Liebherr A 312 Litronic 719 Hydraulic Excavator Operating Manual SN 37405 - PDF DOWNLOAD

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Operating instructions Hydraulic excavator A 312 Litronic from serial number 37405

Document identification Id. number:

10443914

Edition:

07 / 2007

Valid for:

A 312 Litronic from serial number 37405

Author:

LHB - Technical documentation department

Product identification Manufacturer:

LIEBHERR Hydraulikbagger GmbH

Type:

A 312 Litronic

Type no.:

719

Conformity:

CE

Address Liebherr Hydraulikbagger GmbH Liebherr-Straße 12 D - 88457 Kirchdorf / Iller

Operating instructions

Machine data Please fill in the following data when you receive your machine.

This will also be helpful when ordering spare parts.

Vehicle Id. No.: WLHZ . . . . . ZK . . . . . .

Year of manufacture: . . . .

Delivery date: . . / . . / . .

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A 312 Litronic / 10443914

Foreword

This operating manual has been written for the machine operator and for the maintenance personnel of the machine.

It contains: regulations.

Before initial operation and at regular subsequent intervals, the operating manual must be carefully read and observed by all persons who carry out work with or on the machine.

Working with or on the machine includes, for example: Operation including setting up or equipping, rectifying malfunctions during the course of work, resolving output reductions, care, disposal of operating and service materials.

Service, including maintenance, inspection and repair work.

Transportationor loading of the machine.

The operating manual allows the machine operator to familiarize himself with the machine more easily and prevents problems due to improper operation.

The observance of the operating and maintenance instructions by maintenance personnel:

The operating manual is part of the machine. Ensure that one copy is always The operating and maintenance manual should also incorporate information regarding current national regulations for accident prevention and protection. In addition to the operating instructions and the legally binding regulations on accident prevention valid in the user country and the job site, the recognized specialized technical regulations for safe and correct working procedures must also be observed.

This operating and maintenance manual contains all the necessary information to operate and maintain your machine. l may depict details and working devices, which differ from your machine. protective devices and covers have been removed in the interests of better presentation. on our machines, may result in changes to your machine, which are not yet indicated in this operating manual.

However, should you require further explanation or information, LIEBHERR's Technical Documentation, Sales Training and Service departments are available for your convenience.

Operating instructions

You will appreciate that LIEBHERR cannot honor any warranty claims made on the basis of improper operation, insufficient maintenance, use of unauthorized service fluids or non-adherence to safety regulations.

LIEBHERR will void any and all obligations incurred by LIEBHERR and / or its dealers, such as guarantee commitments, service contracts etc. without prior notice in the event that replacement parts other than original LIEBHERR parts or spare parts purchased from LIEBHERR are used for maintenance or repairs.

Modifications, conditions, copyright We reserve the right to make modifications without prior notice in the course of technical progress.

The information and illustrations contained in this manual may neither be copied and distributed nor used for competitive purposes. All rights are expressly reserved in accordance with copyright laws.

The warranty and liability c not be expanded by the above information.

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A 312 Litronic / 10443914

Operating instructions

Table of contents 1

Product description ....................................................................................................................................... 1-1 1.1

1.2 2

Safety information, signs .............................................................................................................................. 2-1 2.1 2.2 2.3

2.4

2.5 3

Assembly - Overview ............................................................................................................................. 1-1 1.1.1 Machine and construction equipment....................................................................................... 1-1 1.1.2 Uppercarriage........................................................................................................................... 1-2 1.1.3 Undercarriage........................................................................................................................... 1-3 Technical data ....................................................................................................................................... 1-3

Symbols in the operating instructions .................................................................................................... 2-1 Use in accordance with the regulations ................................................................................................. 2-2 Safety instructions ................................................................................................................................. 2-2 2.3.1 General Safety instructions ...................................................................................................... 2-2 2.3.2 Crushing and burn prevention .................................................................................................. 2-4 2.3.3 Fire and explosion prevention .................................................................................................. 2-4 Signs on the machine ............................................................................................................................ 2-5 2.4.1 Introduction............................................................................................................................... 2-5 2.4.2 Arrangement of signs ............................................................................................................... 2-5 2.4.3 Explanation of signs ................................................................................................................. 2-6 Identification tags on the machine ....................................................................................................... 2-12

Control, operation.......................................................................................................................................... 3-1 3.1

3.2

3.3

3.4

Operating and control elements............................................................................................................. 3-1 .. 3-1 3.1.2 Arrangement of joysticks .......................................................................................................... 3-3 3.1.3 Overview of control panel, right ................................................................................................ 3-4 3.1.4 Control panel functions............................................................................................................. 3-7 Operation ............................................................................................................................................. 3-13 3-13 3.2.2 Safety lever ............................................................................................................................ 3-15 ............ 3-16 3.2.4 Adjusting the steering column ................................................................................................ 3-20 3.2.5 Front windshield ..................................................................................................................... 3-21 3.2.6 Sun visor ................................................................................................................................ 3-21 dow ............................................................................................... 3-22 3.2.8 Interior illumination ................................................................................................................. 3-22 3.2.9 Fire extinguisher (option)* ...................................................................................................... 3-23 3.2.10 Windshield wiper .................................................................................................................... 3-23 3.2.11 Lighting................................................................................................................................... 3-25 3.2.12 Heating system / heating and air conditioning system (option) .............................................. 3-26 Operation ............................................................................................................................................. 3-29 3.3.1 Safety instructions .................................................................................................................. 3-29 3.3.2 Starting / shutting down the machine ..................................................................................... 3-31 3.3.3 Jump start procedure ............................................................................................................. 3-35 3.3.4 Travel operation ..................................................................................................................... 3-36 3.3.5 Travelling on public roads ...................................................................................................... 3-38 3.3.6 Emergency gear shifting......................................................................................................... 3-40 3.3.7 Towing the machine ............................................................................................................... 3-41 3.3.8 Disengaging transmission ...................................................................................................... 3-42 3.3.9 Oscillating axle locking device................................................................................................ 3-43 3.3.10 Support ................................................................................................................................... 3-44 Working with the machine.................................................................................................................... 3-46 3.4.1 Working with the machine safely ............................................................................................ 3-46 3.4.2 Sensor controlled low idle automatic ...................................................................................... 3-50 3.4.3 Operating the swing gear ....................................................................................................... 3-50

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Operating instructions

3.5

3.6

3.7

4

Malfunctions ................................................................................................................................................... 4-1 4.1

4.2

5

3.4.4 Fine control ............................................................................................................................. 3-52 3.4.5 Locking the superstructure ..................................................................................................... 3-53 3.4.6 Working position ..................................................................................................................... 3-53 3.4.7 Joystick functions ................................................................................................................... 3-54 3.4.8 Lowering the attachment when the engine is not running ...................................................... 3-56 3.4.9 Turning, rotating, locking and unlocking the attachments ...................................................... 3-57 3.4.10 Accessory kits AHS 1, AHS 11 and AHS 12 (option) ............................................................. 3-58 3.4.11 Adjusting the boom to side ..................................................................................................... 3-61 3.4.12 Overload warning device ........................................................................................................ 3-64 Installation and removal of attachment parts ....................................................................................... 3-66 3.5.1 Safe installation and removal of attachment parts.................................................................. 3-66 3.5.2 Safe removal and installation of attachment pins ................................................................... 3-67 3.5.3 Installation and removal of digging tool .................................................................................. 3-67 3.5.4 Attachment of grapple to bucket stick..................................................................................... 3-69 3.5.5 Mechanical quick change adapter (option) ............................................................................. 3-72 3.5.6 Hydraulic quick change adapter (option) ................................................................................ 3-77 3.5.7 LIKUFIX Hydraulic coupling system (option) ......................................................................... 3-83 General working methods .................................................................................................................... 3-85 3.6.1 Tips for the proper operation of the machine preventing damage and wear .......................... 3-85 3.6.2 Preparation ............................................................................................................................. 3-85 3.6.3 Working with the backhoe bucket ........................................................................................... 3-87 3.6.4 Loading transport vehicle ....................................................................................................... 3-88 3.6.5 Grading work .......................................................................................................................... 3-89 3.6.6 Working with grapples ............................................................................................................ 3-90 3.6.7 Excavating and moving material with grapples....................................................................... 3-90 3.6.8 Working with the hydraulic hammer........................................................................................ 3-91 3.6.9 Working with large and heavy attachments ............................................................................ 3-93 3.6.10 Load lifting operation .............................................................................................................. 3-93 Transport.............................................................................................................................................. 3-94 3.7.1 Transporting the machine safely ............................................................................................ 3-94 3.7.2 Transporting the machine on a flatbed trailer ......................................................................... 3-95 3.7.3 Loading the machine with a crane .......................................................................................... 3-97

Problems and remedies ......................................................................................................................... 4-2 4.1.1 Diesel engine and fuel system.................................................................................................. 4-2 4.1.2 Hydraulic system ...................................................................................................................... 4-3 4.1.3 Travel gear ............................................................................................................................... 4-4 4.1.4 Electrical system....................................................................................................................... 4-4 4.1.5 Heating and Air conditioning system ........................................................................................ 4-5 4.1.6 Work attachment ...................................................................................................................... 4-5 Fuses and relays.................................................................................................................................... 4-5 4.2.1 Fuse box E50 ........................................................................................................................... 4-6 4.2.2 Panel ignition switch ................................................................................................................. 4-6 4.2.3 Panel, cab................................................................................................................................. 4-7 4.2.4 Distributor plate ........................................................................................................................ 4-8

Maintenance ................................................................................................................................................... 5-1 5.1

Maintaining the machine safely.............................................................................................................. 5-1 5.1.1 General Safety instructions ...................................................................................................... 5-1 5.1.2 Cleaning ................................................................................................................................... 5-1 5.1.3 Checking for cracks .................................................................................................................. 5-2 5.1.4 Welding..................................................................................................................................... 5-3 5.1.5 Operating and service fluids ..................................................................................................... 5-3 5.1.6 Repair ....................................................................................................................................... 5-3 5.1.7 Electrical system....................................................................................................................... 5-4 5.1.8 Pressure accumulator............................................................................................................... 5-4

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A 312 Litronic / 10443914

Operating instructions

5.1.9 Hydraulic hoses and lines ........................................................................................................ 5-5 5.1.10 Rollover-protection features (ROPS) and falling-object protective systems (FOPS)................ 5-6 5.2 Maintenance access doors .................................................................................................................... 5-6 5.2.1 Overview of access doors ........................................................................................................ 5-6 5.2.2 Door lock .................................................................................................................................. 5-7 5.2.3 Engine hood release ................................................................................................................ 5-8 5.3 Tires....................................................................................................................................................... 5-8 5.3.1 Checking the tire pressure ....................................................................................................... 5-9 5.3.2 Filling with foam...................................................................................................................... 5-10 5.4 Lubricants and operating fluids............................................................................................................ 5-10 5.4.1 General information to change lubricants and operating fluids .............................................. 5-10 5.4.2 Lubrication chart ..................................................................................................................... 5-12 5.4.3 Lubricant table........................................................................................................................ 5-13 5.4.4 Fuels, lubricants and process chemicals................................................................................ 5-14 5.4.5 Fuels and lubricant for the diesel engine................................................................................ 5-15 5.4.6 Hydraulic oil ............................................................................................................................ 5-15 5.4.7 Grease and other process chemicals ..................................................................................... 5-20 5.5 Diesel engine ....................................................................................................................................... 5-20 5.5.1 Check oil level ........................................................................................................................ 5-20 5.5.2 Changing the oil ..................................................................................................................... 5-21 5.6 Cooling system .................................................................................................................................... 5-21 5.6.1 Checking and cleaning the cooling system ............................................................................ 5-21 5.6.2 Checking the coolant level ..................................................................................................... 5-22 5.6.3 Anti-corrosion fluid and antifreeze.......................................................................................... 5-22 5.6.4 Changing water filters............................................................................................................. 5-23 5.6.5 Changing the coolant ............................................................................................................. 5-23 5.7 Fuel system ......................................................................................................................................... 5-25 5.7.1 Refuelling ............................................................................................................................... 5-25 5.7.2 Draining the water from the fuel tank ..................................................................................... 5-26 5.7.3 Emptying and cleaning the fuel tank ...................................................................................... 5-27 5.7.4 Fuel preliminary filter (type 1) ................................................................................................. 5-27 5.7.5 Fuel preliminary filter (type 2) ................................................................................................. 5-28 5.7.6 Replacing the fuel filter cartridge (fine filter) ........................................................................... 5-29 5.8 Dry air filter .......................................................................................................................................... 5-30 5.8.1 Changing the main element ................................................................................................... 5-30 5.8.2 Changing the safety element.................................................................................................. 5-31 5.8.3 Checking the filtered air line ................................................................................................... 5-32 5.9 Hydraulic system ................................................................................................................................. 5-32 5.9.1 Checking the oil level in the hydraulic tank ............................................................................ 5-32 5.9.2 Relieving the pressure in the hydraulic system ...................................................................... 5-33 5.9.3 Emptying and refilling the hydraulic tank ................................................................................ 5-34 5.9.4 Return filter ............................................................................................................................. 5-35 5.9.5 Servo oil filter.......................................................................................................................... 5-36 5.9.6 Servo circuit............................................................................................................................ 5-37 5.9.7 Bleeding the hydraulic pump .................................................................................................. 5-38 5.9.8 Servicing the hydraulic cylinder .............................................................................................. 5-39 5.9.9 Replacing hydraulic hoses ..................................................................................................... 5-40 5.10 Changing the oil on components ......................................................................................................... 5-40 5.10.1 General notes......................................................................................................................... 5-40 5.10.2 Swin gear - oil change............................................................................................................ 5-41 5.10.3 Transmission - oil change ...................................................................................................... 5-42 5.10.4 Steering and rigid axle - oil change ........................................................................................ 5-42 5.10.5 Steering axle, wheel head - oil change .................................................................................. 5-43 .......... 5-43 5.12 Electrical system.................................................................................................................................. 5-44 5.12.1 Notes for electrical system ..................................................................................................... 5-44 5.12.2 Battery master switch ............................................................................................................. 5-44 5.12.3 Battery care ............................................................................................................................ 5-45

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Operating instructions

5.12.4 Slip ring assembly (option) ..................................................................................................... 5-46 5.13 Heating system / heating and air conditioning system (option)............................................................ 5-47 5.13.1 Fresh air filter.......................................................................................................................... 5-47 5.13.2 Heating system ....................................................................................................................... 5-48 5.13.3 Air conditioning system (option) ............................................................................................. 5-48 5.14 Lubricating the machine....................................................................................................................... 5-51 5.14.1 Lubricating the swing gear...................................................................................................... 5-51 5.14.2 Lubricating the attachment ..................................................................................................... 5-52 5.14.3 Lubricating the axles............................................................................................................... 5-52 5.14.4 Lubricating the digging tool / bucket tilt device ....................................................................... 5-53 5.14.5 Lubricating the grapple (option) .............................................................................................. 5-53 5.15 Quick change systems (option)............................................................................................................ 5-54 5.15.1 Lubricate the mechanical quick change adapter .................................................................... 5-54 5.15.2 Hydraulic quick change adapter ............................................................................................. 5-55 5.15.3 Hydraulic coupling .................................................................................................................. 5-56 5.15.4 LIKUFIX electric coupling ....................................................................................................... 5-57 5.16 Parking and swing gear brake ............................................................................................................. 5-58 5.17 General Maintenance points ................................................................................................................ 5-59 5.17.1 Replacing wear parts .............................................................................................................. 5-59 5.17.2 Replacing the teeth on the digging tool .................................................................................. 5-59 5.17.3 Welding work on the machine ................................................................................................ 5-60 5.18 Inspection and maintenance plan ........................................................................................................ 5-60

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A 312 Litronic / 10443914

1 Product description 1.1 Assembly - Overview This section contains an overview of the machine and descriptions of the components shown.

1.1.1

Machine and construction equipment

Fig. 1-1

Machine and construction equipment

100

Uppercarriage

330

Adjusting cylinder

370

Bucket cylinder

200

Undercarriage

340

Boom

380

Bucket

310 320

Basic boom Hoist cylinder

350 360

Stick cylinder Stick

Product description

Operating instructions

Assembly - Overview

1.1.2

Uppercarriage

Fig. 1-2

Uppercarriage

500

Diesel engine

7100 Hydraulic tank

530 560

Dry air filter Radiator

7300 Hydraulic pump 7600 Control valve block

700 Swing gear 6000

8700 9300 Fuel tank

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A 312 Litronic / 10443914

Operating instructions

Product description Technical data

1.1.3

Undercarriage

Fig. 1-3

Undercarriage

600 Transmission 1000 Rotary connection

4000 Steering axle 4100 Fixed axle

1500 Outriggers 1700 Blade support

9680 Step with toolbox 9690 Step

1.2 Technical data Please refer to the accompanying technical description.

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Product description

Operating instructions

Technical data

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A 312 Litronic / 10443914

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2 Safety information, signs Working with the machine holds dangers to which you as the owner, machine operator or maintenance expert could be exposed. If you regularly read and observe the safety information, you can guard against dangers and accidents. This applies especially to persons, who are working on the machine only occasionally, such as for maintenance work. The following information comprises safety regulations which, if followed conscientiously, will guarantee your safety and that of other persons, as well as avoid damage to the machine.

Following these regulations does not release you from the responsibility to follow all safety regulations and guidelines valid for the jobsite, as required by law or issued by trade associations.

For EU countries, guideline 89/655/EEC contains the minimum safety information applicable to the operator.

2.1 Symbols in the operating instructions Work processes and actions that could cause danger are accompanied by safety information in these operating instructions. This safety information describes various dangers which are emphasized by the terms Danger, Caution and Note.

These terms are identified by symbols in the operating instructions and have the following significance: Danger!

Warning relating to a danger that carries a high risk of death or serious injury if the appropriate preventative measures are not taken.

Caution!

Warning relating to dangers that could result in physical injury and/or damage to the machine if the appropriate preventative measures are not taken.

Note!

This symbol is used to identify user tips as well as operating and maintenance procedures, which should be followed to keep your machine operational and to insure long service life and / or to facilitate certain operating or working procedures.

This symbol signifies the following: The machine operator or the maintenance personnel must first fulfill the given prerequisite, i. e. the machine must be brought into a particular work position in order to be able to carry out the actions subsequently described.

Safety information, signs

Operating instructions

Use in accordance with the regulations

This symbol identifies an action.

The machine operator or the maintenance personnel should be active at this location and carry out the action described.

