not indicate any wear (depressed rope profile, too small a diameter D1).
The twist compensator is fixed: when using hoist ropes which are not free to rotate.
The twist compensator is freely rotatable: when using hoist ropes which are free to rotate.
Fig. 10-28 Checks before reeving the ropes

1250 HC 40 / 49516 10 - 31
Ropes
Fig. 10-29 Checking the nominal rope diameter (example)
X Reeve a rope that is the same type, strength and nominal diameter as the original, and check the
nominal rope diameter. (1)
Note
In the event of multilayer drum winding, the actual rope diameter may be a maximum 3,5 % over the
nominal rope diameter.
Gradient of the groove on the rope drum totals 4%. If the rope featured the same tolerance, this
could lead to the rope becoming clamped. Each winding of the rope may not come into contact with
the previous winding on any one layer.
Fig. 10-30 Utilisation of hoisting stockings

X Securing the rope on a ready-mounted old rope or on an auxiliary rope.

At the same time, ensure that no rigid connection between the old rope and the new is resulted
otherwise any twists in the old rope will be transferred onto the new rope. The utilisation of two
open cable grips, connected to one another for example via a chord or a thin wire is recommen-
ded.
X Fasten the ropes securely to the rope drums and rope end fittings (e.g. wedge sockets, twist com-
pensators).
X Reeve the rope with the same direction as the rope drum.
10 - 32 1250 HC 40 / 49516
Ropes
X Ensure when reeving that the rope is running correctly in the grooves of the rope pulleys.
X If certain length of rope has to be laid out on the ground for reeving: Ensure that the rope runs in
without any twists.
X A test-run of several lifts under partial load and later with alternately loaded and unloaded hook
block is required. The rope thus adapts itself to the direction of bending and the bending radii.
10.6.6 Rectifying twists in the hook block
Caution!
If the hook block becomes twisted, the ropes above the hook block will clash with each other. This
will result damage to the rope.
Caution and expertise are required to rectify twisting of the ropes. Do not forcefully turn the ropes
over short rope lengths!
With twist-free hoist ropes (twist compensator open), if should be sufficient to run the crane trolley
without a load a few times.
Further possibility:
X Trolley-in to the minimum radius.
X Attach a load.
X Hoist-up, at the same time trolley-out to the jib tip end stops.
If the twists have still not been rectified:

X Hoist-down to lower the hook block onto supports on the ground. Use a suitable support.
X If working with fast-erecting cranes: Set down the jib.
X Open the twist compensator and turn the twist compensator or the hoist rope so that twisting of
the hook block is compensated.
X Fix the twist compensator.
X Raise and lower the hook block without load. At the same time, move the trolley backwards and
forwards.
ª The twists are distributed over the entire rope length.
X Release the twist compensator again.
Twisting of the hook block has not been rectified?
The hoist rope is still twisted.
X Repeat the aforementioned procedure
1250 HC 40 / 49516 10 - 33
Ropes
10 - 34 1250 HC 40 / 49516
Instruction Manual Optional equipment
11 Optional equipment
1250 HC 40 / 49516 11 - 1
Optional equipment Instruction Manual
Centralised lubrication system (Display)
11.1 Centralised lubrication system (Display)
Fig. 11-1 Centralised lubrication system components

(a) Display window (f) Reducing fitting (j) Control panel
(b) Cover, receptacle (g) Hose line to distributor (k) Connecting plug, power
supply
(c) Receptacle, 8 l (h) Connecting plug, piston (l) Membrane key switch,
detector pause time display / pause
time setting / fault acknow-
ledgement
11 - 2 1250 HC 40 / 49516
Fig. 11-1 Centralised lubrication system components

(d) Receptacle, 4 l (i) Filling nipple, pump (m) Membrane key switch, auxi-
liary lubrication / pause time
setting
(e) Pressure relief valve
11.1.1 Laying diagram, hydraulic diagram
Note
Consumer lines must always be connected to outlets 1 and 2. Never connect the outlets with closure
plugs.
Fig. 11-2 Laying diagram and hydraulic diagram (6 connections)