This symbol means "Carry out an activity".

If the machine operator or maintenance personnel have carried out the activities described in an action, the result of this action will be described here.

Following these notes does not relieve you of the responsibility for following additional rules and guidelines!

Additional points that should be observed are:

2.2 Use in accordance with the regulations grapple, bucket ) designed to loosen, take on, transport and dump soil, rocks and other materials, where the load is predominantly transported without moving the machine. Moving the machine when it is carrying a load must be carried out by observing the appropriate safety measures (see section "Notes for machine operating safety").

special equipment and may also require special safety devices. These devices (eg. tree grab, demolition hammer, concrete cutter etc.) may only be attached and used with approval and in accordance with the original manufacturer of the device. intended use. The manufacturer is not liable for damage resulting from this action. The risk must be assumed solely by the user. ns and the inspection / maintenance instructions is also deemed to be appropriate and destined use in accordance with regulations.

2.3 Safety instructions 2.3.1

General Safety instructions with the operating instructions before starting the machine. understood these (this may concern special options for the machine). perate, maintain or repair the machine.

The legal minimum age must be observed.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Safety information, signs Safety instructions

Clearly define who is responsible for the operation or set up, maintenance and repair. Allow personnel to refuse unsafe instructions given by a third person. This also applies to traffic regulations. Reject unsafe instructions by third parties and/or allow your personnel to reject these.

This also applies in regards to traffic regulations. should only operate or work on the machine under the constant supervision and guidance of an experienced person. periodically if they observe safety instructions and guidelines given in the Operating manual. wearing rings, watches, ties, scarves, open jackets or loose clothing. There is a danger of injury, as these items could get caught or be pulled in.

The following are mandatory for certain tasks: Safety glasses, safety shoes, safety helmet, work gloves, reflecting vest, hearing protection, ... for special safety instructions and regulations.

especially sure that they are free of dirt, oil, ice and snow.

NOTE: To ensure that the doors open in all weather conditions, lubricate the weather strips at least every two month, or more often, if necessary, with talcum powder or silicon. Lubricate the door hinges and locks regularly. panel or the joysticks as handholds. Inadvertent movements, which could cause accidents, should be touched off. provided to climb off or on the machine. three-point support, so that at all times either two hands and one foot, or two feet and one hand are in contact with the access system. h the emergency exit through the front window. ructions, if no other instructions are available for maintenance and repairs: to the ground.

pressure of the tank prior to any operation on the hydraulic system as described in these operating instructions. ng a thorough inspection and check, if safety tags are missing or are illegible. chments or retrofits on the machine, which could inhibit safety, without the prior consent of the manufacturer. This also applies to the installation and adjustment of safety devices and safety valves as well as to any welding on load carrying parts.

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MJFCIFSS

2-3

Safety information, signs

Operating instructions

Safety instructions

2.3.2

Crushing and burn prevention long as it is not safely resting on the ground or properly supported. as ropes or chains. lign bores with your fingers, always use a suitable alignment tool. sure that hands or objects cannot get into the fans. The fan can cause severe injury, objects can be catapulted away or destroyed, and the fan can be damaged by the objects. pressure. Avoid contact with any components containing coolant. Danger of severe burns. diator cap on the expansion tank is cool enough to touch. Turn the cap carefully to relieve the pressure. ine and the hydraulic oil are hot. Do not allow your skin to come into contact with hot oil or components containing hot oil. sparks and open flames. sure that the side doors are properly secured with the appropriate supports to prevent them from closing inadvertently. has been raised with the aid of work equipment unless it has been properly and securely supported.

2.3.3

Fire and explosion prevention

ll defects, such as loose connections, blown fuses and burned out light bulbs, burned or frayed cables. d open flames when filling the tank or loading the batteries. instructions. ine except in appropriate storage tanks.

prevent vibration, rubbing and heat build up. insufficiently ventilated areas. ds to start Diesel engines with preheat system or flame glow systems. DANGER OF EXPLOSION! location and use of fire extinguishers on the machine as well as the local fire reporting procedures and fire fighting possibilities.

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A 312 Litronic / 10443914

Operating instructions

Safety information, signs Signs on the machine

2.4 Signs on the machine 2.4.1

Introduction The machine displays several types of signs: Safety plates provide warnings relating to dangers of accidents which could result in serious injury or death.

Information plates indicate specific points relating to the operation, maintenance and characteristics of the machine.

Nameplates are attached to components for which the machine number must be provided when ordering spare parts.

Danger!

Non-observance of safety plates can result in serious injury or death.

Check warning plates regularly to ensure that they are complete and clearly legible.

Replace missing or illegible safety and information plates immediately.

2.4.2

Arrangement of signs

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2-5

Safety information, signs

Operating instructions

Signs on the machine

Fig. 2-1

Arrangement of signs on the machine

4

Identification tag

51

Warning sign Danger zone

15 20

Lubrication chart Prohibition sign

52 60

Warning sign Engine shut-down

22

Sign Operating symbols

65

Load chart

30

Lubrication chart, engine

66

32/62 Speed plate (Germany)

67

Warning sign Accident prevention, safety lever, attachments Warning sign Operating brake, parking brake

35

Information sign Loading and anchoring points

80-1 Information sign Safety belt

40 45

Information sign Latch points Information sign Tackle - lifting point

80-2 Warning sign Operating brake 85 Information sign Engine hood release

47 50

Information sign Jump starting Warning sign Danger zone

90 250

sound output level Lwa

2.4.3

Information sign Engine cleaning Information sign Emergency exit rear window

Explanation of signs Sign 4: Machine identification tag The identification tag displays the following information:

Sign 15: Lubrication chart Displays the relevant filling capacities as well as the change intervals, grease quality, filling and lube point.

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Operating instructions

Safety information, signs Signs on the machine

Sign 20: Prohibition sign Entering the marked area is prohibited.

Sign 22: Operating symbols Describes the functions of the operating devices which are not labelled.

Sign 30: Lubrication chart, engine Refers to the maintenance intervals for the Diesel engine.

Sign 32/62: Speed sign 16, 20 km/hr. (only for Germany) Displays the construction-dependent top speed of the machine.

Sign 35: Loading and anchoring points Identifies the positions of the loading and anchoring points, as well as the relevant weight of the machine.

Sign 40: Latch point

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Safety information, signs

Operating instructions

Signs on the machine

Sign 45: Tackle lifting point

Sign 47: Jump starting The information in the operating instructions must be carefully observed when jump starting the machine.

Sign 50: Danger zone It is prohibited for anyone to remain in the danger zone.

Sign 52: Engine shut-down The engine hood may only be opened when the engine is shut off.

Sign 60: Acoustic sound output level Lwa Indicates the sound output level of the machine to the environment in dB(A). *XX = The applicable value for the machi

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Operating instructions

Safety information, signs Signs on the machine

Sign 65: Load chart Shows the permissible loads at the end of the stick, depending on the radius.

Sign 66, Part 1: Accident prevention The accident prevention regulations given in the operating instructions must be strictly observed when operating the machine.

Sign 66, Part 2: Safety lever

Sign 66, Part 3: Attachments The attachment reaches as far as the cab! Caution when attachment is retracted.

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2-9

Safety information, signs

Operating instructions

Signs on the machine

Sign 67: Operating brake / parking brake It is not permitted to apply the operating and parking brakes simultaneously when the machine is operating.

The operating brake may only be applied when the machine is operating. The operating brake may not be used as a parking brake when leaving the machine.

Sign 80-1: Safety belt The safety belt must be fastened before starting the machine.

Sign 80-2: Operating brake (only applicable for Germany) The operating brake may only be applied when the machine is operating. The operating brake may not be used as a parking brake when leaving the machine.

Sign 85: Hood release Indicates remote control release of the engine hood.

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Operating instructions

Safety information, signs Signs on the machine

Sign 90: Engine cleaning The engine compartment may only be cleaned when the Diesel engine is shut down.

Before cleaning with water or steam, cover / tape off all openings whose safety and function could be affected by infiltration of water or steam.

The rubber weather strip can be loosened and removed and the rear window pushed out by pulling the tab on the inside of the rear window.

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Safety information, signs

Operating instructions

Identification tags on the machine

2.5 Identification tags on the machine

Fig. 2-2

Important identification tags on the machine

1

Control valve block

5

Axles

2

Diesel engine

6

Travel gear with oil motor

3

Heating /air conditioning unit

7

Swing gear

4

Hydraulic pump

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3 Control, operation 3.1 Operating and control elements 3.1.1

Overview of the

Fig. 3-1 1

Safety lever servo control

10

Positioning swing brake*

6

Operating brake

18

Heater

7

Traveling pedal

20

Fuse box

8 9

Air vent for heater Control attachment*

P5 S4

Hour meter Horn

* Option

Control, operation

Operating instructions

Operating and control elements

Fig. 3-2 A

Control panel A

S1

Ignition switch

B

Control panel B

S5

C

Control panel C

S32

Push buttons Turn / swing attachment* Blinker lever

3

Joystick, right

S44

4

Joystick, left

S75

5

Outrigger control

S263 Travelling direction switch

14

Various installation kits*

S382 Switch - Fine control on / off

R76

Fine control

Switch - emergency blinker system Switch - oscillating axle automatic

* Option

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Operating instructions

Control, operation Operating and control elements

3.1.2

Arrangement of joysticks

Fig. 3-3

Joystick, right ( 3) and left (4)

Caution!

The machine is delivered in series with standard control.

On request, the machine can be equipped with a control system that deviates from the norm (e.g. with LIEBHERR control). In this case, the additional operating instructions for this control system must be observed.

PCSA controls The left joystick (4) controls the stick or swing movements: a and b: The stick is moved in or out. c and d: The uppercarriage is turned to the left or to the right.

The right joystick (3) controls the boom or bucket and grapple movements: e and f: The bucket will be tilted in or out, the grapple will be closed or opened. g and h: The boom will be raised or lowered.

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Control, operation

Operating instructions

Operating and control elements

3.1.3 3.1.3.1

Overview of control panel, right Control panel A

Fig. 3-4

Control panel A

Display instruments P6

Coolant temperature display

P7

Fuel level display

P50

Clock

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Operating instructions

Control, operation Operating and control elements

Indicator lights H7 H11

Engine oil pressure Preheating

H26 Quick change adapter* H167 Travel direction, forward

H12

Battery charge

H168 Travel direction, reverse

H13

Air filter contamination

H175 Engine overheating

H15

Hydraulic oil temperature

H176 Oscillating axle automatic

H16

Overload warning device*

H196 Scrap cutter / sorting grapple*

H18

Coolant level

H311 Oscillating axle - lock

H20 H23

Indicator light, parking brake Accumulator charge pressure (Operating brake)

H307 Fine control (delta P) H336 Water in fuel filter

H19

Turn signal

* Option

Operation R75

Throttle control

S204 - S207 Outrigger support, individual control

S18

Overload warning device*

S241 Hydraulic hammer*

S19 S21

Grapple rotator Creeper gear

S335 Blade support S360 Acknowledge buzzer for quick change adapter *

S42 S47

First gear Quick change adapter*

S422 Radio mute

* Option

3.1.3.2

Control panel B

Fig. 3-5

Control panel B

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3-5

Control, operation

Operating instructions

Operating and control elements

Operation S20 S74

Sensor controlled low idle automatic Immobilizer*

S318 Air conditioning system*

13 S16

Heating system / heating and airconditioning system* Parking brake

S35

Servo control

Headlights

S398 Reversing switch for fan * Option

3.1.3.3

Control panel C

Fig. 3-6

Control panel C

Operation S8

Rotating beacon*

S61

S11 S14

Windshield washer system Windshield wiper

S218 Roof windshield wiper* E8 Cigarette lighter

S22

Work headlight, front, roof headlight, front* S22-1 Roof headlight, rear*

19

Ashtray

21

Fuse box

* Option

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Operating instructions

Control, operation Operating and control elements

3.1.4 3.1.4.1

Control panel functions Display instruments P5 - Indicator - Operating hourmeter Displays the operating hours.

Serves as the basis for adhering to the maintenance schedule.

P6 - Display - Engine coolant temperature Displays the engine coolant temperature.

P7 - Display - Fuel reserves Shows the available amount of fuel in the fuel tank.

To reduce the condensation, always keep the fuel level as high as possible.

P50 - Clock Displays the current time.

3.1.4.2

Indicator lights H7 - Indicator light - Low engine oil pressure (red) The indicator light lights up if the engine oil pressure drops below 0.5 bar during machine operation.

The buzzer in the cab sounds simultaneously.

Bring the Diesel engine to low idle immediately.

Continue to let the engine run in low idle for approx. 5 seconds.

Shut down the Diesel engine.

H11 - Indicator light - Preheating (yellow) The indicator light lights up as long as the preheating procedure is actuated. When the preheating procedure is completed, the indicator light turns off and the Diesel engine can be started.

H12 - Indicator light - Battery charge (orange) The indicator light lights up if the ignition key is moved to contact position.

The indicator light turns off as soon as the Diesel engine is started.

During operation, this indicator light lights up if the alternator V-belt or the electrical charging system are defective.

Bring the Diesel engine to low idle immediately.

Continue to let the engine run in low idle for approx. 5 seconds.

Shut down the Diesel engine.

Remedy the error.

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3-7

Control, operation

Operating instructions

Operating and control elements

H13 - Indicator light - Air filter contamination (orange) The indicator light lights up if the air filter is very dirty.

Bring the Diesel engine to low idle immediately.

Continue to let the engine run in low idle for approx. 5 seconds.

Shut down the Diesel engine.

If necessary, replace the filter element.

H15 - Indicator light - Hydraulic oil temperature (red) The indicator light lights up if the hydraulic oil temperature in the tank exceeds 98 °C. Bring the Diesel engine to low idle immediately.

Shut down the Diesel engine as quickly as possible.

Find and remedy the error (radiator dirty, etc.).

H16 - Indicator light - Overload warning (red)* The indicator light lights up if the maximum permissible load carrying capacity of the machine is reached and the overload warning device S18 is turned on.

The buzzer in the cab sounds simultaneously.

Avoid increasing the load any further.

Reduce the load on the machine.

H18 - Indicator light - Coolant level low (red) The indicator light lights up if the coolant level drops below a specified level.

Bring the Diesel engine to low idle immediately.

Shut down the Diesel engine as quickly as possible.

Find and fix the leak.

Caution!

This monitoring device increases the level of security in case of loss of larger amounts of water (e.g. hose rupture). It does not relieve the operator or maintenance personnel from the responsibility of regularly checking the coolant level in the expansion tank.

H19 - Indicator light, turn signal The indicator light lights up if the turn signal switch and the hazard warning system are actuated.

H20 - Indicator light, parking brake The indicator light lights up if the parking brake is applied (S16) or if the parking brake's release pressure is too low.

H23 - Indicator light, accumulator charge pressure - operating brake (red)* The indicator light lights up if the accumulator charge pressure is too low. The brake function is endangered.

Bring the machine to a standstill.

Bring the Diesel engine to low idle immediately.

Fold the safety lever up.

Check the brake system.

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Operating instructions

Control, operation Operating and control elements

H26 - Indicator light - Quick change adapter (red)* The indicator light lights up during the unlocking procedure or when the locking pins are retracted.

H167 - Indicator light, travel forward (green) Lights up if travel direction is selected.

H168 - Indicator light, travel reverse (green) Lights up if travel direction is selected.

H175 - Indicator light - Engine overheating (red) The indicator light lights up if the coolant overheats.

The buzzer in the cab sounds simultaneously.

Bring the Diesel engine to low idle immediately.

Shut down the Diesel engine as quickly as possible.

Remedy the error.

Note!

If a V-belt breaks or the battery charge system is defective, the buzzer will not function.

H176 - Indicator light, oscillating axle automatic (green)

H196 - Indicator light - Grapple / hydraulic hammer (green)* The indicator light lights up if switch S241 is in position 1 (center position).

H307 - Indicator light - Fine control (green) Lights up after activation of fine control via rocker switch S382.

H311 - Indicator light, oscillating axle lock (green)

H336 - Indicator light, water in fuel filter Lights up if too much water is present in the fuel pre-filter.

Drain water from the fuel filter.

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3-9

Control, operation

Operating instructions

Operating and control elements

3.1.4.3

Switch S8 - Rotating beacon (green)* Press switch down.

The rotating beacon blinks.

The indicator light in the switch lights up.

Press switch up.

The rotating beacon is turned off.

The indicator light in the switch turns off.

S11 - Windshield washer system (green) Press the button down and hold.

Water will be sprayed onto the front windshield through nozzles.

The windshield wiper runs continuously.

Release the button.

The water flow stops.

The windshield wiper continues to run continuously for approx. 3 seconds.

S14 - Windshield wiper (green) This switch has three settings: Neutral (0), Position 1 and 2.

Push the switch in position 1 down (center position).

Continuous operation is activated.

Push the switch in position 2 down (final position).

Intermittent control is activated.

S16 - Parking brake (green) Press switch down.

The parking brake is applied.

The indicator light in the switch lights up.

Press switch up.

The parking brake is released.

The indicator light in the switch turns off.

S18 - Overload warning device (red)* Press switch down.

The overload warning device is activated.

The indicator light in the switch lights up.

Press switch up.

The overload warning device is deactivated.

The indicator light in the switch turns off.

S19 - Rotating grapple drive (green)* Press switch down.

The rotating grapple drive is activated.

The indicator light in the switch lights up.

Press switch up.

The rotating grapple drive is deactivated.

The indicator light in the switch turns off.

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3 - 10

MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Operating and control elements

S20 - Sensor controlled low idle automatic (red) Press switch down.

The sensor controlled low idle automatic is activated.

The indicator light in the switch lights up.

Press switch up.

The sensor controlled low idle automatic is deactivated.

The indicator light in the switch turns off.

S21 - Creeper gear (green) Press switch down.

Creeper gear is activated.

The indicator light in the switch lights up.

Press switch up.

Creeper gear is deactivated.

The indicator light in the switch turns off.

S22 - Work headlight, front / roof headlight, front (green)* This switch has three settings: Neutral (0), Position 1 and 2.

Push the switch in position 1 down (center position).

The front work headlight is turned on.

Push the switch in position 2 down (final position).

The front work headlight is turned on.

The rear roof headlight is turned on.

S22-1 - Roof headlight, rear (green)* This switch has three settings: Neutral (0), Position 1 and 2.

Push the switch in position 1 down (center position).

No function.

Push the switch in position 2 down (final position).

The rear work headlight is switched on.

The rear roof headlight is turned on.

S35 - Servo control (green) Press switch down.

The servo control is activated.

Left and right joysticks are operational.

The indicator light in the switch lights up.

Press switch up.

The servo control is deactivated.

Left and right joysticks are not operational.

The indicator light in the switch turns off.

S47 - Hydraulic quick change adapter Press the button down and hold.

The hydraulic quick change adapter is activated.

The indicator light in the switch lights up.

Release the button.

The hydraulic quick change adapter is deactivated.

The indicator light in the switch turns off.

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3 - 11

Control, operation

Operating instructions

Operating and control elements

S61 - Headlight This switch has three settings: Neutral (0), Position 1 and 2.

Push the switch in position 1 down (center position).

The parking light is activated.

Push the switch in position 2 down (final position).

The headlight is activated.

The switch is also functioning if the ignition key is in position 0 or P.

Press switch.

The corresponding outrigger is activated.

The indicator light in the switch lights up.

Press switch again.

The corresponding outrigger is deactivated.

The indicator light in the switch turns off.

S218 - Windshield wiper on cab roof (green) This switch has three settings: Neutral (0), Position 1 and 2.

Push the switch in position 1 down (center position).

Continuous operation is activated.

Push the switch down to position 2 and hold (final position).

Water will be sprayed on the windshield.

The windshield wiper runs continuously.

S241 - Auxiliary user (green)* This switch has three settings: Neutral (0), Position 1 and 2.

Push the switch in position 1 down (center position).

The auxiliary user with high pressure (e.g. sorting grapple, scrap cutter) is activated.

The indicator light H196 lights up.

Push the switch in position 2 down (final position).

The auxiliary user with reduced pressure (e.g. hydraulic hammer, ram) is activated.

The indicator light H196 turns off.

The indicator light in the switch lights up.

S318 - Air conditioning system (green)* Press switch down.

The air conditioning system is turned on.

The indicator light in the switch lights up.

Press switch up.

The air conditioning system is turned off.

The indicator light in the switch turns off.

S335 - Blade support (green) Press switch.

The dozer blade is activated.

The indicator light in the switch lights up.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Operation

S360 - Acknowledge buzzer quick coupler (green)* The button is available if the machine is equipped with an overload warning device.

Press switch down.

The buzzer for the quick change adapter is deactivated.

S398 - Reversing switch (green) Press switch down.

The air flow will be changed from outlet nozzles 8c (head area) to outlet nozzles 8a (foot area) and 8b (front window).

The indicator light in the switch lights up.

Press switch up.

The air flow will be changed from outlet nozzles 8a (foot area) and 8b (front window) to outlet nozzles 8c (head area).

The indicator light in the switch turns off.

S422 - Radio mute Press switch down.

The radio is muted The indicator light in the switch lights up.

Press switch up.

Radio plays again at original volume.

The indicator light in the switch turns off.

3.2 Operation 3.2.1 3.2.1.1

Entering or leavi Entering Caution!

Ensure that the safety lever is always in its uppermost position when entering or leaving the cab.

Always use the handholds provided for this purpose when entering or leaving the machine.

Do not use the control levers as handholds.

Never jump off the machine.

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3 - 13

Control, operation

Operating instructions

Operation

Fig. 3-7

3.2.1.2

Climb up using the handholds

Getting in

Fig. 3-8 1

Door - exterior

Door handle

2

Latch

11 Door lock

Press the door lock 11 on the door handle 1 and open the door.

If the door is to remain open during operations, swing the door back by 180° and secure in latch 2.

Climb in facing the machine and Adjust the seat and steering column if necessary.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Operation

3.2.1.3

Getting out

Fig. 3-9 3

Door - interior

Door handle on door lock

4

Lever for the latch

Shut down the machine and raise the safety lever.

Push the door handle 3 on the lock down.

Open the door fully and secure it in latch 2.

Climb out facing the machine.

To release the door latch: The door is secured in latch 2.

Move the lever 4 next to the cab frame outward.

The door is now unlocked.

Close the door.

3.2.2

Safety lever

Fig. 3-10

Safety lever

To prevent inadvertent movements of the machine, the left control console is equipped with a safety lever.

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3 - 15

Control, operation

Operating instructions

Operation

Caution!

When entering or exiting the operator's cab, always ensure that the safety lever is in its top position (arrow).

When the safety lever is tilted up, a number of machine functions are disabled or otherwise modified:

in movement of the machine. ewing gear brake are applied, and the oscillating axle is locked. The respective indicator lights are on. ing axle cannot be released.

By moving the safety lever to its bottom position, the initial switching statues of the brakes and the oscillating axle are re-established, and the pilot control units are enabled.

Before commencing work with the machine while seated on the operator seat, move the safety lever to its bottom position.

Fig. 3-11 option) 1

Upper horizontal adjustment

4b Rear seat incline adjustment

7

Lumbar support adjustment

2

Lower horizontal adjustment

5

Seat suspension adjustment

8

Seat heater

3

Armrest adjustment

6

Lumbar support adjustment

10 Backrest adjustment

4a Front seat incline adjustment

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Operation

This will avoid unexpected movements of the machine.

3.2.3.1

Adjusting the armrests

Fig. 3-12

Adjusting the armrests

Turn the knurled screw 3 on the armrest in direction a.

The armrests incline upwards.

Turn the knurled screw 3 on the armrest in direction b.

The armrests incline downward.

3.2.3.2

Adjusting the seat and backrest

Fig. 3-13

Adjusting the seat and backrest

Rear seat incline: Pull lever 4a up, set the incline and release the lever.

Front seat incline: Pull lever 4b up, set the incline and release the lever.

Backrest: Pull lever 10 up, set the incline and release the lever.

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3 - 17

Control, operation

Operating instructions

Operation

3.2.3.3

Adjusting the horizontal seat position

Fig. 3-14

Horizontal seat adjustment

Pull up the lever 1 to push the operator's seat in the horizontal direction.

Pull up the lever 2 to push the operator's seat including the control panels in the horizontal direction.

3.2.3.4

Adjusting the seat suspension

Fig. 3-15

Adjusting the seat suspension

Use the turning knob 5 to adjust the seat suspension to match the body weight.

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A 312 Litronic / 10443914

Operating instructions

Control, operation Operation

3.2.3.5

Adjustments on switch arrangement (air- cushioned

Fig. 3-16 To adjust the vibration damper: Press button 5 (+ or -) and set the vibration system according to body weight.

To adjust the lumbar support: Press button 6 (+ or -) to inflate or deflate the lower lumbar chamber.

Press button 7 (+ or -) to inflate or deflate the upper lumbar chamber.

To turn on the seat heater: Use switch 8 to turn the seat heater on or off.

The seat heater turns off automatically when the proper temperature is reached.

3.2.3.6

Putting on / releasing the safety belt

Fig. 3-17

Safety belt

The safety belt is automatic. It is not necessary to adjust the length of the belt.

Pull the belt and buckle 2 from the roller mount 1.

If pulled out of the roller mount jerky, the belt may lock.

Push the buckle into the belt lock 3 until it is properly engaged.

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3 - 19

Control, operation

Operating instructions

Operation

Danger!

The safety belt is designed to protect the operator.

Before starting the machine, always fasten the safety belt.

Ensure that the safety belt is not twisted when it is fastened.

To ensure your safety, check the condition, function and fastening of the belt regularly and replace any damaged parts immediately.

To open the lock 4, push the belt lock down using your thumb.

The safety belt will slide automatically back into the roller mount 1.

3.2.3.7

Vibration damper The seat complies with ISO 7096.

If the machine is used in accordance with regulations, the values of the vibration excitation vibration for the relevant machine class in accordance with ISO 7096.

The values for vibration accelerations a zw, measured in accordance with ISO 26311, therefore comply with the requirements for protection against whole body vibration according to EN 474-1.

3.2.4

Adjusting the steering column

Fig. 3-18

Steering column

By adjusting the steering column, the position of the steering wheel to the body can be set.

Press the release lever 2 down with the foot.

Set the desired position by pulling or pushing the steering wheel.

Take the foot off the release lever 2; the steering column is locked in the desired position.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Operation

3.2.5

Front windshield

Fig. 3-19

Front windshield

The front windshield can be locked in two positions. a: Window closed. b: Window fully opened (locked in place on the roof of the cab).

Pull pin 1 in and down.

The window is unlocked.

Move the windshield with bracket 2, secure in one of the two window positions (a or b) and relock with the pin 1.

3.2.6

Sun visor

Fig. 3-20

Sun visor, front windshield and cab roof

The cab is provided with two sun visors on the front windshield and on the window pane in the cab roof.

Front windshield Pull the sun visor down on the cross bar 1.

The sun visor can be adjusted as desired.

Press button 2 (red).

The sun visor rolls up by itself.

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3 - 21

Control, operation

Operating instructions

Operation

Cab roof Pull out the sun visor and secure it in the retainers designed for this purpose.

To retract the sun visor, remove it from the retainers and let it roll up slowly.

Fig. 3-21 By pulling the bracket 1 on the inside of the rear window, the rubber weather strip 2 can be released and removed.

In case of an emergency, pull off the rubber weather strip 2 from the circumference of the window and push the window out.

3.2.8

Interior illumination

Fig. 3-22

Interior illumination

The interior lighting is turned on with the slide regulator 1.

Push the slide regulator to the right.

Light 2 is turned on.

Push the slide regulator to the left.

The spot light 3 is turned on.

Push the sliding regulator to the center position.

The interior illumination is turned off.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Operation

3.2.9

Fire extinguisher (option)*

Fig. 3-23

Fire extinguisher / First-aid kit

The storage compartment for the fire extinguisher is located on the lower right in the operator's cab. *Operator regulations

3.2.10

Windshield wiper

3.2.10.1

Windshield wiper With the ignition turned on, press switch S14 on control panel C to activate the windshield wiper operation.

This switch has two settings: Push the switch in position 1 down (center position).

Continuous operation is activated.

Push the switch in position 2 down (final position).

Intermittent control is activated.

3.2.10.2

Window washer system With the ignition turned on, press switch S11 on control panel C fo activate the windshield washer system.

Press the button down and hold.

Water will be sprayed onto the front windshield through nozzles.

The windshield wiper runs continuously.

Release the button.

The water flow stops.

The windshield wiper continues to run continuously for approx. 3 seconds.

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3 - 23

Control, operation

Operating instructions

Operation

3.2.10.3

Windshield washing fluid container

Fig. 3-24

Windshield washing fluid container

The container for the windshield washing fluid is located at the rear of the cab.

Open the cover (see arrow) to refill the container with commercially available windshield washing fluid.

Quantity: see Lubrication Chart

3.2.10.4

Window wiper on cab roof

Fig. 3-25

Window wiper on cab roof

With the ignition turned on, press switch S14 on control panel C to activate the windshield wiper operation.

This switch has two settings: Push the switch in position 1 down (center position).

Continuous operation is activated.

Push the switch down to position 2 and hold (final position).

Water will be sprayed on the windshield.

The windshield wiper runs continuously.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Operation

3.2.11

Lighting

Fig. 3-26 1 2

Arrangement of lights

Parking and headlight Attachment headlights

3 4

Roof headlight (option) Rotating beacon (option)

The switches for the lights are located on control panel C.

3.2.11.1

Parking light and low beam light With the ignition turned on and off, the parking light or low beam light is turned on by pressing switch S22.

This switch has two settings: Push the switch in position 1 down (center position).

The parking light is activated.

Push the switch in position 2 down (final position).

The headlight is activated.

3.2.11.2

Attachment headlight, front Front roof headlight (option) With the ignition turned on, the roof and attachment headlights are turned on by pressing switch S22.

This switch has two settings: Push the switch in position 1 down (center position).

The front work headlight is turned on.

Push the switch in position 2 down (final position).

The front work headlight is turned on.

The front roof headlight is turned on.

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3 - 25

Control, operation

Operating instructions

Operation

3.2.11.3

Rear roof headlight (option) With the ignition turned on, the rear roof headlight is turned on by pressing switch S22-1.

This switch has two settings: Push the switch in position 1 down (center position).

No function.

Push the switch in position 2 down (final position).

The rear work headlight is switched on.

The rear roof headlight is turned on.

3.2.11.4

Rotating beacon (option) With the ignition turned on, press switch S8 to turn the rotating beacon on.

Press switch down.

The rotating beacon blinks.

The indicator light in the switch lights up.

Press switch up.

The rotating beacon is turned off.

The indicator light in the switch turns off.

3.2.12

3.2.12.1

Heating system / heating and air conditioning system (option) Overview The cab is equipped with a heating system as standard. The heating system can be used to heat and ventilate the cab. The switches for heater operation are located on control panel B. On request, the machine can be equipped with an air conditioning system.

Fig. 3-27

Overview of heating / air conditioning system

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A 312 Litronic / 10443914

Operating instructions

Control, operation Operation

S92 S93

Control - Air vent Heat output control

S318 Air conditioning system (option) S398 Reversing switch

S284 Blower control

3.2.12.2

Blower control The blower output is regulated via rotary switch S284.

Position 0: The blower is turned off.

Positions 1 to 4: The fan motor runs in four different output stages.

3.2.12.3

Air duct The air flow is regulated via rotary switch S92 and via turnable and closeable air vents.

Fig. 3-28

Position of front air vents (left view) and vents on the rear cab wall (right view)

The air flow is either directed via nozzles 8a (foot area) and 8c (front windshield) or via air vents 8d (overhead area).

By pressing the reversing switch S398, the air flow will be reversed.

Press switch S398 down.

The air flow will be changed from nozzles 8d to nozzles 8a and 8c.

The indicator light in the switch lights up.

Push switch S398 upward.

The air flow will be changed from nozzles 8a and 8c to nozzles 8d.

The indicator light in the switch turns off.

When the reversing switch S398 is turned off, the air flow between nozzles 8a (foot area) and 8c (front windshield) is regulated via the knob S92.

Turn the knob S92 to the left.

The air flow will be changed from nozzles 8a to nozzles 8c.

Turn the knob S92 to the right.

The air flow will be changed from nozzles 8c to nozzles 8a.

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Control, operation

Operating instructions

Operation

3.2.12.4

Heater operation The desired heat output can be set via knob S93.

The Diesel engine must be running.

Turn the knob S93 to the left.

The heat output is decreased.

The heater is turned off when position "0" (left stop) is reached.

Turn the knob S93 to the right.

The heat output will be increased.

Note!

To attain optimum comfort when heating, it is recommended to use nozzles 8a (foot area) and 8c (front windshield).

3.2.12.5

Air conditioning operation (option) On request, the machine can be equipped with an air conditioning system. The air conditioning system is activated via switch S318.

The Diesel engine must be running.

Press switch S318 down.

The air conditioning system is turned on.

The indicator light in the switch lights up.

Push switch S318 upward.

The air conditioning system is turned off.

The indicator light in the switch turns off.

When turning on the air conditioning system and the knob S284 (blower control) is in position 0, the blower speed will automatically jump to position 1.

In air conditioning mode, the forced air will be cooled. The desired room temperature can be set with knob S93 (heater operation). The forced air is coldest when the knob S93 is in position 0 (left stop).

To dehumidify the cab, the air conditioning system can also be activated when the heater is on. In this case, turn on the air conditioning system only until the windows are no longer fogged.

Note!

For optimum comfort when operating the air conditioning system, it is recommended to use the nozzles on the rear cab wall 8d.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Operation

3.2.12.6

Notes for down time

Fig. 3-29

Water taps on the Diesel engine

ed for an extended period of time without using the air conditioning system, it is recommended to operate the air fly every two weeks by pressing switch S318. If the compressor is out of service for a longer period of time, its shaft seal could be damaged due to vibration. taps (see arrows) on the Diesel engine should be closed.

3.3 Operation 3.3.1 3.3.1.1

Safety instructions Bringing the machine safely into service

remain unlocked. he inside and outside mirrors are clean.

Secure all doors and windows to prevent unintentional movement. the surrounding area with the horn before starting the machine. and the other items to ensure comfortable and safe working conditions. chine must be in functional protective position during operation. ive for the relevant site.

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3 - 29

Control, operation

Operating instructions

Operation

3.3.1.2

Starting the machine safely and instruments for proper function, bring all controls into neutral position and raise the safety lever. located near the machine. regulations in the operating instructions, if you have not received any other instructions. controls for their proper indication. ntilated area, if the area is enclosed. If necessary, open doors and windows in the building to provide ample fresh air. cause a slow reaction of the controls.

3.3.1.3

Shutting down the machine safely secured with chocks, wenn setting it on a slope, to secrure it against rolling away.

gear brake. the operating instructions and move the

secure the machine against any unauthorized use.

3.3.1.4

Towing the machine safely operating manual. move the machine away from a dangerous place. towing the machine, check all cables, hooks and couplers for safety and stability. ile strength and must be attached to the undercarriage at the provided stops.

Be aware that any damage or accidents caused by towing the machine are never covered by the manufacturer's warranty.

permissible speed and distance.

service.

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A 312 Litronic / 10443914

Operating instructions

Control, operation Operation

3.3.2 3.3.2.1

Starting / shutting down the machine Activities before starting Caution!

It is only possible to extinguish the source of fire if it is accessible.

Before starting, unlock all locks on the covers of the hydraulic excavator.

In the event of a fire, the doors can be opened immediately and the fire can be extinguished.

Location of locks: see Maintenance chapter Caution!

With the activities referred to below and a machine that is already at operating temperature, there is a risk of scalding or burning from hot coolant or hot oil.

Make sure to first read the information provided in the Maintenance chapter before carrying out these activities.

Before starting the machine, the following tasks should be carried out on a daily basis:

the hydraulic tank*.

cooling and combustion air intake. * To complete these tasks, refer to the Maintenance chapter.

3.3.2.2

Starting the Diesel engine Switch positions of ignition key

Fig. 3-30

Ignition switch

0

Neutral position

2

Preheat

1

Contact position

3

Starting position

P

Parking position

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Control, operation

Operating instructions

Operation

Turning the electrical system on

Fig. 3-31

Battery master switch

The battery master switch must be in position 1 (ON).

Turn the ignition key to contact position 1.

As soon as the ignition is turned on, the keypads and the display instruments runs through a self check.

Note!

If the keypad and display instruments do not run through a self check when the ignition key is in contact position, check if the battery master switch is positioned on

Make sure that the display instruments are functioning perfectly when they are turned on.

All indicator lights must turn on briefly.

Electronic immobilizer (option) On request, the machine can be equipped with an electronic immobilizer.