(a) Multi-line pump (d) Conduit pipe (g) Inlet fitting
(b) Outlet fitting (e) Fitting (h) Hose line
(c) Piston detector (f) Distributor
1250 HC 40 / 49516 11 - 3
Fig. 11-3 Laying diagram and hydraulic diagram (10 connections)

(i) Multi-line pump (l) Conduit pipe (o) Inlet fitting
(j) Outlet fitting (m) Fitting (p) Hose line
(k) Piston detector (n) Distributor
11 - 4 1250 HC 40 / 49516
11.1.2 Wiring diagram

Colour identification in the wiring diagram in accordance with DIN IEC 60757.
Fig. 11-4 Wiring diagram

(a) Pump (d) Control (g) X1: 3-pin square plug
(b) Piston detector (e) Empty report (h) X3: AMP-flat plug
(c) Membrane keyboard (f) Power pack
11.1.3 Operation
Fig. 11-5 Membrane key switch and display possibilities in the control panel
(a) Test display following connection of the supply (e) Membrane key switch, auxiliary lubrication
voltage (all segments and decimal points light / pause time setting
up for two seconds)
1250 HC 40 / 49516 11 - 5
Fig. 11-5 Membrane key switch and display possibilities in the control panel
(b) Error message: „EP“ lights up (error in the (f) Error message: „LL“ lights up (empty
membrane key switches) report not acknowledged)
(c) Lubrication mode (segments light up in circula- (g) Pause time (lowermost right-hand seg-
tion) ment lights up)
(d) Error message: „Er“ lights up (functional error (h) Membrane key switch, pause time display
not acknowledged) / pause time setting / fault acknowledge-
ment
In the display mode, information regarding functions and malfunctions of the pump are displayed. The
pump is in display mode as soon as it is supplied with voltage. The lowermost right-hand segment
lights up in the display.
Calculating the pause time
Roller track, roller slewing ring (reservoir capacity 8 l) 7000,0 cm³
Toothing, roller slewing ring (reservoir capacity 4 l) 1500,0 cm³
Tab. 11-1 Amount of grease required per year (cm³)
Note
In the example for the calculation, the time for the assumed operating hours and day for which the
crane is connected must be set.
The amount of grease released per lubrication cycle is dependent on the size of the distributor.
6-way distributor: 1.2 cm³ (amount of grease released per lubrication cycle)
10-way distributor: 2.0 cm³ (amount of grease released per lubrication cycle)
Berechnungsbeispiel
(using the example of slewing ring roller track (reservoir capacity 8 l; 10-way distributor)
Operation hours / working day (h) × Working days / year (d) × Lubricant output / lubrication cycle (cm³)
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------ = Pause time
Annual grease consumption / year (cm³)
12 h/day ⋅ 250 days/year ⋅ 2,0 cm³

----------------------------------------------------------------------------- = 0,85 h = 0 h 51 min
7000 cm³/year
ª Here the pause time must be set to 51 minutes. For further information, see: › Setting the
parameters ‹
Berechnungsbeispiel
(using the example of roller slewing ring toothing (reservoir capacity 4 l; 6-way distributor)
Operation hours / working day (h) × Working days / year (d) × Lubricant output / lubrication cycle (cm³)
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------ = Pause time
Annual grease consumption / year (cm³)
12 h/day ⋅ 250 days/year ⋅ 1,2 cm³

----------------------------------------------------------------------------- = 2,4 h = 2 h 24 min
1500 cm³/year
ª Here the pause time must be set to 2 hours and 24 minutes. For further information, see: › Setting
the parameters ‹
11 - 6 1250 HC 40 / 49516
Checking the set parameters
Note
This may only be carried out during the pause time when in operating mode. No operation is pos-
sible during the pause time (pump run time).
Upon call-up of the parameters, the set pause time (PP), the remaining pause time (rP), the number
of automatically triggered cycles (AC), the manually triggered cycles (UC) (auxiliary lubrication), as
well as the number of complete greasing processes of the distributor (P3) and the set output signal
(P4) are displayed one after another.
In the display field, minutes are displayed via a decimal point on the left and hours are displayed
via a decimal point on the right .
Example:
Pause time (PP): 1 h 36 min / remaining pause time (rP): 45 min / number of automatically triggered
cycles (AC): 0625 cycles / number of manually triggered cycles (UC): 50 cycles / number of com-
plete greasing processes of the distributor (P3): 1 revolution / display of the output signal (P4): nc
Display Action
Note
The following displays appear once and are
quit after approx. 40 seconds. Each display
changes every 2 seconds.
X Press the membrane key switch at least every two se-
conds.
ª „PP“ (set pause time) lights up in the display field.
After two seconds ª The set hours and the right-hand decimal point (e.g: 01.)
light up in the display field.
After two seconds ª The set minutes and the left-hand decimal point (e.g: .36)
After two seconds ª „rP“ (remaining pause time) lights up in the display field.
After two seconds ª The remaining hours until the next lubrication and the
right-hand decimal point (e.g: 00.) light up in the display
field.
After two seconds ª The remaining minutes until the next lubrication and the
left-hand decimal point (e.g: .45) light up in the display
field.
Tab. 11-2 Calling up the set parameters
1250 HC 40 / 49516 11 - 7
Display Action
After two seconds ª „AC“ (number of automatically initiated lubrication times -
up to 9999 cycles, then the clock begins over) lights up in
the display field.
After two seconds ª The thousandths and hundredths, as well as the right-
hand decimal point (e.g: 06.) light up in the display field.
After two seconds ª The tenths and single units, as well as the left-hand deci-
mal point (e.g: .25) light up in the display field.
After two seconds ª „UC“ (number of manually initiated lubrication times - up

to 9999 cycles, then the clock begins over) lights up in the
display field.
After two seconds ª The thousandths and hundredths, as well as the right-
hand decimal point (e.g: 00.) light up in the display field.
After two seconds ª The tenths and single units, as well as the left-hand deci-
mal point (e.g: .50) light up in the display field.
After two seconds ª „P3“ (number of complete greasing processes of the dis-
tributor) lights up in the display field.
After two seconds ª The number of complete greasing processes of the distri-
butor, as well as the right-hand decimal point (e.g: 3.)
After two seconds ª „P4“ (programming of the output signal) lights up in the
display field.
After two seconds ª The output signal „Normally closed“ (nc) or „Normally
open“ (no) lights up in the display field. (e.g: nc.).
After ª End of operating mode

approx. 40 overall
Tab. 11-2 Calling up the set parameters
11 - 8 1250 HC 40 / 49516
Initiating the auxiliary lubrication
Note
sible during the lubrication time (pump run time).
Display Action
X Press the membrane key switch at least every two se-

conds.
ª The lubrication time begins.
A rotating segment is visible throughout the entire run-ti-
me.
The expired pause time is reset.
Tab. 11-3 Initiating the auxiliary lubrication
Setting the parameters
Note
sible during the lubrication time (pump run time).
When setting the parameters, the pause time (P1 (hours) and P2 (minutes)), the number of comple-
te greasing processes of the distributor (P3) and the output signal (P4) are set one after the other.
To avoid an incorrect setting, always perform the entire setting sequence: P1 (hours), P2 (minutes),
P3 (distributor revolutions), P4 (output signal) and P- (programming end).
In the display field, minutes are displayed via a decimal point on the left and hours are displayed
via a decimal point on the right .
Example:
Pause time (P1 and P2): 1 h 36 min / number of distributor revolutions (P3): 1 revolution / display
of the output signal (P4): nc
Display Action
X Press the membrane key switches simultaneously