Fig. 3-32

Electronic immobilizer

Insert the coding key 1 in the coding lock S74 and then remove it again.

The LED turns off.

A signal tone sounds.

Turn the electrical system on.

Use the ignition key to start the electrical system within 9 seconds.

If the ignition is not turned on within 9 seconds, the coding key must be reinserted in the coding lock.

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A 312 Litronic / 10443914

Operating instructions

Control, operation Operation

When the ignition is switched on, the immobilizer activates independently after approx. 30 seconds.

To reorder the coding key, state the code number noted on the accompanying code card (cheque card format).

3.3.2.3

Starting the engine Note!

Only actuate the starter when the Diesel engine is shut down.

Do not actuate the starter continuously for longer than 10 seconds.

If the engine does not start, turn the ignition key back to contact position 1.

Wait at least 1 minute before repeating the starting procedure.

Turn the ignition key back to position 0 before restarting the engine.

Starting procedure at ambient temperatures above 0 °C If the engine and batteries are in good condition, the engine can be started without preheating.

Sensor controlled low idle automatic S20 must be turned off.

The indicator light may not light up.

Turn the throttle control R75 from the zero point a ¼ turn to the right.

Turn the ignition key to starting position 3.

Release the ignition key as soon as the engine is running.

All indicator lights must turn off.

The buzzer will sound briefly when the engine starts until the engine oil pressure builds up.

Starting procedure at ambient temperatures below 0 °C Preheating improves the starting behavior of the Diesel engine at low temperatures.

Sensor controlled low idle automatic S20 must be turned off.

The indicator light may not light up.

Turn the throttle control R75 from the zero point a ¼ turn to the right.

Turn the ignition key to position 1.

The indicator light H11 lights up.

Wait until the indicator light H11 turns off.

Preheating is completed.

Turn the ignition key to starting position 3.

Release the ignition key as soon as the engine is running.

All indicator lights must turn off.

The buzzer will sound briefly when the engine starts until the engine oil pressure builds up.

Note!

Do not preheat an engine which is at operating temperature.

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3 - 33

Control, operation

Operating instructions

Operation

3.3.2.4

Throttle control

Fig. 3-33

Throttle control

The throttle control R75 permits continuous adjustment of the engine RPM over the full RPM range.

3.3.2.5

Engine overheating If the engine overheats, the indicator light H175 lights up and a warning signal (buzzer) sounds simultaneously.

Shut down the Diesel engine immediately (see also the Deutz engine operating and maintenance manual).

Fig. 3-34

Diesel engine air intake

Note!

To ensure optimum conditions for the engine, remove any ice and snow from the engine hood in the area of the cooling and combustion air intake before starting the Diesel engine.

3.3.2.6

Notes after starting the engine Danger!

Danger of suffocation.

When operating in closed spaces, run the engine only with sufficient ventilation.

Open doors and windows to ensure sufficient supply of fresh air.

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A 312 Litronic / 10443914

Operating instructions

Control, operation Operation

Caution!

At low oil temperatures, increased wear occurs in the Diesel engine and the hydraulic system and the controls will react sluggishly.

Bring the engine and hydraulic oil to operating temperature. The control operates sluggishly at low oil temperatures.

Carefully move the machine to an open area to check the function of the travel and swing gear brake.

Check that all attachment functions are operating properly.

3.3.2.7

Shutting the Diesel engine down Caution!

The engine could be damaged.

Do not shut down the engine suddenly from full throttle.

Reduce the engine RPM via the throttle control R75 to low idle.

Allow the Diesel engine to run in low idle for another 2 minutes to even out the temperature.

Now turn the ignition key to position 0 to shut down the engine.

Remove the ignition key.

3.3.3

Jump start procedure Danger!

When connecting to jump start batteries, old batteries can be subject to increased gas formation.

Wear safety glasses and protective gloves during the jump start procedure and avoid open flames and creating any sparks in the vicinity of the discharged vehicle battery. DANGER OF EXPLOSION! Only use jump start cables with a sufficient cross section. Always follow the established jump starting procedure.

3.3.3.1

Connecting the batteries First connect the cable to the positive terminal (+) of the discharged battery and then to the positive terminal (+) of the jump start battery.

Connect the second cable to the negative terminal (-) of the discharged battery and then to the negative terminal (-) of the jump start battery.

Start the engine as described above.

Caution!

Before removing the jump start cable, be sure to bring the Diesel engine of the jump started machine into low idle.

For safety reasons, turn on a large user, such as work headlights, uppercarriage lighting etc. to avoid overvoltage. The electronics could otherwise be damaged.

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Control, operation

Operating instructions

Operation

3.3.3.2

Disconnecting the batteries First remove the cable from the negative terminal (-) of the jump start battery and then from the negative terminal (-) of the discharged battery.

Remove the second cable from the positive terminal (+) of the jump start battery and then from the positive terminal (+) of the discharged battery.

Check the electrical functions of the machine.

For battery care and maintenance, see the chapter "Battery care".

3.3.4

Travel operation The safety belt must always be worn before travel operation.

For travel, the uppercarriage must be positioned to the undercarriage in travel position, i.e. the steering axle (oscillating axle) on the front, the rigid axle to rear.

For travel on public roads, the uppercarriage and the undercarriage must be interlocked.

Fig. 3-35

Controls for travel

1

Retainer

H167 Indicator light, travel direction forward

3

Joystick, right

H168 Indicator light, travel direction reverse

6

Brake pedal

S263 Rocker switch travel direction

7

Traveling pedal Before starting to travel, use your foot to release the retainer 1 on the brake pedal 6.

Release parking brake S16.

3.3.4.1

Gear selection The machine is equipped with a power shift 2-speed transmission with downshift lock.

When the machine is started up, the second gear is automatically engaged.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Operation

Note Maximum travel performance is only obtained when the servo control S35 is turned off.

3.3.4.2

Changing gear when stationary Press switch S42 down.

The 1st gear is engaged.

Press switch S42 again.

The 2nd gear is engaged.

3.3.4.3

Changing gear during travel Since the transmission can be shifted under load, the gears can also be changed during travel.

During travel in 2nd gear: Press switch S42 down.

The 1st gear is preselected.

The shifting procedure is carried out automatically when the corresponding low travel speed has been reached.

During travel in 1st gear: Press switch S42 again.

The shifting procedure is carried out immediately. The 2nd gear is engaged.

3.3.4.4

Creeper gear Note!

The creeper gear should be selected when stationary or for slow driving to prevent a jerky braking action of the machine.

To obtain better traction on inclines and difficult terrain, the creeper gear can be shifted with switch S21.

Press switch S21 before or during travel to turn on the creeper gear.

To turn the creeper gear off, press switch S21 again.

3.3.4.5

Travel movement The selection of the travel direction is made via the rocker switch S263 on the left joystick. An infinitely variable regulation of the travel speed is possible with the accelerator pedal 7.

Danger!

Before driving in reverse, make sure that the area behind you can be entered safely.

After completing the travel movements, bring the travel selector switch to the 0 position.

If the uppercarriage is rotated by 180° to the undercarriage, the travel and steering directions are reversed.

Travelling forward Press rocker switch S263 down a.

The indicator light H167 lights up.

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Control, operation

Operating instructions

Operation

Slowly press travel pedal 7 down.

Travelling reverse Press rocker switch S263 up b.

The indicator light H168 lights up.

Slowly press travel pedal 7 down.

3.3.4.6

Travelling downhill The machine is equipped with an automatic brake valve, which prevents the hydraulic drive train from overspeeding.

Danger!

Before travelling downhill, turn the sensor controlled low idle automatic S20 off.

Travel downhill with maximum Diesel engine RPM. Regulate the speed using the travelling pedal.

3.3.4.7

Travelling on downhill grades of more than 10% Caution!

Applying the operating brake does not ensure safe parking on a downhill slope (loss of pressure due to leakage is possible).

Before leaving the cab and / or shutting down the machine, apply the parking brake S16.

Raise the safety lever.

Always use the 1st gear to travel downhill slopes of more than 10%.

Before travelling downhill, stop and engage the 1st gear.

3.3.5

Travelling on public roads Note!

Travelling on public roads is subject to national regulations.

Before starting to travel, inform yourself about local requirements.

Observe all regulations and conditions.

Fig. 3-36

Required additional equipment, Germany

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Operation

In Germany, for example, the following safety devices must be carried in accordance with the motor vehicle C.U.R. and the conditions in the exception authorization:

Before travelling on a public road, carry out the following tasks and checks: Clean the machine of all coarse dirt.

Clean the tire treads.

Empty the digging equipment.

Close all doors and the covers.

Turn the uppercarriage in the direction of travel (attachment over steering or oscillating axle) and lock to the undercarriage with the locking pin (see chapter Uppercarriage lock).

Fig. 3-37

Position of bucket for on road travel

To bring the attachment into a road travel position: Fully extend the hydraulic cylinder 1 and retract the boom adjustment cylinder 2 fully.

Tilt in the bucket and pull the stick as close as possible to the uppercarriage.

Fig. 3-38

Securing the grapple for on road travel

On undercarriage with 2 point outriggers: Attach the grapple to the grapple bar.

On undercarriage with 4 point outriggers: Place the grapple with the aid of tension ropes 3 on the undercarriage, do not remove the ropes while travelling.

Tilt the connecting link 4 up.

Secure the connecting clip 4 with two screws.

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Control, operation

Operating instructions

Operation

To bring the support into a road travel position:

Fig. 3-39

Outrigger support for road travel

Retract the outrigger support to the stop.

Fold the hinged support feet of the outriggers inward.

Fig. 3-40

Blade support for road travel

If installed, fold the step 1 up and secure.

Push the blade support up to the stop.

Attach additional rear reflectors 2 on the left and right hand side on the blade and secure.

Before starting to travel: To turn off the control for the working hydraulics: Push switch S35 up.

The indicator light in the switch turns off.

The joysticks do not function.

The sensor controlled low idle automatic is deactivated.

Switch the automatic oscillating axle lock S75 to position 0.

3.3.6

Emergency gear shifting If the parking brake cannot be released, this could be due to a failure of the solenoid valve of the gear shifting system. In this case, turn in the valve manually (emergency operation).

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A 312 Litronic / 10443914

Operating instructions

Control, operation Operation

Fig. 3-41

Valve block of the gear shifting system

The valve block is located at the uppercarriage below the basic boom.

Turn in the T-handle at the solenoid valve Y6.

The machine is now in second gear and the parking brake is released.

The machine can now be moved.

3.3.7

Towing the machine Towing the machine is a dangerous manoeuvre, and the responsibility for any damage in connection with towing rests with the operator.

The machine may only be towed in exceptional situations, e.g. if the machine must be moved for safety reasons or if it must be repaired at the workshop.

Injuries to persons or damage to equipment caused by towing of the machine are not covered by the manufacturer's warranty.

Note!

The travel drive can be damaged, if the machine is towed over a certain distance without disengaging the transmission.

If possible, disengage the transmission before towing the machine (see 3.3.8).

Adhere to the maximum distance and speed for towing.

Danger!

Risk of injury! Risk of damage to property!

To tow the machine, use a suitably dimensioned rod.

Never use a cable or rope.

Secure the towing rod to the towing hitch at the undercarriage.

When towing the machine, adhere to the following limits:

from a dangerous position).

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Control, operation

Operating instructions

Operation

3.3.8

Disengaging transmission Danger!

When the transmission is disengaged, the parking brake is disabled. The machine might roll away, if another brake (working brake) is disabled.

When the diesel engine is off and the transmission is disengaged, all brakes (working brake, parking brake) are disabled. The machine might roll away, and the steering is stiff so that its operation requires some force.

Before disengaging the transmission, secure the machine against rolling off (with towing rod or chocks).

The machine may only be towed away from the danger zone but not any further!

Fig. 3-42 1

Disengaging transmission

Lubrication nipple

2

Bleeder

3

Pressure relief valve

Releasing clutch: The transmission can be disengaged by pressing grease into the lubrication nipple 1.

Press grease into the lubrication nipple 1 using a grease gun, until the grease escapes at the pressure relief valve 3.

The transmission is disengaged.

The machine can now be towed from the danger area.

When the diesel engine is on and no other malfunctions are apparent, the machine can be stopped with the working brake (foot pedal) and steered with the servo steering.

If the diesel engine is not on: all brakes of the machine are disabled!

Caution!

The transmission might be damaged, if it is disengaged for a prolonged period of time while the machine is in motion.

Do not put the machine into gear and do not press the gas pedal while the transmission is disengaged.

Engaging clutch: Open the bleeder 2 of the emergency activation.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Operation

Put the machine into on-road gear.

Close the bleeder 2.

The transmission is engaged.

3.3.9

Oscillating axle locking device

Fig. 3-43

Oscillating axle locking device

The oscillating axle can be operated locked (rigid) or unlocked (oscillating). The relevant selection is chosen with the switch S75.

S75

Function

Application

0

Oscillating axle unlocked

Travel operation without load, onroad travel

1

Oscillating axle locked

Working and moving machine with attached load

A

Automatic oscillating axle locking; the oscillating axle is automatically locked when the working brake is applied.

Preconditions: S35 is switched on.

Working, travel operation without load

Fig. 3-44

Functions of the oscillating axle

Danger!

When the automatic oscillating axle locking function (switch S75 in position A) is on and the working brake is released, or the servo control S35 is switched off, the oscillating axle is released.

This results in a reduced stability of the machine. When a load is taken up and the uppercarriage is swivelled, the machine might topple over, resulting in injury and damage to equipment.

To move the machine with load (e.g. filled digging tool, suspended load), proceed as follows: Before taking up the load, permanently lock the oscillating axle (set switch S75 to position 1).

Never switch off the servo control system S35 when the automatic oscillating axle locking mechanism is activated (switch S75 in position A).

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Control, operation

Operating instructions

Operation

Locking oscillating axle: Turn the switch S75 to position 1 The indicator light H311 (oscillating axle locking system) is on.

The oscillating axle is permanently locked.

The machine's stability is enhanced.

Releasing oscillating axle: Turn the switch S75 to position 0 The indicator light is off.

The oscillating axle is permanently unlocked.

The machine's stability is reduced.

Switching on the automatic oscillating axle locking mechanism The servo control system S35 must be switched on and remain activated during the operation of the automatic oscillating axle locking mechanism.

Turn the switch S75 to position A When the working brake is applied, the oscillating axle is automatically locked in its current position, and the indicator light for H176 is on.

When the working brake is released, the oscillating axle is also released, and the indicator light is off.

Note!

To make best use of the oscillating axle, set it according to the actual task: Lock the oscillating axle when working with the machine.

Lock the oscillating axle before travelling with an attached load.

Release the oscillating axle before travelling without load and before on-road travel.

3.3.10

Support

Fig. 3-45

Support variations

The machine can be equipped with different support systems: 1 Blade support 2 Blade support, front and rear 3 Outriggers 4 Blade and outrigger support It is possible to combine the support variations on the front and / or at the rear, depending on installation kit. The outrigger support can be expanded to include the individual control function (option).

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Operation

3.3.10.1

Operating the blade / outrigger support

Fig. 3-46

Operating the blade support

The support is operated using control lever 5.

To extend the outriggers or the blade, move the control lever 5 forward a.

To retract the outriggers or the blade, move the control lever 5 backward a.

If the machines is also equipped with a blade, in addition to the blade / outrigger support, then it must be separately activated with switch S335.

If necessary, press switch S355 down.

The blade support is activated.

The indicator light in the switch lights up.

To extend the blade, move the control lever 5 forward a.

To retract the blade, move control lever 5 backward b.

3.3.10.2

Individual outrigger control (option)

Fig. 3-47

Individual outrigger control

The selection of the individual outriggers to be used is made via switches S204 S207 in the control panel A. S204 = Outrigger, left front S205 = Outrigger, right front S206 = Outrigger, left rear S207 = Outrigger, right rear Each outrigger can be controlled individually or together with the other outriggers.

Press the corresponding switch .

The indicator light in the corresponding switch lights up.

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Control, operation

Operating instructions

Working with the machine

To extend the outrigger(s), move the control lever 5 forward a.

To retract the outrigger(s), move control lever 5 backward b.

3.4 Working with the machine 3.4.1

Working with the machine safely the special regulations and warning signals. Part of the surrounding area includes, for example, the obstacles in the working or movement area, the load carrying capacity of the ground and required safeguards for the job site to shield it from public highway traffic. and an unsecured substrate. conditions of reduced visibility and changing ground conditions. position of the supply lines, and be especially careful when working close to them. Make sure you are aware of local regulations regarding safety distances from supply lines and observe them. When necessary, inform the relevant authorities. overhead lines. Do not approach the line with the equipment when working near electrical overhead lines. Danger of fatal injury! Inform yourself about required safety distances.

secured. regulations and, if necessary, first bring the machine into proper condition to meet federal and local highway standards. s of poor visibility or darkness.

are carried out immediately.

operating manual. long as the machine is still moving. d operated in such way that the stability is ensured and that there is no danger of tipping over. Only known loads may be moved with the attachments, especially in grapple operation. depends on the attached equipment as well as the substrate.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Working with the machine

ngthwise direction and hold the load as close as possible to the ground.

EXCEPTION: see WHEN LOADING AND UNLOADING

uphill, never sideways on a slope. e permitted speed or you could loose control over the machine. since you may otherwise loose control of the machine. The Diesel engine must run in the upper revolution range and be reduced by selecting the low driving speed range / the lowest gear. to a lower gear. When doing this, the Diesel engine must run at maximum RPM and the speed may only be reduced using the accelerator pedals. truck driver leaves the cab, even if a rock protection is present. r their specific use for demolition work, clearings, hoisting operations, etc. overview of and whenever necessary, ask for assistance of a guide. Have only one person signal you. operator. The guide must position himself within view of the operator or be in voice contact with him. nt combination, there can be a danger of collision s cab, the cab protection or the boom cylinders. To avoid damage, utmost attention is required when the bucket teeth enter this range.

3.4.1.1

Safe use when in materials handling operation (especially when travelling with loads with raised work equipment) can be necessary to move the machine with a raised attachment and picked up load, for example when handling wood or timber. machine upward in vertical direction. The travel behaviour of the machine will be strongly influenced, for example reduction of dynamic stability.

For that reason, the following rules must be strictly observed: surrounding conditions. aking, acceleration, changes in travel direction.

en on the load, lifted it and turned the uppercarriage in travel position. ised, there is a danger due to possible oscillating movements and falling of the picked up load.

A protective screen (FOPS) according to ISO 10262 must be attached on the front on the cab.