for at least four seconds.
ª The display switches to programming mode.
ª „P1“ lights up in the display field.
Tab. 11-4 Setting parameters
1250 HC 40 / 49516 11 - 9
Display Action
P1: Setting the hours
ª The actual set value (set here at 6 hours at the fac-
tory) appears when both membrane key switches
are released. 6 hours).
X To set the hours: Actuate the membrane key switch.
(e.g: 01.)
Setting is resulted in one direction only: 0, 1, 2,
3, …, 59 h
Individual actuation of the key:Increase by 1 hour
Continuous actuation:Rapid increase
X Actuate the membrane key switch.
P2: Setting minutes

ª The actual set value (set here at „no“ - normally open
at the factory) appears when the membrane key
switch is released). 0 minutes).
Note
The minimum pause time is 4 minutes.
For settings less than 4 minutes (and
an hour entry of „00.“) „.04“ appears au-
tomatically in the display field
X To set the minutes: Actuate the membrane key
switch. (e.g: .36)
Setting is resulted in one direction only: 0, 1, 2,
3, …, 59 min
Individual key actuation:Increase by 1 minute
Continuous actuation:Rapid increase
P3: Setting the number of distributor revolutions

switch is released). 1 distributor revolution).
X To set the number of distributor revolutions: Actuate
the membrane key switch. (e.g: .01)
Setting is resulted in one direction only: 1, 2, …, 5 (ma-
ximum number of distributor revolutions: 5)
P4: Setting the output signal on the monitoring re-

lay „Display“
switch is released).
11 - 10 1250 HC 40 / 49516
Display Action
X To set the output signal: Actuate the membrane key
switch. (e.g: no or nc)
ª The output signal is set to „no“ - normally open - or
„nc“ - normally closed -.

ª „P-“ lights up in the display field.
Setting is now complete.
Note
The membrane key switch (auxiliary lu-
brication) must be actuated within 30
seconds in order that the set parame-
ters can be adopted.
ª The set parameters are adopted.
ª An auxiliary lubrication is adopted at the same time.
ª The display changes to the display mode following
auxiliary lubrication

1250 HC 40 / 49516 11 - 11
11.1.4 Maintenance, inspection and repair
Warning!
Risk of injury due to rotating agitator blades in the pump container.
X Switch off the voltage supply before commencing any tasks on the pump.
Note
Maintenance and inspection of the pumps is essentially limited to refilling fresh lubricant at the right
time. The maintenance and inspection tasks can be combined with the maintenance and inspection
tasks at the switch cabinet.
The following checks should nevertheless be carried out regularly:
X Ensure that lubricant is being exuded from all lubrication points
X Check all main lines and lubrication point lines for damage, replace as necessary.
Note
Ensure utmost cleanliness when carrying out all tasks on the central lubrication system ! Dirt in the
system will result in malfunctions.
X Only clean the system with petroleum or petroleum ether.
X Only fill the system with Liebherr special grease CTK.

Every three months
Every six months
10000h / 2 years*
Special intervals
2000h / 2 years*
n by maintenance personnel
r by specialist personnel
Once a year
Monthly
Weekly
* the earlier point of time is decisive

Daily
Centralised lubrication system
Check pump for error messages
as required Fill pump
as required Check pressure relief valve
Checking the pump for error messages

X Read off any error messages on the pump display field (see: Fig. 11-5).
Error messages are being displayed
X Remedy the faults (For further information see: Chap. 11.1.5 Faults and their causes).
X Acknowledge the error message after remedying the fault see: Fig. 11-5).
11 - 12 1250 HC 40 / 49516
Filling the pump
Fig. 11-6 Filling the pump

(a) Hand pump (c) Cover, receptacle (e) „Max“ marking
(b) Filler hole, container (d) Filling nipple (f) „Min“-marking
Warning!
There is a danger of the container bursting if overfilled.
X Ensure with hand pumps featuring high delivery rates that the „Max.“-marking is not exceeded.