The protective screen (FOPS) according to ISO 10262 must be installed if there is a danger of falling objects from overhead.

NOTE: The weight of absorbent material, such as wooden logs, depends on the

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Control, operation

Operating instructions

Working with the machine

length, the diameter and the specific weight. The existing influencing factors for a natural product, such as moisture, must be considered. special instruction and training of the machine operator. sufficient training and practical experience.

3.4.1.2

Safe application of machines with tower elevation the center of gravity of the machine will shift upward in vertical direction. The travel and work behaviour of the machine will thereby be strongly influenced, for example reduction of dynamic stability. the machine must be aligned in horizontal direction before starting to work. In horizontal direction, the center of gravity of the uppercarriage is above the center of the undercarriage, which reduces the danger of tipping over.

For that reason, the following rules must be strictly observed: When driving the machine:

uneven road surfaces endanger the stability of the machine. changed machine characteristics (higher center of gravity) and surrounding conditions. aking, acceleration, changes in travel direction. in lengthwise direction, to avoid impermissible transverse slopes of the machine. slowly!

In material handling operation: ge from transport position, the machine must be supported and horizontally aligned. ace of the outriggers (load carrying capacity of ground). Sinking of an outrigger below ground level would result in devastating consequences! s with increased caution.

(Caution! Oscillating grapple), while holding the load as close as possible to the undercarriage and above the ground.

3.4.1.3

Additional notes for mach elevation lengthwise and horizontal direction. Position the uppercarriage to the undercarriage in such a way that the steps and ladders are aligned. three point support, i.e. always have two hands and one foot or two feet and one hand in contact with the entry system.

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A 312 Litronic / 10443914

Operating instructions

Control, operation Working with the machine

climbing higher. External influences, such as wind, can make it more difficult to open the door. For that reason, always guide the door by hand when opening the door. Make sure that the door is engaged when it is open, to prevent it from banging open or closed. close the door and fasten the safety belt. and climbing up the machine. undercarriage in such a way that the steps and ladders are aligned. face the machine and use the three point support. Climb down until you can close the door safely. Always guide the door by hand when closing the door.

3.4.1.4

Protection from vibrations manner of utilization. Especially the following parameters have a significant influence: braking, control of operating elements of the machine during travel as well as working. himself selects the speed, the gear ratio, the working manner and the travel route.

This results in a wide range of various vibration impacts for the same machine type.

The full body vibration impact for the machine operator can be reduced if the following recommendations are observed: ine, equipment parts and auxiliary devices for the corresponding tasks. machines, for example hydraulic excavators, a seat which meets EN ISO 7096).

weight and the size of the operator. that the characteristics of the seat remain as specified by the seat manufacturer. pressure, brakes, steering, mechanical connections, etc. machine in a jerky manner.

n where the machine is working and travelling in good order:

able terrain conditions, keep machines available and allow for sufficient time.

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Control, operation

Operating instructions

Working with the machine

for travel, utilize special auxiliary systems for travel (if installed), which reduce the vibration for this application.

If such auxiliary systems are not available, regulate the speed to keep the machine from "rocking".

3.4.2

Sensor controlled low idle automatic This device automatically reduces the engine RPM to low idle after 6 seconds, if no hydraulic functions are activated by the joystick or the pedals. This saves fuel and reduces noise. Touching the joystick or operating the pedals resets the engine RPM to its original setting.

Actuate the sensor controlled low idle automatic by pressing switch S20.

Press switch down.

The sensor controlled low idle automatic is activated.

The indicator light in the switch lights up.

Press switch up.

The sensor controlled low idle automatic is deactivated.

The indicator light in the switch turns off.

Caution!

The sensor controlled low idle automatic must be turned off when starting up the Diesel engine. The indicator light in the switch may not light up.

3.4.3

Operating the swing gear Caution!

The machine is delivered in series with PCSA controls.

On request, the machine can be equipped with a control system that deviates from the PCSA controls (e.g. LIEBHERR control). In this case, observe the additional operating instructions for this control.

The joystick functions described here refer exclusively to PCSA controls.

3.4.3.1

Turning the uppercarriage The uppercarriage is turned with the left joystick.

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Operating instructions

Control, operation Working with the machine

Fig. 3-48

Turning the uppercarriage

Deflect the joystick to the left c.

The uppercarriage turns to the left.

Deflect the joystick to the right d.

The uppercarriage turns to the right.

3.4.3.2

Slowing the uppercarriage down The machine is equipped with a hydraulic and a mechanical swing gear brake.

Hydraulic swing gear brake Move the left joystick 4 to neutral.

The uppercarriage will be adequately slowed down hydraulically.

Move the left joystick 4 in the opposite direction.

The uppercarriage will be hydraulically slowed down to the maximum degree.

Positioning swing brake (option) The positioning swing brake is used for progressive and sensitive braking action of the uppercarriage.

Fig. 3-49

Positioning swing brake

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Control, operation

Operating instructions

Working with the machine

Note!

Increased wear.

Do not use the positioning swing brake purely as an operating brake, only as a retaining and parking brake for the swing gear.

We recommend to slow down the uppercarriage hydraulically (by counter rotating).

Actuate the pedal 10.

The uppercarriage is located in the desired position after sensitive braking action.

3.4.4

Fine control Fine control is used to adapt the working speed for precision work.

Control in the left joystick:

Fig. 3-50

Fine control, control in left joystick

The maximum pump flow can be limited with the selector R76 in the right control panel. The movements of the hydraulic excavator are slowed down according to the switch position.

Press down rocker switch S382 on the left joystick.

The fine control is activated.

The indicator light H307 lights up. The fine control is activated.

Set the pump flow with knob R76: Position 1: high pump flow, maximum working speed Position 2: low pump flow, minimum working speed.

Operate the attachment and check the speed.

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Operating instructions

Control, operation Working with the machine

3.4.5

Locking the superstructure

Fig. 3-51

Superstructure locking

When driving on public roads, transporting, taking out of service or carrying out maintenance and repair work, the superstructure must be locked to the chassis.

Locking of the superstructure happens automatically with the help of a hydraulic locking pin.

Locking: Rotate the superstructure in the direction of travel parallel to the chassis.

If necessary, correct the position of the superstructure until the locking pin 1 is located centrally to the pillow block 2.

Switch off servo control S35 or push the safety lever up.

The locking pin 1 extends, the superstructure is locked (B).

When the diesel engine is shut down, locking pin 1 also extends.

Unlocking: Switch on servo control S35 and push the safety lever down.

Locking pin 1 retracts, the superstructure is released (A).

3.4.6

Working position

Fig. 3-52

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Control, operation

Operating instructions

Working with the machine

Work with the machine is generally to be carried out over the rigid axle.

Fig. 3-53

Locking the oscillating axle

Fig. 3-54

Locking the oscillating axle

1

Retainer

6

Brake pedal

Caution!

Parking brake S16 may not be applied.

A buzzer sounds as a warning signal when the parking brake is applied.

Preselector switch S263 for travelling forward and reverse must be in position 0.

Press down fully on brake pedal 6 until the retainer 1 engages.

To lock the oscillating axle: Turn switch S75 to position I. The oscillating axle is completely locked.

- or Turn switch S75 to position A. Lock the oscillating axle via the brake pedal.

3.4.7

Joystick functions Caution!

The machine is delivered in series with PCSA controls.

On request, the machine can be equipped with a control system that deviates from the PCSA controls (e.g. LIEBHERR control). In this case, the additional operating instructions for this control system must be observed.

The joystick functions described here refer exclusively to PCSA controls.

3.4.7.1

Operating the stick cylinder The stick cylinder is operated using the left joystick 4.

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Operating instructions

Control, operation Working with the machine

Fig. 3-55

Operating the stick cylinder

Pull the joystick back a.

The stick will be retracted.

Push the joystick forwards b.

The stick will be extended.

3.4.7.2

Operating the boom cylinder The boom cylinder is operated using the right joystick 3.

Fig. 3-56

Operating the boom cylinder

Pull the joystick back g.

The attachment will be raised.

Push the joystick forward h.

The attachment will be lowered.

3.4.7.3

Operating the bucket cylinder The bucket cylinder is operated using the right joystick 3.

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Control, operation

Operating instructions

Working with the machine

Fig. 3-57

Operating the bucket cylinder

Move the joystick to the left e.

The bucket will be curled in.

Push the joystick to the right f.

The bucket will be curled out.

3.4.7.4

Operating the grapple cylinder The grapple cylinder is operated using the right joystick 3.

Fig. 3-58

Operating the grapple cylinder

Danger!

Never allow anyone to guide the grapple by hand!

Move the joystick to the left e.

The grapple will close.

Push the joystick to the right f.

The grapple will open.

3.4.7.5

Combined movements Moving a joystick diagonally allows a combination of the corresponding work functions. Thus different attachment movements can be actuated at the same time.

3.4.8

Lowering the attachment when the engine is not running In an emergency, the attachment can be lowered, even if the engine is not running.

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Operating instructions

Control, operation Working with the machine

Fig. 3-59

Lowering the attachment when engine is not running

Turn the ignition key to contact position 1.

Operate the joystick or the foot pedals until the attachment is lowered.

Note This reserve is limited and is only sufficient for small movements of the pilot control devices.

Move the joystick only in the direction for lowering the attachment.

3.4.9

Turning, rotating, locking and unlocking the attachments Switch S19 is used to activate an additional function:

Fig. 3-60

Attachment examples

To operate, press the push button. The push buttons are located on the left and /or right joystick (depending on the machine configuration):

Fig. 3-61

Push button on the joystick

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Control, operation

Operating instructions

Working with the machine

E

Operation with left joystick (standard)

F

Operation with left and right joystick (option)

Danger!

Never allow anyone to guide the grapple by hand!

Press switch S19 down.

Additional function (e.g. rotating grapple) is activated.

The indicator light in the switch lights up.

Press and hold left push button L. Grapple will rotate to the left (counterclockwise).

- or The rotating bucket is turned to the left (counterclockwise), i. e. it moves down to the left.

- or Locking pins will be extended.

Press and hold right push button R. Grapple will rotate to the right (clockwise).

- or The rotating bucket is turned to the right (clockwise), i. e. it moves down to the right.

- or Locking pins will be retracted.

3.4.10

Accessory kits AHS 1, AHS 11 and AHS 12 (option) With accessory kits AHS 1, AHS 11 and AHS 12, additional users can be operated with different pressure and flow settings.

Caution!

Incorrect preselection of the pressure and flow setting can result in damage to the working tool (e.g. hydraulic hammer) or in limited function (e.g. adjustable boom cylinder).

Danger!

If a large or wide working tool (such as the grapple) is fluctuating in the vicinity of the cab, the cab could be touched or penetrated, which would endanger the operator.

Note!

If the machine is generally being used for hammer operation, there is a risk that the hydraulic oil becomes contaminated quicker than usual.

Adjust the maintenance intervals for hydraulic oil and filter cartridge changes for heavy dust application.

3.4.10.1

Accessory kit AHS 1 Accessory kit AHS 1 can be used to operate the adjustable boom cylinders for a hydraulically adjustable boom or for a side adjustable gooseneck boom.

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Operating instructions

Control, operation Working with the machine

Fig. 3-62

Accessory kit AHS 1

To operate the adjustable boom cylinder: Push the foot pedal k down.

The adjustable boom cylinder will be extended, i.e. the attachment moves up.

Push down foot pedal m.

The adjustable boom cylinder will be retracted, i.e. the attachment moves down.

3.4.10.2

Accessory kit AHS 11 With accessory kit AHS 11, only one additional user can be operated, i. e. one working tool (such as the hydraulic hammer) can be operated with the gooseneck boom.

Fig. 3-63

Accessory kit AHS 11

A suitable operating mode can be selected using switch S241. The switch has three positions: Press switch to position 0.

The auxiliary user with high pressure is activated (e.g. sorting grapple, scrap cutter).

Both foot pedals m and k full oil flow, right pedal k is pressure reduced.

Move switch to position 1 (center position).

The auxiliary user with high pressure is activated (e.g. sorting grapple, scrap cutter).

The indicator light H196 lights up.

Both foot pedals m and k full oil flow and full pressure.

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Control, operation

Operating instructions

Working with the machine

Move switch to position 2 (final position).

The auxiliary user with reduced pressure (e.g. hydraulic hammer, ram) is activated.

The indicator light H196 turns off.

The indicator light in the switch lights up.

The right foot pedal k is pressure and flow reduced, the left foot pedal m full oil flow and pressure.

Operate the attachment using pedals m and k.

Push foot pedal k down: Scrap cutter or sorting grapple will be closed.

- or The hydraulic hammer is activated.

Push foot pedal m down: Scrap cutter or sorting grapple will be opened.

3.4.10.3

Accessory kit AHS 12 With accessory kit AHS 12, two additional users can be operated, i. e. the adjustable boom cylinder and one working tool (such as the hydraulic hammer) can be operated.

Fig. 3-64

Multi-function kit AHS 12

A suitable operating mode can be selected using switch S241. The switch has three positions: Press switch to position 0.

The adjustable boom cylinder is activated.

The attachment can be lowered or raised via the foot pedals m and k.

Move switch to position 1 (center position).

The auxiliary user with high pressure is activated (e.g. sorting grapple, scrap cutter).

The indicator light H196 lights up.

Both foot pedals m and k full oil flow and full pressure.

Move switch to position 2 (final position).

The auxiliary user with reduced pressure (e.g. hydraulic hammer, ram) is activated.

The indicator light H196 turns off.

The indicator light in the switch lights up.

The right foot pedal k is pressure and flow reduced, the left foot pedal m full oil flow and pressure.

Operate the attachment using pedals m and k.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Working with the machine

Push foot pedal k down: The adjustable boom cylinder will be extended, i.e. the attachment moves up.

- or Scrap cutter or sorting grapple will be closed.

- or The hydraulic hammer is activated.

Push foot pedal m down: The adjustable boom cylinder will be extended, i.e. the attachment moves up.

- or Scrap cutter or sorting grapple will be opened.

3.4.11 3.4.11.1

Adjusting the boom to side Height and side adjustable gooseneck boom The height and side adjustable gooseneck boom is operated with the two foot pedals of the AHS accessory kit.

Fig. 3-65

Height and side adjustable gooseneck boom

Accessory kit AHS 1 available: Push the foot pedal k down.

The boom is turned to the right.

Push down foot pedal m.

The boom is turned to the left.

Accessory kit AHS 12 available: Move switch S241 to position 0.

The indicator light H196 does not light up.

Push the foot pedal k down.

The boom is turned to the right.

Push down foot pedal m.

The boom is turned to the left.

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Control, operation

Operating instructions

Working with the machine

3.4.11.2

Height and side adjustable boom

Fig. 3-66

Warning sign

Since additional dangers can occur due to the side adjustable boom, the operating and maintenance personnel must be informed about this.

For that reason, the displayed warning sign (see Fig. 3-66) must also be installed in Make sure that this warning sign is always installed and legible.

Meaning of sign: Danger!

The attachment reaches as far as the cab!

There is a danger of collision between the cab and the boom, if is fully extended and For that reason, set the boom straight or to the right until you move the basic boom in the upper position.

The height and side adjustable boom is operated with the two foot pedals of the AHS accessory kit.

Accessory kit AHS 12 available This variation is only possible if no attachments, such as a hydraulic hammer or scrap cutter, is attached.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Working with the machine

Fig. 3-67

Height and side adjustable boom

To adjust the height of the boom: Move switch S241 to position 0.

The indicator light H196 does not light up.

Push the foot pedal k down.

The adjustable boom cylinder will be extended, i.e. the attachment moves up.

Push down foot pedal m.

The adjustable boom cylinder will be retracted, i.e. the attachment moves down.

To adjust boom to side: Press switch S241 in position 1 (center position).

The indicator light H196 lights up.

Push the foot pedal k down.

The boom is turned to the right.

Push down foot pedal m.

The boom is turned to the left.

Accessory kit AHS 12 and changeover spool available This variation is required if an attachment such as a hydraulic hammer or a scrap cutter is to be operated in addition to the adjustable boom.

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Control, operation

Operating instructions

Working with the machine

Fig. 3-68

Height and side adjustable boom, change over

To adjust the height of the boom: Press switch S241 in position 0.

The indicator light H196 does not light up.

Push the foot pedal k down.

The adjustable boom cylinder will be extended, i.e. the attachment moves up.

Push down foot pedal m.

The adjustable boom cylinder will be retracted, i.e. the attachment moves down.

To adjust boom to side: Press switch S241 to position 0.

The indicator light H196 does not light up.

Press switch S356.

Side adjustment is activated.

The indicator light in the switch lights up.

Push the foot pedal k down.

The boom is turned to the right.

Push down foot pedal m.

The boom is turned to the left.

3.4.12 3.4.12.1

Overload warning device General The overload warning device shows the machine operator when the permissible load carrying capacity has been reached, both optically via the indicator light H16 and acoustically, via a buzzer.

The overload warning device is designed to prevent the permissible load level from being exceeded unintentionally. In this event, the working range must be reduced or the load must be set down without increasing the working range.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Working with the machine

The overload warning device does not relieve the operator of the responsibility of lifting only known loads or permissible loads, based on the load carrying capacity of the machine.

The permissible load carrying capacity depends on the condition of the machine (undercarriage, attachment) and must be taken from the load chart in the cab.

The load carrying capacity values attain a maximum of 75% of the tipping capacity or 87 % of the hydraulic lifting power in accordance with ISO 10567.

Note!

The load values change due to the installation or removal of attachment parts and working tools.

For backhoe attachment (without the backhoe, incl. bucket cylinder, change over lever and connecting link) the values on the top of the stick apply. The machine can be turned by 360° on solid, level ground. If the bucket cylinder, change over lever and connecting link are removed, the values increase by an additional 240 kg. If a quick change adapter is used, the values are reduced by 116 kg (QCA 33) or 225 kg (QCA 48).

3.4.12.2

Operating principle Danger!

When carrying out load lifting work with the machine, the applicable accident prevention regulations must be observed.

The overload warning device does not shut down the machine if the permissible load level is exceeded. The machine operator is only informed of the situation.

The overload warning device consists of a simple pressure switch, which is connected to the piston side of the hoist cylinder.

If the load pressure in the hoist cylinder reaches the level of the shift pressure, the pressure switch emits a signal, the indicator light H16 lights up and the buzzer sounds.

The shift pressure in the pressure switch is selected in such a way that the stability factors can be maintained, even in unsupported condition (small stability momentum).

3.4.12.3

Operation Danger!

No load lifting work may be carried out if the overload warning device is defective.

The overload warning device must be repaired by an expert technician.

The overload warning device is activated via switch S18 in the control panel A in the right control console.

Press switch S18 down.

The overload warning device is activated.

The indicator light in the switch lights up.

Note!

The overload warning device must be checked before the first use and annually by an expert technician in accordance with the inspection and adjustment guidelines provided in the service manual.

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Control, operation

Operating instructions

Installation and removal of attachment parts

The operator must check the function of the overload warning device before each work shift.

To check the overload warning device, extend the hoist cylinder to the stop.

Continue to move the joystick in the direction Raise boom.

The warning symbol must light up.

The buzzer must sound.

Note!

Deactivate the overload warning device when working with a digging tool, since the increased effort of the machine will cause the overload warning device to be constantly active.

Press switch S18 up.

The overload warning device is deactivated.

The indicator light in the switch turns off.

3.5 Installation and removal of attachment parts 3.5.1

Safe installation and removal of attachment parts

machine without prior written approval by LIEBHERR. LIEBHERR must be provided with the required technical documentation necessary for this purpose. parts, which are supplied via the machine's hydraulics system, such as an attachment with cylinder movement, it must be ensured that different types of oil are not mixed together.

Mixing environmentally friendly hydraulic oils made by different manufacturers as well as mixing them with mineral oils must be avoided. of equipment parts.

to being supported. propping the machine. system as described in these operating instructions. itable lifting devices with sufficient load carrying capacity. gloves when handling wire cables. lever upward. Never align the holes with your fingers; use a suitable mandrel. lic lines are properly attached and that all fittings and connections are properly tightened. in the hydraulic circuit to prevent dirt infiltration. Permit only authorized persons near the machine or the lifting device.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Installation and removal of attachment parts

3.5.2

Safe removal and installation of attachment pins lling device to push out the pins on the attachment. held by another person. from the tool box in the threaded bore of the pin and hit the screw only. castle nut and cotter pin, drive the pin in first to the stop, then install the castle nut by hand until contact and tighten it only to the point where the cotter pin can be installed.

3.5.3

Installation and removal of digging tool

Fig. 3-69

Installation and removal of digging tools

The following is a description of the installation and removal of digging tools. Digging tools include backhoe bucket, ditch cleaning buckets or ripper.

3.5.3.1

Removing the digging tool Position the attachment in such a way that the entire bottom part of the digging tool is laying on the ground.

Unscrew the locking plate 5 and remove the locking plate 6 and knock out pin 3 and pin 4.

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Control, operation

Operating instructions

Installation and removal of attachment parts

If necessary, raise the attachment slightly when knocking out pin 4 to relieve it.

3.5.3.2

Installing a new digging tool Position the digging tool to be installed in such a way that its entire flat bottom is laying on the ground.

Start the engine and move the attachment until the bucket stick bearing and the bearing points 1 of the digging tool are aligned.

Guide in pin 4 and secure it with plate 6.

Extend the bucket cylinder slowly until the bore hole in the connecting link 7 is located precisely between the bearing points 2.

Guide in pin 3 and secure it with plate 5.

Grease all lube points on pins 3 and 4 until clean grease emerges on the corresponding bearing points.

3.5.3.3

Bucket cylinder operation Two hydraulic lines on the stick are used either for bucket cylinder operation or grapple operation.

The lines are switchable via a valve block 15: a - Bucket cylinder operation (for digging tools) b - Grapple operation (for grapple, scrap cutter etc.)

Turn the both square head bolts on valve block 15 in such a way that the markings are positioned transverse to the travel direction (position a, bucket cylinder operation).

Note!

If the machine is equipped with a hydraulic quick change adapter and LIKUFIX, it is not necessary to switch between bucket cylinder operation and grapple operation. There is no valve block 15.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Installation and removal of attachment parts

3.5.4

Attachment of grapple to bucket stick

Fig. 3-70

Attaching grapple to bucket stick

Danger!

Risk of injury Ensure that the machine operator follows the instructions of the instructor when moving the equipment.

Two workers are required to attach or remove the grapple.

3.5.4.1

Attaching grapple Before attaching a clamshell grab or multiple grab, ensure that the necessary hydraulic lines for grapple operation are mounted to the bucket stick.

The grapple must be in a stable position (grabs fully opened).

If necessary, dismantle the digging bucket.

Move the attachment in order to position the bucket stick between the bearing points of the grapple suspension 1.

Insert the bolts 2 and secure them with the plate 3.

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Control, operation

Operating instructions

Installation and removal of attachment parts

Caution!

The hydraulic lines are under pressure.

Before connecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick and press the buttons of the "Rotate grapple" function).

Move the safety lever up.

Connect the hydraulic hoses 4 and 5 (for the supply of the grab cylinders) to the pipelines.

For grapples with hydraulic rotator, also connect the hydraulic hoses 6 and 7 to the pipelines for this auxiliary equipment.

3.5.4.2

Attachment of connecting link

Fig. 3-71

Securing of connecting link

After the grapple has been removed, secure the connecting link 1. There are various ways to do this (depending on the machine equipment).

Fully retract the bucket tilt cylinder 6.

Attach the holder 5 to the change lever 2.

Insert the securing device 3 in the connecting link 1 and mount it to the holder 5.

Insert securing plugs 4 on both sides.

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A 312 Litronic / 10443914

Operating instructions

Control, operation Installation and removal of attachment parts

3.5.4.3

Changeover to grapple operation

Fig. 3-72

Valve block for tilt cylinder operation / grapple operation

Two hydraulic lines on the bucket stick are used for the operation of the tilt cylinder or the grapple.

The lines are switchable by means of a valve block: a - Tilt cylinder operation (for digging buckets) b - Grapple operation (for grapples, scrap shears, etc.)

Note If the machine is equipped with a quick-change adapter and LIKUFIX, there is no need for this changeover. The valve block is therefore omitted.

Turn the two square head screws on the valve block until the marks are aligned in the direction of travel (position b, grapple operation).

Complete all working movements several times without load (opening and closing grapple, moving grapple to the right and left) in order to let any trapped air escape from the hydraulic circuits.

3.5.4.4

Removing grapple If necessary, remove the securing device 3 from the connecting link.

Fully open the grabs and place the grapple in a vertical position on level ground.

Caution!

The hydraulic lines are under pressure.

Before disconnecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick and press the buttons of the "Rotate grapple" function).

Move the safety lever up.

Disconnect the hydraulic hoses from the pipelines on the bucket stick.

Immediately seal open lines to prevent dirt from entering the system.

Prop up the grapple to ensure that it cannot topple over.

Unscrew the plate 3 and carefully drive out the bolt 2. To do this, you might have to start the diesel engine and lift the attachment slightly from the ground.

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Control, operation

Operating instructions

Installation and removal of attachment parts

3.5.5 3.5.5.1

Mechanical quick change adapter (option) Safety instructions and removal of working tools. Move the attachment as slowly as possible when installing or removing a working tool.

Familiarize yourself with the operating principle of the quick change adapter before installing or removing any working tools. the ground as possible when locking and unlocking to avoid dangerous movements. stand on the working tool or attachment. e machine operator must ensure that the locking pins for the quick change adapter are inserted in the proper bore holes on the working tool and that the working tool is attached properly. Check visually to ensure that the working tool is tightly seated. e tool, but only lift the tool to the point where the seating can be checked, for example the pin in the pin eye, by curling the bucket in and out. to ensure it is still seated tightly. ck change adapter or the integrated load hook can exceed or fall below the load carrying capacity of the carrier machine.

During operation, make sure that the values given in the load chart and the technical data of the carrier machine are adhered to.

3.5.5.2

Overview

Fig. 3-73

Mechanical quick change adapter

1

Locking pin (extended)

3

Crank

5

Load hook

2

Locking screw

4

Plug

6

Pick-up hook for working tool

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Installation and removal of attachment parts

3.5.5.3

Attaching the working tool Bring the equipment into position:

Fig. 3-74

Positioning the attachment

The working tool must be in stable position or lying loosely on the ground.

Move the stick and working tool into position.

Retract the bucket cylinder fully.

To unlock the quick change adapter: Danger!

Danger of injury!

Ensure that the attachment or tool cannot be moved by others when this action is being carried out.

Approach the quick change adapter from the side and unscrew the locking screw 2 from the locking pin 1 using the crank 3 (see Fig. 3-73).

Insert the crank 3 in the locking pin 1 and turn to the left (counterclockwise) until both locking pins 1 are retracted completely.

Picking up the working tool:

Fig. 3-75

Picking up the working tool

Move the quick change adapter into a position that allows the working tool to be picked up with the pick-up hook.

Lift the working tool off the ground and fully extend the bucket cylinder until the bearing plate for the working tool is resting on the quick change adapter stop.

The bore holes of the working tool and the locking pins of the quick change adapter must be aligned.

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Control, operation

Operating instructions

Installation and removal of attachment parts

To lock the quick change adapter:

Fig. 3-76

Locking the quick change adapter

Danger!

Prior to locking, there is no fixed connection between the working tool and the quick change adapter. The working tool could under certain circumstances fall out and injure people.

Approach the quick change adapter with the utmost caution.

Raise the safety lever to secure the attachment against unintentional movement.

No work movements can be carried out when pilot control devices, e.g. the joystick or foot pedals, are operated.

Insert the crank 3 in the locking pin 1 and turn to the right (clockwise), until both locking pins 1 are fully extended.

If properly picked up, the working tool is now connected.

Screw the locking screw 2 into the locking pin.

Danger!

An incorrectly locked quick change adapter could open during operation!

Ensure that the locking pins are always closed off by the plug 4 on the one side and by the locking screw 2 on the other side.

Check daily to ensure that the locking screw 2 is seated tightly.

Caution!

Hydraulic lines are pressurized!

Before connecting the hydraulic lines, release the pressure using the joystick (shut down the Diesel engine, turn the ignition key to the contact position, operate the joystick).

Connect the hydraulic lines or electrical lines, if necessary (e.g. for grapple installation).

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Operating instructions

Control, operation Installation and removal of attachment parts

3.5.5.4

Removing a working tool Bring the equipment into position: Caution!

Hydraulic lines are pressurized!

Before disconnecting the hydraulic lines, release the pressure using the joystick (shut down the Diesel engine, turn the ignition key to the contact position, operate the joystick).

Disconnect hydraulic lines or electrical lines, if necessary (e.g. for removal of grapple).

Extend the bucket cylinder fully.

To unlock the quick change adapter:

Fig. 3-77

Unlocking the quick change adapter

Danger!

Danger of injury!

Once unlocked, there is no fixed connection between the adapter and the working tool. The working tool could work itself out independently.

Ensure that the attachment or tool cannot be moved by others when this action is being carried out.

During the unlocking procedure, always keep the working tool as close to the ground as possible to avoid dangerous movements.

Approach the quick change adapter from the side and unscrew the locking screw 2 from the locking pin 1 using the crank 3.

Insert the crank 3 in the locking pin 1 and turn to the left (counterclockwise) until both locking pins 1 are retracted completely.

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Control, operation

Operating instructions

Installation and removal of attachment parts

To place down the working tool:

Fig. 3-78

Placing the work tool down

Slowly retract the bucket cylinder and place the working tool down on the ground.

The new working tool can be picked up.

3.5.5.5

Using the quick change adapter for load lifting work

Fig. 3-79

Mechanical quick change adapter

The quick change adapter is equipped with two integrated load hooks. The machine may only be used for load lifting work if the safety devices required for this purpose are present and functioning correctly (see The maximum load carrying capacity of each individual load hook is stated on the quick change adapter. The load carrying capacity of the quick change adapter or the integrated load hook can exceed or fall below the load carrying capacity of the carrier machine.

During operation, make sure that the values given in the load chart and the technical data of the carrier machine are adhered to.

Load lifting work can be carried out with attached or removed working tools. With removed working tools, it is appropriate to fully retract the locking pins when carrying out lifting work. This prevents the load lift device from being deflected too strongly and damaged by the locking pins.

Danger!

Never use the pick-up hook 6 to fasten a load, because there is no secure hold for the load pick-up device, e.g. ropes or chains, in the pick-up hook.

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A 312 Litronic / 10443914

Operating instructions

Control, operation Installation and removal of attachment parts

3.5.6 3.5.6.1

Hydraulic quick change adapter (option) Safety instructions and removal of the working tools. Move the work equipment as slowly as possible when attaching and dismounting a working tool.

Familiarize yourself with the control and operating principle of the quick change adapter before installing or removing any working tools. adapter is monitored by a visual and acoustic warning device (buzzer and indicator light). The function of the warning device should be checked daily by operating the quick change adapter. vated without initiation of a deliberate locking or unlocking procedure, stop all work at once. If the buzzer and indicator light are not activated while a deliberate locking or unlocking procedure is being carried out, stop all work at once.

This could be caused by an uncontrolled position change of the locking pins, due to mechanical or hydraulic damage. A defect may also be present in the electrical system (e.g. proximity switch or buzzer).

Resume operation only after any defective parts have been repaired or replaced. as the switch / button designed for this purpose is pressed.

Always keep the working tool as close to the ground as possible during the unlocking procedure to avoid dangerous movements. Activate the quick change adapter only to carry out a deliberate locking or unlocking procedure. machine operator must ensure that the locking pins for the quick change adapter are inserted in the proper bore holes on the working tool and that the working tool is attached properly. Check visually to ensure that the working tool is tightly seated. e tool, but only lift the tool to the point where the seating can be checked, for example the pin in the pin eye, by curling the bucket in and out. hook can exceed or fall below the load carrying capacity of the carrier machine.

During operation, make sure that the values given in the load chart and the technical data of the carrier machine are adhered to.

3.5.6.2

Overview

Fig. 3-80 1

Hydraulic quick change adapter

Locking pin (extended)

5

Load hook

6

Pick-up hook for working tool

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Control, operation

Operating instructions

Installation and removal of attachment parts

3.5.6.3

Operating elements

Fig. 3-81

Operating elements for the hydraulic quick change adapter

Use switch S19 to activate the auxiliary hydraulic device for the grapple rotator and quick change adapter.

Press switch down.

The auxiliary hydraulic device is activated.

The indicator light in the switch lights up.

Press switch up The auxiliary hydraulic device is deactivated.

The indicator light in the switch turns off.

Press button S47 to activate the quick change adapter function.

Press the button down and hold.

The quick change adapter is activated.

The indicator light in the button lights up.

Press push buttons L and R to lock and unlock the work tool.

The indicator light H26 lights up during the unlocking procedure or when the locking pins are retracted. The buzzer in the cab sounds simultaneously.

3.5.6.4

Two-hand operation The quick change adapter is activated via a two-hand control. The locking pins can only be moved at first if button S47 is pressed and held down and one of the push buttons L or R are pressed simultaneously.

The control is equipped with a retaining function, allows both joysticks to be operated simultaneously for the installation or removal of working tools. If one of the push buttons, L or R is continually pressed, then button S47 can be released and the direction of movement of the locking pins is retained.

If the direction of movement is to be changed, the key switch S47 must be pressed down again and the corresponding push button L or R must be pressed.

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Operating instructions

Control, operation Installation and removal of attachment parts

3.5.6.5

Attaching the working tool Bring the equipment into position:

Fig. 3-82

Bringing the equipment into position

The working tool must be in stable position or lying loosely on the ground.

Bring the stick and working tool into position.

Retract the bucket cylinder fully.

To unlock the quick change adapter: Press switch S19 down.

The auxiliary hydraulic device is activated.

The indicator light in the switch lights up.

Press and hold button S47 down.

The hydraulic quick change adapter is activated.

The indicator light in the switch lights up.

On the left joystick 4, press and hold the right push button R down until the locking pins are fully retracted.

The buzzer sounds.

The indicator light H26 lights up.

The quick change adapter is unlocked.

To pick up the working tool:

Fig. 3-83

Picking up the working tool

Move the quick change adapter into a position that allows the working tool to be picked up with the pick-up hook.

Lift the working tool off the ground and fully extend the bucket cylinder until the bearing plate for the working tool is resting on the quick change adapter stop.

The bore holes of the working tool and the locking pins of the quick change adapter must align.

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Control, operation

Operating instructions

Installation and removal of attachment parts

To lock the quick change adapter: Press switch S19 down.

The auxiliary hydraulic device is activated.

The indicator light in the switch lights up.

Press and hold button S47 down.

The quick change adapter is activated.

The indicator light in the switch lights up.

On the left joystick 4, press and hold the left push button L down until the locking pins are fully extended.

The buzzer turns off.

The indicator light H26 turns off.

The quick change adapter is locked.

If properly picked up, the working tool is now connected.

Release button S47.

The hydraulic quick change adapter is deactivated.

The indicator light in the switch turns off.

Press switch S19 up.

The auxiliary hydraulic device is deactivated.

The indicator light in the switch turns off.

Caution Hydraulic lines are pressurized!

Before connecting the hydraulic lines, release the pressure using the joystick (shut down the Diesel engine, turn the ignition key to the contact position, operate the joystick).

Connect hydraulic lines or electrical lines, if necessary. (e.g. for grapple installation).

A direct visual check must be made to ensure that the working tool is seated tightly.

This means that the working tool should be raised before use to the point where tight seating of, for . example, the pin in the pin eye, can be checked by curling in and out.

Danger!

The electronic monitoring system for the quick change adapter displays defective functions. This could be caused by an uncontrolled position change of the locking pins, due to mechanical or hydraulic damage. A defect may also be present in the electrical system (e.g. proximity switch or buzzer).

If the buzzer and indicator light are activated without initiation of a deliberate locking or unlocking procedure, stop all work at once.

If the buzzer and indicator light are not activated while a deliberate locking or unlocking procedure is being carried out, stop all work at once.

Only resume working only after any defective parts have been repaired or replaced.

Perform the working cycle.

Before starting to use the working tool (e.g. grapple, ditch cleaning bucket), the special installation guide

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A 312 Litronic / 10443914

Operating instructions

Control, operation Installation and removal of attachment parts

3.5.6.6

Removing a working tool Bring the equipment into position: Caution Hydraulic lines are pressurized!

Before disconnecting the hydraulic lines, release the pressure using the joystick (shut down the Diesel engine, turn the ignition key to the contact position, operate the joystick).

Disconnect hydraulic lines or electrical lines, if necessary (e.g. for removal of grapple).

Extend the bucket cylinder fully.

To unlock the quick change adapter: Danger!

Danger of injury!