The voltage supply to the pump is switched off.
X Connect the hand pump (a) to the filling nipple (d) and fill the container via the filling nipple (d) to
the „Max.“ marking (e).
- or -
Remove the cover (c) and fill the container via the filling hole up to the „Max.“ marking (e).
X Re-establish the voltage supply to the pump.
Note
After being discharged completely, the pump may require up to 10 minutes running time before at-
taining full delivery rate again.
X Initiate auxiliary lubrication (For further information, see: › Initiating the auxiliary lubrication ‹).
X Acknowledge any error messages after filling.
1250 HC 40 / 49516 11 - 13
Bleeding the pump
Fig. 11-7 Bleeding the pump

(a) Pressure relief valve (c) Hose line to distributor (d) Membrane key switch, auxi-
(b) Lubricant liary lubrication / pause time
setting
X Unscrew the hose line (c) to the distributor at the pressure relief valve (a). (1)
X Initiate auxiliary lubrication (d) (For further information, see: › Initiating the auxiliary
lubrication ‹). (2)
ª The lubricant (b) must be exuded bubble-free.
X Screw on the hose line (c) at the pressure relief valve (a) once again. (3)
Cleaning the lines

X Clean blocked lines with petroleum or petroleum ether. LBC/en/01/Issued: 07.11
11 - 14 1250 HC 40 / 49516
Checking the pressure relief valve
Fig. 11-8 Checking the pressure relief valve

(a) Pressure relief valve (c) Relief tap (e) Hose line (min. 1 m)
(b) Pressure gauge (0 - 600 (d) T-piece (f) Membrane key switch, auxi-
bar, 0 - 8702 psi) liary lubrication / pause time
setting
Caution!
The pump can become blocked.
If the pressure gauge is connected directly to the pump element, extremely high pressure is resulted
when auxiliary lubrication is initiated and the pump could become blocked. The pump can be blo-
cked for 30 minutes without any lasting damage being effected.
X Do not connect the pressure gauge directly to the pump element.
X Connect the pressure gauge (0 - 600 bar, 0 - 8702 psi) to the pressure relief valve. (1)
X Initiate auxiliary lubrication (For further information, see: › Initiating the auxiliary lubrication ‹). (2)
ª The pressure relief valve should open when the pressure reaches 270 bar, otherwise the pressure
relief valve must be replaced.
1250 HC 40 / 49516 11 - 15
11.1.5 Faults and their causes
Fault Cause Remedy
– Voltage supply interrupted, segment X Check / establish voltage supply (con-

The motor of the pump is not running,
display on the display window (On) nection, lines, fuses).

the agitator blade is not turning
is not lit.
– Voltage supply from the printed cir- X Check / establish feed line from the fu-
cuit board to the motor interrupted, ses to the plug of the pump.
electric motor faulty.
X Check / establish voltage supply to the
motor.
X If necessary, replace the motor.
– Printed circuit board faulty. X Replace the printed circuit board.
– Control key on the membrane key- X Replace the housing with the membra-
board faulty („EP“-display lights ne keyboard.
up).
– Blockage (clogging) in the system. X Remove the main line to the distributor
(throughout the duration of the monitoring time
and check whether the pump is con-

The motor of the pump is conveying non-stop
veying lubricant.
(30 minutes)), grease is exuded at the
ª If so, the system is blocked (clogged) -

remove the blockage (clogging).
– Piston detector faulty. X Unscrew the piston detector.

pressure relief valve
X Check the piston detector: Insert a sui-

table iron pin into the borehole of the
piston detector for at least 2 seconds.
ª If the pump does not cut out upon remo-
val of the iron pin - check the cable con-
nection.
– Cable connection of the piston de- X Ensure that the cable connection is se-
tector to the pump interrupted. cure and check for damage.
ª If no irregularities can be found in the
cable connection - replace piston de-
tector with connecting plug.
– Printed circuit board faulty. X Replace the printed circuit board.
Tab. 11-5 Faults and their causes