Once unlocked, there is no fixed connection between the adapter and the working tool. The working tool could work itself out independently.

During the unlocking procedure, always keep the working tool as close to the ground as possible to avoid dangerous movements.

Press switch S19 down.

The auxiliary hydraulic device is activated.

The indicator light in the switch lights up.

Press and hold button S47 down.

The quick change adapter is activated.

The indicator light in the switch lights up.

On the left joystick 4, press and hold the right push button R down until the locking pins are fully retracted.

The buzzer sounds.

The indicator light H26 lights up.

The quick change adapter is unlocked.

To place down the working tool:

Fig. 3-84

Placing the work tool down

Slowly retract the bucket cylinder and place the working tool down on the ground.

The new working tool can be picked up.

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Control, operation

Operating instructions

Installation and removal of attachment parts

3.5.6.7

Using the quick change adapter for load lifting work

Fig. 3-85

Hydraulic quick change adapter

The quick change adapter is equipped with two integrated load hooks. The machine may only be used for load lifting work if the safety devices required for this purpose are present and functioning correctly (see The maximum load carrying capacity of each individual load hook is stated on the quick change adapter. The load carrying capacity of the quick change adapter or the integrated load hook can exceed or fall below the load carrying capacity of the carrier machine.

During operation, make sure that the values given in the load chart and the technical data of the carrier machine are adhered to.

Load lifting work can be carried out with attached or removed working tools. With removed working tools, it is appropriate to fully retract the locking pins when carrying out lifting work. This prevents the load lift device from being deflected too strongly and damaged by the locking pins.

Danger!

Never use the pick-up hook 6 to fasten a load, because there is no secure hold for the load pick-up device, e.g. ropes or chains, in the pick-up hook.

Before load-lifting work, deactivate the quick change adapter.

Switches S19 and S47 are pushed up.

The indicator lights in the switches are turned off.

3.5.6.8

Quitting the buzzer (warning tone) The indicator light H26 and the buzzer (warning tone) indicate that the quick change adapter is not locked or is incorrectly locked.

After placing down the work tool, the buzzer (warning tone) continues to sound as long as the locking pins remain retracted.

When the overload warning device is switched on, the warning tone for the quick change adapter can be quitted.

If no new working tool is to be taken up, it is sensible to switch off the warning tone so avoid constant noise disturbance. Also, another buzzer (overload warning device) can be heard more easily.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation Installation and removal of attachment parts

Press switch S360.

The buzzer is turned off.

The indicator light H26 lights up.

The acoustic warning device will only activate automatically if the locking pins have been extended again.

To reactivate the warning tone for the quick change adapter, fully extend the locking pins until the indicator light H26 turns off.

The buzzer (warning tone) for monitoring the quick change adapter is reactivated.

3.5.7

LIKUFIX Hydraulic coupling system (option) LIKUFIX enables automatic coupling of hydraulic lines in connection with the hydraulic quick change adapter. The machine operator does not need to connect or disconnect hydraulic lines for working tools himself.

3.5.7.1

Overview

Fig. 3-86

3.5.7.2

LIKUFIX

1

Protective cover on quick change adapter

4

LIKUFIX hydraulic coupling on working tool

2

Protective cover on working tool

5

Alternative hydraulic connection on working tool

3

LIKUFIX hydraulic coupling on quick change adapter

Installation and removal of working tools Installation and removal is carried out as described in the chapter "Hydraulic quick change adapter".

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Control, operation

Operating instructions

Installation and removal of attachment parts

Fig. 3-87

Connecting LIKUFIX

In addition, note the following: Before installation, remove the protective covers on the quick change adapter 1 and the working tool 2.

Always keep hydraulic couplings 3 and 4 clean.

Perform a visual check for cleanliness before installation. If necessary, clean all coupling parts and the sealing surfaces with a clean, oil-soaked cloth.

When changing a work tool, connect or disconnect the hydraulic coupling slowly.

When attaching the quick change adapter, tilt it until the coupling plates are connected due to the curb weight of the working tool.

Extend the locking pins.

If the plates do not connect as a result of curb weight, foreign objects (such as stones) may be the cause. In this case, clean all coupling parts to prevent damage when connecting.

The oil flow and pressure must be matched to the corresponding work tool.

When the work is completed, and particularly before transport, reattach the protective covers 1 and 2.

3.5.7.3

Installing LIKUFIX work tools to a quick change adapter without LIKUFIX It is possible at any time to attach a working tool with a LIKUFIX hydraulic coupling to a machine with a quick change adapter (mechanical or hydraulic).

Fig. 3-88

LIKUFIX work tool on quick change adapter without LIKUFIX

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Operating instructions

Control, operation General working methods

Caution!

The LIKUFIX hydraulic coupling could be damaged.

Do not use a quick change adapter with a reinforcement kit, since the reinforced steel part 6 could damage the LIKUFIX hydraulic coupling on the work tool.

In this case, the quick-change adapter must be modified by LIEBHERR Service.

For installation without LIKUFIX hydraulic coupling, LIEBHERR work tools usually have an alternative connection option.

Example: On the ditch cleaning bucket, the hydraulic lines are either connected using LIKUFIX 4 or using an auxiliary hydraulic connection 5.

3.6 General working methods 3.6.1

Tips for the proper operation of the machine preventing damage and wear In order to prolong the service life of the machine and to prevent avoidable damage, observe the following instructions: not halt the swivelling upper carriage by moving it or the attachment to the ditch walls. attachment is used to hammer against a hard material to remove it. Repeated impact of the working attachment against rock or other hard materials results in damage to the steel structure and the machine components. tool are combined, there is a risk that the tool collides with the operator's cab. This can result in damage to the operator's cab, and the operator might suffer injury. equipment would result in prolonged working cycles, and there is also a risk of damage to the bucket and other machine components. load or special applications. illing into hard material is not permitted. with the attachment. If this happens by accident, slowly lower the machine back onto the ground. Do not lower the machine quickly onto the ground, and do not attempt to dampen this movement with the hydraulics, as this can damage the machine.

3.6.2

Preparation Danger!

Risk to life and limb! Risk of damage to machine during operation.

Adhere to the safety instructions in chapter "Instructions for safe work" included in this operating manual.

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Control, operation

Operating instructions

General working methods

Fig. 3-89

Working position of the machine

Position the machine in such a way that the load or the excavated material can be borne by the rigid axle or the idler.

When using a mobile machine, lower the support, if possible, and lock the oscillating axle.

Danger!

Insufficient support and damage to the machine.

Do not use the dozer blade to support the machine.

Fig. 3-90

Safe work

Danger!

Risk to life and limb when the machine is swivelled.

Ensure that no persons are standing inside the danger area r of the machine.

Caution!

Risk of injury during work.

Always wear safety footwear. When leaving the cab during demolition work, wear a hard hat and protective goggles.

Always wear the safety belt.

Before starting work, operate the horn to warn other workers.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Control, operation General working methods

3.6.3

Working with the backhoe bucket Danger!

Risk to life and limb! Risk of damage to machine during movement of the backhoe bucket. The backhoe bucket can collide with and damage the operator's cab and injure the operator.

Prevent the backhoe bucket from swinging near the operator's cab.

Ensure that no persons are standing in the danger area of the backhoe bucket.

Note!

If the parking brake is applied, the forces occurring during excavation work could damage the travel gearbox.

When working with the backhoe bucket, do not apply the packing brake S16.

Use only the working brake (foot pedal).

Put the machine into its working position.

Fig. 3-91

Aligning machine, taking up excavated material, lifting

Aligning bucket stick and backhoe bucket (1): Align the bucket stick in such a way that its bottom side is at an angle of approx.

45° to the ground.

Align the backhoe bucket in such a way that its bottom side enters the ground at an angle of approx. 90°.

Lifting the excavated material (2): To lift the excavated material, slowly swivel in the bucket stick at a uniform pace, while slowly swivelling in the backhoe bucket.

As soon as the bucket stick is at a right angle to the ground continue swivelling in the bucket stick and the backhoe bucket while slowly lifting the boom. Abrupt stops can cause vibration and unnecessary impact stress.

Lifting excavated material (3): If the backhoe bucket is filled, or if the bucket stick cannot be swivelled in any further, lift the boom, swivel in the backhoe bucket until the filled surface is aligned parallel to the ground.

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Control, operation

Operating instructions

General working methods

3.6.4

Loading transport vehicle Danger!

Risk to life and limb from falling excavated material.

Do not overload the transport vehicle and ensure that the load cannot fall from the platform.

While loading the vehicle, ensure that no persons are in the danger area of the excavator or in the transport vehicle.

Never swivel the equipment over the driver's cab.

Fig. 3-92

Releasing excavated material

If possible, position the machine at a higher point than the transport vehicle, in order to avoid unnecessary lifting of the excavated material.

Position the transport vehicle in such a way that it is accessible from the rear or the side.

Swivel the attachment across the loading platform of the transport vehicle.

Distributed the excavated material evenly across the loading platform of the vehicle. To do this, swivel out the backhoe bucket and the bucket stick while swivelling the uppercarriage. If necessary, also move the boom.

To remove excavated material from the backhoe bucket: Repeatedly swivel the backhoe bucket fully in and out so that it is completely emptied.

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A 312 Litronic / 10443914

Operating instructions

Control, operation General working methods

3.6.5

Grading work

Fig. 3-93

Grading work

Grading work can be completed with the digging bucket or a dozer blade (optional equipment).

Put the machine into its working position.

Ensure that the supports are lifted.

Danger!

There is a serious risk of injury when the machine is moved.

Ensure that no persons are standing in the working area of the machine.

Caution!

Risk of damage to the machine.

Do not move the machine while the attachment is in contact with the ground.

To carry out grading work with the backhoe bucket, place the flat side of the bucket on the ground and slowly move the stick forward and back. During the stick movement, move the boom up and down at a slow even rate.

If the machine is equipped with a dozer blade (optional equipment), lower the blade to the ground and slowly move the machine forward and back.

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Control, operation

Operating instructions

General working methods

3.6.6

Working with grapples Danger!

Risk to life and limb or damage to the machine by swinging grapple: the operator's cab and injure the operator. ffect the stability of the machine.

Prevent the grapple from swinging near the operator's cab.

Ensure that the stick is in a position where the grapple cannot collide with the machine when the excavator travels or when the brakes are applied.

Move the joystick slowly and smoothly to prevent swinging of the grapple.

Ensure that the moving grapple cannot collide with persons.

Do not lift heavy loads with a fully extended boom and stick. Do not move loads to the far right or left.

Observe the load lift chart showing the permissible lift loads that can be attached to the end of the stick, depending on its actual extension.

3.6.7

Excavating and moving material with grapples Put the machine into its working position.

Fig. 3-94

Clamshell bucket: align stick, close jaws, lift excavated material

Align stick (1): Open the claws fully.

Lower the stick vertically to excavated area.

Closing jaws (2): Danger!

When being closed, the clamshell bucket might lift the machine. As a result, the machine might inadvertently roll away.

Avoid situations where the machine could become unstable by lifting the equipment sufficiently before closing the grapple.

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A 312 Litronic / 10443914

Operating instructions

Control, operation General working methods

Close the jaws.

Lift the stick only slightly in order to relieve the pressure on the ground.

To lift excavated material (3): Close the jaws.

Lift the boom.

Move the machine to the unloading area (e.g. transport vehicle).

Fig. 3-95

Releasing excavated material

Swivel the stick as far possible in order to prevent any risk from the slewing bucket.

Open the jaws and release the excavated material.

3.6.8

Working with the hydraulic hammer Danger!

Incorrect use of the hydraulic hammer can cause serious injury to persons or damage to the equipment.

The use of unapproved hydraulic hammers might also result in damage to steel construction parts and other machine components.

Use only hydraulic hammers that have been approved by LIEBHERR and always adhere to all instructions of the manufacturer.

Before starting working with the hammer, close all windows of the operator's cab.

Hydraulic hammers may only be used for the breaking of stones, concrete and other similar breakable material.

Do not attempt to break up stone or concrete by means of lever movements of the attachment or the hydraulic hammer.

Do not let the hydraulic hammer drop to break materials by means of impact.

Do not attempt to move objects with the hydraulic hammer. Do not lift the machine by propping it onto the hydraulic hammer.

Never point the hydraulic hammer against the machine, as broken off material could damage the machine and even injure the operator).

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Control, operation

Operating instructions

General working methods

Fig. 3-96

Risk of injury and damage to equipment due to incorrect operation of the hydraulic hammer

Position the machine on firm and level ground Ensure that the stick is not in a vertical position.

None of the cylinders may be fully extended or retracted.

Carefully mount the hydraulic hammer and operate it.

Do not continue hammering the same point for a prolonged period of time.

Do not operate the hammer continuously for more than 15 seconds. Move the hydraulic hammer frequently (to prevent overheating of the hydraulic oil from continuous operation).

If necessary, move the machine and change the angle of impact of the hammer.

Fig. 3-97

Permissible (A) and prohibited (B) working ranges of the machine with attached hydraulic hammer

Danger!

The stability of the machine might be compromised when a hydraulic hammer is attached.

Operate the hammer only in longitudinal direction of the machine.

When using a hydraulic hammer, operate the machine only within the range A.

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A 312 Litronic / 10443914

Operating instructions

Control, operation General working methods

3.6.9

Working with large and heavy attachments Large (heavy) attachments* put a considerably higher load onto the working equipment, as the levers are longer.

To prevent damage to the machine, the following instructions must be strictly adhered to. * Examples: concrete crusher, scrap shears, hydraulic hammer, swivel rotator, stick extension

Fig. 3-98

Permitted working range for large attachments

1

Possible swivel range

2

3

Locked range

4

5

Hydraulic cylinder

Permissible working range with 10 ° distance to end position Boom or stick

Caution!

The load on the working equipment is greatest, if the hydraulic cylinders are at their end positions (fully extended or retracted).

When using large (heavy) attachments, the stress can result in serious damage to the cylinders or the deflection mechanism.

Move the attachment only within the working range 2 and not in the locked range 3.

At all times, maintain a distance of approx. 10 ° to the end position of the hydraulic cylinder.

3.6.10

Load lifting operation Load lifting operation includes all manoeuvres where loads attached to the machine with lifting tackle (cables, chains, etc.) are lifted, transferred and lowered, whereby the load must be attached manually to the machine. Loading operations thus also include lifting and lowering of pipelines, shaft rings and vessels.

Danger!

The machine may only be used for lifting operations, if it is equipped with the necessary safety devices and when these devices are in proper working order.

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Control, operation

Operating instructions

Transport

According to the European standard EN 474-5, machines used to lift loads must be equipped with the following safety devices: Lifting tackle that allows for the safe attachment of a load (optional equipment) An example of a safe lifting tackle are lift hooks that are attached to the machine instead of the digging bucket. Load lift hooks may be replaced with safety hooks welded to the digging bucket.

Overload warning system (optional equipment) If the actual load reaches or even exceeds the permissible load according to the load lift chart, the overload warning system must generate a visual and audible alarm signal to the machine operator.

Pipe fracture safety valve at the boom cylinders (optional equipment) The pipe fracture safety valve must conform to the requirements laid down in ISO 8643.

If one or more of the above requirements is not met, the machine may not be used for load lifting operations.

3.7 Transport 3.7.1

Transporting the machine safely sport, use only suitable transporting and lifting devices with sufficient capacity

of 30° and be provided with a wood covering to prevent sliding. chains / wheels must be free of snow, ice and sludge prior to driving onto the ramp. ing (crawler excavator) to the driving pedals.

tight over the loading surface and drive it carefully onto the ramp and further into the transporting vehicle. the undercarriage by using locking bolts (only for A-equipment), after loading the machine onto the low loader. against shifting according to national regulations for loading and transporting. ignition key and pull the safety lever up prior to leaving the machine.

in reference to limits for width, height and weight prior to the transport.

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Operating instructions

Control, operation Transport

electrical lines and bridges and when passing through tunnels.

3.7.2 3.7.2.1

Transporting the machine on a flatbed trailer Preparatory activities Before driving onto the flatbed trailer, proceed as follows:

Fig. 3-99

Loading ramp

The ramp incline must be flatter than th incline angle W < = 30°.

Have wedges ready.

Carefully place and secure wooden planks on metal ramp surfaces.

Before driving on the ramp, clean the tires to remove any ice, snow or mud.

3.7.2.2

Loading the machine onto the flatbed trailer To drive the machine onto the flatbed trailer:

Fig. 3-100 Driving up on the flatbed trailer 1

Fixed axle

2

Oscillating axle

The machine must be driven up on to the flatbed trailer with the rigid axle 1 in front. To do this, turn the uppercarriage by 180°.

Danger!

If the uppercarriage is rotated by 180° to the undercarriage, the travel and steering directions are reversed.

Drive and steer with increased caution.

Align the machine precisely to the loading ramp.

Drive the machine onto the flatbed trailer.

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Control, operation

Operating instructions

Transport

Note Have another person guide and sign you.

Turn the uppercarriage carefully by 180º (travel direction over oscillating axle) and lower the attachment (see Fig. 3-101).

Press switch S16 down.

The parking brake is applied.

The indicator light in the switch lights up.

Fig. 3-101 Transport position - machine Shut down the engine, raise the safety lever.

Secure the uppercarriage to the undercarriage with the bearing block.

Lower the safety lever.

Turn the ignition key to the contact position and relieve pressure lines by moving the joystick carefully several times.

Remove the ignition key and raise the safety lever.

Close and lock all doors, covers and panels on the machine.

To secure the machine: The machine must be secured against slipping before starting to travel.

Fig. 3-102 Securing the machine 1

Blade support, front

3

Outrigger, rear

2

No support, front

4

Blade support, rear

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Operating instructions

Control, operation Transport

Danger!

Serious accidents can occur if the machine slips on the loading ramp.

Secure the machine against slipping.

To do this, use wedges and a tension cable or tension chains.

Secure the machine at the points provided for the purpose using tension cables or tension chains (see Fig. 3-102). The loading points are identified on sign 45 on the undercarriage.

Secure tension cables and chains on the flatbed trailer, depending on the type.

3.7.2.3

Transport route Danger!

Driving beneath obstacles which are too low can cause serious accidents.

Drive under obstacles, particularly electrical lines, with increased caution.

Check out the travel route before starting the trip.

3.7.3

Loading the machine with a crane If the machine is to be loaded using a crane (e.g. onto ships or rail freight cars), the type of suspension should be selected according to the attachment.

Danger!

The load could slip or fall if incorrectly loaded.

Only permit experienced personnel to secure loads and signal the crane operator.