11 - 16 1250 HC 40 / 49516
Fault Cause Remedy
– Container empty. „LL „ display on X Fill the container with clean grease and
the membrane keyboard lights up. allow the pump to run (For further infor-
– Pump is not conveying any lubricant mation, see: › Filling the pump ‹), until
Pump is not conveying „Er „ display on the membrane key- the lubricant is exuded from all lubrica-
board. ting points.
– Trapped air in lubricant. X Bleed the pump (For further informati-

on, see: › Bleeding the pump ‹).
– Unsuitable lubricant. X Replace lubricant.
– Intake bore of the pump element X Dismantle pump element, examine in-
blocked. take bore for foreign particles and re-
move as required.
– Pump piston worn. X Replace pump element.
– Non-return valve in the pump ele- X Replace pump element.

ment faulty or clogged.
Tab. 11-5 Faults and their causes

1250 HC 40 / 49516 11 - 17
11 - 18 1250 HC 40 / 49516

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Volume 1:

1250 HC tower standard

Serial No.: 49516

1250 HC tower system

Observing the operating instructions

Additional documentation and instruction

Fax: +49 (0) 7351 41 28 79

1250 HC 40 / 49516 1-1

Symbols in the operating instructions

– This symbol indicates a listing.

X This symbol means: „Carry out this task“.

 This symbol means: „Prerequisite must be fulfilled“.

ª This symbol means: „Subsequent to task“.

Symbols in the pictures

Tab. 0-1 Danger symbols

1-2 1250 HC 40 / 49516

Danger resulting from spur gear running when Danger of falling

Tab. 0-1 Danger symbols

Put on a safety harness! Close trapdoors!

Keep environment clean! Observe the wind conditions!

Tab. 0-2 Regulatory signs

1250 HC 40 / 49516 1-3

Direction of move- Incorrect!

Movement stops! Check!

Order of operational Order of individual

Clean! Fill in oil!

Location of grease Check oil level!

Carry out lubrication! Do not use any lubri-

Tightening torque Observe the weight

Tab. 0-3 Further symbols

1-4 1250 HC 40 / 49516

1 Notes on Safety .................................................................................................................... 1-1

2 Technical description .......................................................................................................... 2-1

3 Specifications ....................................................................................................................... 3-1

3.2.4 Electrical connection data .............................................................................. 3-13

4 Corner pressures, foundation loadings and ballast data ................................................. 4-1

5 Preparing for application of the crane................................................................................ 5-1

6 Erection ................................................................................................................................. 6-1

6.2 Fundamental notes on erection.................................................................................... 6-4

6.10 Preparing crane for 4-fall / 2-fall operation ............................................................... 6-193

1250 HC 40 / 49516 III

6.11.4 Setting the overload protection system ........................................................ 6-208

7 Climbing the crane ............................................................................................................... 7-1

9 Maintenance and inspection ............................................................................................... 9-1

9.4.5 Analysing / changing gear oil ......................................................................... 9-13

10 Repair .................................................................................................................................. 10-1

10.1 Notes on safety for repair........................................................................................... 10-2

10.2.2 Components of the hydraulic brake ............................................................... 10-4

11 Optional equipment ............................................................................................................ 11-1

1.1 Avoiding dangers

1.2 Intended use

aforementioned points being neglected.

1250 HC 40 / 49516 1-1

1.3 Personnel qualification

1.4 Particular dangers

1.4.1 Risk of instability

1.4.2 Danger of crushing

1.4.3 Danger resulting from damaged ropes

re the rope end fittings are located.

1.4.4 Dangers resulting from copied Liebherr crane parts

1-2 1250 HC 40 / 49516

To prevent hazardous situations,

1.4.5 Dangers resulting from electrical energy

1.4.6 Dangers resulting from hydraulic energy

This symbol means: „Prerequisite must be fulfilled“.