The guide must position himself within view of the operator or be in voice contact with him.

Ensure that the length of the suspension gear is sufficient.

Loading a machine with a gooseneck boom:

Fig. 3-103 Suspending the machine with gooseneck boom Only use cargo handling gear which is sufficiently dimensioned or which has been specially developed by LIEBHERR for this purpose.

Lower the equipment, retract the stick and curl the digging tool in completely.

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Control, operation

Operating instructions

Transport

Press switch S16 down.

The parking brake is applied.

The indicator light in the switch lights up.

Shut down the engine, raise the safety lever.

Secure the uppercarriage to the undercarriage using the locking pin.

Lower the safety lever.

Turn the ignition key to the contact position and relieve pressure lines by moving the joystick carefully several times.

Remove the ignition key and raise the safety lever.

Close and lock all doors, covers and panels on the machine.

Attach the cargo handling gear to the points designed for this purpose.

Danger!

Standing under the raised machine is not permitted!

Raise the machine carefully with the crane and load.

Proceed only according to the operating instructions when putting the machine back in service.

Loading a machine with adjustable attachment:

Fig. 3-104 Suspending a machine with adjustable attachment Only use cargo handling gear which is sufficiently dimensioned or which has been specially developed by LIEBHERR for this purpose.

Extend the hydraulic cylinder, retract the adjustable boom cylinder and position the stick about vertically.

Press switch S16 down.

The parking brake is applied.

The indicator light in the switch lights up.

Shut down the engine, raise the safety lever.

Secure the uppercarriage to the undercarriage using the locking pin.

Lower the safety lever.

Turn the ignition key to the contact position and relieve pressure lines by moving the joystick carefully several times.

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Operating instructions

Control, operation Transport

Remove the ignition key and raise the safety lever.

Close and lock all doors, covers and panels on the machine.

Attach the cargo handling gear to the points designed for this purpose.

Danger!

Standing under the raised machine is not permitted!

Raise the machine carefully with the crane and load.

Proceed only according to the operating instructions when putting the machine back in service.

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Control, operation

Operating instructions

Transport

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4 Malfunctions Warning and error messages: symbols (see chapter "Operating and control elements").

Identification and remedy of problems and errors: maintenance.

For that reason, in case of a problem, carefully read the corresponding chapter in the operating instructions again.

possible if you contact LIEBHERR Service.

Precise information makes it possible to find and remedy cause of the problem quickly. To do so, precise information about the type and serial number of the machine is required.

Fig. 4-1

LIEBHERR Service

If the cause of the problem cannot be determined or remedied by using the error codes and problem charts, please consult LIEBHERR Service.

Malfunctions

Operating instructions

Problems and remedies

4.1 Problems and remedies 4.1.1

Diesel engine and fuel system

Problem / error Diesel engine does not start

Cause

Remedy

Fuel tank almost or completely empty

Refuel and bleed fuel system

Under pressure in tank

Remove tank cap

Fuel filter dirty

Clean or change filter and bleed fuel system, drain fuel / clean tank

Ambient temperature below 0°C

For control and operation in specific climatic conditions, see operating instructions

Starter motor not pulling through

Check line connections, overhaul starter motor

Batteries have no power

Charge / replace

Fuel tank empty (under pressure in tank)

Refuel and bleed fuel system

Fuel filter dirty

Clean or change filter and bleed fuel system (tank)

Particularly in winter: high viscosity engine oil used

Use engine oil suitable for ambient temperature.

Dry air filter dirty

Clean or change main filter element

Air in fuel system

Bleeding the fuel system

Vent on fuel tank obstructed

Clean

Fuel line kinked

Check line and repair, if necessary

Diesel engine emitting grey or black smoke

Dry air filter dirty

Clean or change filter

Diesel engine continually emitting white smoke (steam)

Water in combustion chamber

Consult LIEBHERR Service

Diesel engine does not reach full RPM

Throttle control is not set to maximum value

Set throttle control to maximum value

Injection system is adjusted incorrectly

Consult LIEBHERR Service

Dry air filter dirty

Clean or replace filter

Insufficient fuel supply

Clean fuel filter, change fuel filter, check lines, drain water from tank

Insufficient coolant

Add coolant, check for leaks

Water pump defective

Repair

Thermostats do not work

Change thermostats

Radiator contaminated

Clean radiator

Oil level too low

Correct oil level

Oil pressure display faulty

Change oil pressure switch

Engine starts, but stops right away again or runs irregularly

Diesel engine gets too hot

Diesel engine has insufficient oil pressure Note Shut down Diesel engine immediately

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Operating instructions

Malfunctions Problems and remedies

Problem / error

Cause

Diesel engine uses too much oil

Remedy

External leak on Diesel engine

Oil in coolant or coolant in oil

Consult LIEBHERR Service

Unusual noise / sound development on exhaust side

4.1.2

Retighten screws, replace seals, if necessary

Exhaust system leaking

Check exhaust system / repair

Hydraulic system

Problem / error

Cause

Remedy

Unusual noise / sounddevelopment on hydraulic pumps Note Shut down Diesel engine immediately

Shut off valve on hydraulic tank closed

Open shut off valve

Hydraulic pumps sucking air

Check oil level in hydraulic tank, check suction lines for leaks

Engine is stalling

No performance setting via proportional solenoid valve Y50

Unplug cable of Y50 connection, remove cotter pin, move lever to emergency setting

Hydraulic oil temperature too high

Radiator contaminated

Clean radiator

Fan or fan control defective

Remedy error / consult LIEBHERR Service

Hydraulic oil level too low

Oil loss

Repair leaks, replace hoses, add oil via return filter

No travel function

Raise safety lever

Lower safety lever

No travel direction preselected

Determine travel selection switch via travel selector switch in right joystick

Pressure switch - parking brake defective

Consult LIEBHERR Service

Parking brake not released

Release parking brake via switch

Parking brake will not release despite pressing the switch

Servo pressure available: Actuate emergency function Y6 Servo pressure not available: Consult LIEBHERR Service

Swing gear not functioning

Operating brake engaged

Release operating brake

No servo control

Lower safety lever

Swing brake activated

Lower safety lever

Turn on servo control Release swing brake No working movement

No servo control

Lower safety lever Turn on servo control

No servo pressure present

Consult LIEBHERR Service

No pump high pressure present

Consult LIEBHERR Service

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4-3

Malfunctions

Operating instructions

Problems and remedies

4.1.3

Travel gear

Problem / error

Cause

Remedy

Machine does not move, neither forward nor backward

Safety lever is raised Parking brake has been applied via switch S16 No travel direction preselected Apply operating brake, using brake pedal and retainer

Lower the safety lever. Release parking brake using switch S16.

Preselect direction of travel using switch S30.

Release operating brake by releasing the retainer. Consult LIEBHERR Service.

Machine moves too slowly

Incorrect gear reduction via switch S42.

Creeper gear activated via switch S21. Travel pedal cannot fully shift through.

Select a different reduction via switch S42.

Deactivate creeper gear via switch S21.

Clean cab floor.

Consult LIEBHERR Service.

4.1.4

Electrical system

Problem / error

Cause

Remedy

Battery charge indicator light does not turn off

V- belt for alternator loose or torn

Tension or replace V-belt

Alternator defective

Replace alternator

Batteries do not charge or charge insufficiently

Batteries defective

Replace batteries

Battery connections dirty / oxidized

Clean battery connections

Cable loose or damaged

Connect or replace cable

Indicator light or display instrument not functioning or functioning incorrectly

Bulb burnt out, display instrument defective

Replace defective part

Some or all functions on instrument panel malfunction

Plug connector separated or damaged, ground lead interrupted, short circuit - fuse defective

Install plug connector correctly or change, repair short circuit, replace fuse or activate circuit breakers

Engine throttle control via knob R75 not functioning

Excavator electronic for throttle control not functioning.

Consult LIEBHERR Service

Switch S20 Sensor controlled low idle automatic is activated.

Joystick or deactivate switch S20 for sensor controlled low idle automatic.

Consult LIEBHERR Service

No signal coming from RPM sensor B12.

Consult LIEBHERR Service

Sensor controlled low idle automatic not functioning, RPM does not drop

Permanent sensor signal

Consult LIEBHERR Service

Switch S20 is deactivated

Activate switch S20

Servo control cannot be activated via switch

Switch defective Problem in excavator electrical system

Replace switch Consult LIEBHERR Service

Parking brake cannot be released with the switch Swing gear brake cannot be released with the switch

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Operating instructions

Malfunctions Fuses and relays

4.1.5

Heating and Air conditioning system

Problem / error

Cause

Heater does not supply warm air

Heater fan is not running Only low air flow in cab

4.1.6

Remedy

Shut off valves for coolant line on Diesel engine closed

Open shut off valve

Engine not at operating temperature

Bring engine to operating temperature

No power supply

Check fuse and wiring / repair

Fan motor defective

Change fan motor

Outside air filter / recirculated air filter dirty

Clean air intake opening, replace outside air filter

Air vent closed

Open air vent

Work attachment

Problem / error

Cause

Remedy

Cylinder gives way under load

Piston seal in cylinder defective

Overhaul cylinder

Bearing clearance too high on attachment

Bearing points worn out

Replace bearing parts

Grapple / bucket do not move

Valve block on bucket cylinder incorrectly switched

Change over valve block

Attachment unit cannot be turned, rotated or operated

Auxiliary function has not been released

Release auxiliary function using switch S19

Lines are not connected

Connect lines

4.2 Fuses and relays Danger!

Incorrect or bypassed fuses do not provide the required protection for machine operator or the electrical system.

Only use original fuses.

If required, order replacement fuses from LIEBHERR. Never bypass electrical fuses.

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MJFCIFSS

4-5

Malfunctions

Operating instructions

Fuses and relays

4.2.1

Fuse box E50

Fig. 4-2

Fuse box E50

Fuse box E50 is located on the left hand side in the engine compartment, on the rear of the hydraulic tank.

4.2.2

F19

50 A

Preheating

F20

50 A

Main fuse

F22

7.5 A

Sensor, engine coolant level + hazard warning system

F303 F332

7.5 A 25 A

Engine stop Starter

K16-1 K288

Relay terminal 50 Relay terminal 15

K302

Preheating relay

Panel ignition switch

Fig. 4-3

Fuses panel ignition switch

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A 312 Litronic / 10443914

Operating instructions

Malfunctions Fuses and relays

F304 F305

15 A 15 A

Ignition switch back-up fuse Interior lighting / cigarette lighter / clock

F306 F312

15 A 7.5 A

Reserve Turn signal

F313

5A

Brake light

F314

3A

Safety lever

F315

15 A

Excavator control

F316

7.5 A

Sensoric sensor control / panel

F318

20 A

Heater / air conditioner* (terminal 30)

F319 F320

15 A 15 A

Heater / air conditioner* (terminal 15) Reserve

F321

15 A

Reserve

F322 F326

7.5 A 15 A

Voltage transformer Creeper gear / quick change adapter

F325 F327

7.5 A 15 A

Parking brake / drive Reserve

F328 F329

15 A 5A

Reserve Servo control

F330

7.5 A

AHS / AS 1 / Mode

F331 F336

15 A 20 A

Reserve Back-up fuse for lighting

F337 F338

15 A 15 A

Support / magnet Horn

F339

20 A

Air conditioning condenser*

* Option

4.2.3

Panel, cab

Fig. 4-4

Fuses and relays panel cab

F307

7.5 A

Parking light, left / tail light

F308 F309

7.5 A 7.5 A

Parking light, right / tail light Headlight, left

F310

7.5 A

Headlight, right

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MJFCIFSS

4-7

Malfunctions

Operating instructions

Fuses and relays

F311

15 A

Windshield wiper / washer system

F317

7.5 A

Rotating beacon*

F323 F324

15 A 15 A

Attachment work headlight* Work headlight / roof*

F343

7.5 A

Roof windshield wiper*

K414

Relay Intermittent control

* Option

4.2.4

Distributor plate All other relays are located in the distributor plate of the right control panel.

Fig. 4-5

Relay Distributor plate

K250 K251

Oscillating axle automatic Hand brake

K252 K315

Servo - hand brake Brake light

K370

Servo control

K375 K386

Installation kit - quantity Safety lever

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A 312 Litronic / 10443914

5 Maintenance 5.1 Maintaining the machine safely 5.1.1

General Safety instructions ied out by trained expert technicians. ods for repeat checks / inspections as outlined in the Operating manual. Always use appropriate tools to carry out maintenance work. sets out precisely who should, or is allowed to carry out which jobs.

The machine operator (and his staff) are allowed to carry out certain jobs, but other jobs must be carried out only by qualified and trained staff. rements set forth by the manufacturer.

This is always ensured with Original spare parts. use suitable personal protective equipment. In addition to a protective helmet and safety boots, for certain jobs protective goggles and gloves are also necessary. the machine during maintenance.

work. Make sure he knows the person who is in charge of the work. with the working equipment lowered and the Diesel engine turned off, unless described otherwise in the operating instructions. maintenance operations, especially when working under the machine. Pull the ignition key and set the main battery switch to position 0. ain during maintenance and repairs. re-attached and inspected directly upon conclusion of the operations.

5.1.2

Cleaning n the machine, especially connections and fittings to remove oil, fuel or cleaning substances.

Do not use harsh cleaning products and use only lint-free cleaning cloths. eaning products or steam within the first two months after delivery (or after repainting).

cleaning products, infiltration of water and steam into the bearing points. exposed to water, steam or cleaning products.

This applies especially to electric motors, electric components, switch boxes,

Maintenance

Operating instructions

Maintaining the machine safely

plug connections and air filters. of the fire warning system and the fire extinguisher do not come in contact with hot cleaning fluids when cleaning the engine compartment.

The fire extinguishing system could be actuated.

chafing and damage.

infiltrated water or cleaning fluid.

5.1.3

Checking for cracks s, depending on application, job site, duration of use and conditions of use. The different load conditions result in the different service life durations for various machines components. This could lead to cracks and loose connections, particularly on load bearing parts. This applies particularly in the case of machines used in material handling or industrial applications or for machines with special equipment, such as demolition excavators. To ensure that operating safety is maintained, the machine must be checked regularly for cracks, loose connections or other visible damage. keep the machine clean and to clean it regularly. schedule, e personnel of the machine operator. tions with the machine supported, on firm and level ground, at changing loads with the attachment in length and crosswise direction. The currently valid accident prevention regulations must be adhered to. especially: th axle and gear mounting, support, lower swing ring seating with tower and ball swing ring. cylinder, upper swing ring seating, cab bearing, mounting of swing gear and counterweight. nts, e. g. boom, stick, quick change adapter, digging tool and grapple. and pin connections, steps, ladders and mounting elements. the level of inspection, if a crack is suspected or is in areas which are not easily visible, such as the swing ring seating, then the dye penetration procedure should be used to check for cracks. ely. Welding on load bearing parts of earth moving machines, material handling and transport units may only be made by especially trained expert personnel and only in accordance to accepted regulation of welding technology. In case of doubt, contact LIEBHERR Service to discuss suitable measures.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Maintenance Maintaining the machine safely

5.1.4

Welding if expressly agreed by the manufacture, and before carrying out the welding, burning or grinding work, clean the machine and its environment to remove any dust and combustible material.

Ensure that there is sufficient ventilation. There is a potential danger of fire and/ or explosion. out any arc welding work on the machine.

Disconnect the negative pole first, then the positive pole. Proceed in reverse order when reconnecting. welding location.

5.1.5

Operating and service fluids applicable safety regulations for the corresponding product. disposal of operating and service fluids as well as exchange parts.

(Danger of burning and scalding).

5.1.6

Repair able lifting devices with sufficient load carrying capacity. When replacing individual parts and larger components, attach and secure them carefully to the lifting tackle, to avoid any danger. Use only suitable and technically sound lifting devices as well as load tackle with sufficient load carrying capacity.

Never stand or work under swinging loads. ciently sized lifting devices.

Always wear work gloves when handling wire ropes.

The guide must position himself within view of the operator or be in voice contact with him. platforms.

Do not use parts of the machine as climbing devices, if they are not designed for this purpose.

Wear a harness when working in great heights.

Keep handles, steps, railings, platforms, and ladders free of dirt, ice and snow. the machine is properly supported. Never use metal on metal support. equipment unless it has been properly and securely supported. ways that any shifting weight will not endanger the stability of the machine and avoid metal to metal contact. especially trained expert personnel.

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MJFCIFSS

5-3

Maintenance

Operating instructions

Maintaining the machine safely

secure the uppercarriage to the undercarriage with the locking pin. onnel may work on the hydraulic system. can have enough pressure to penetrate the skin.

Diesel engine and relieving the hydraulic system. After the Diesel engine has been turned off, you must move all pilot controls (right handed joystick and pedals) into all directions to reduce the control pressure and the dynamic pressure in the work cycles. Then relieve the pressure in the tank, as described in this operating manual.

5.1.7

Electrical system All defects, such as loose connections, burnt out fuses and bulbs, burnt or damaged wires or cables must be repaired immediately by an electrician or especially trained personnel.

immediately. supervision of an electrician may work on the electrical equipment of the machine, according to the electro-technical guidelines. emergency off or master switch with voltage release. Rope of the work area off with a red and white safety chain and a warning sign. Use only insulated tools. mponents, shut off the voltage and connect the supply cable to the ground and ground the components, such as the condenser, with a grounding rod. truly free of current, ground them and short circuit them. Insulate adjacent, current carrying parts. out any arc welding work on the machine.

Disconnect the negative pole first, then the positive pole. Proceed in reverse order when reconnecting.

5.1.8

Pressure accumulator

accidents.

operating instructions prior to working on a hydraulic accumulator. mechanical work on them.

The pressure accumulator can be damaged due to heat exposure and can rupture due to mechanical treatment. THERE IS A DANGER OF EXPLOSION!

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Maintenance Maintaining the machine safely

r only with nitrogen. When using oxygen or air, there is a DANGER OF EXPLOSION! ring operation, there is a danger of burning. application before use. the pressure accumulators. Make sure that the marking remains visible.

5.1.9

Hydraulic hoses and lines d regularly, every 2 weeks, in case of suspected intentional damage immediately for leaks and external visible damage!

Any damaged parts must be replaced immediately! Escaping oil can cause injuries and fires. process. For that reason, their service live is limited. and impermissible use are the most frequent causes of failure. standards, regulations and guidelines for hoses and lines at the job site must be observed. ranges of permitted use can shorten the service life ( for example in high temperatures, frequent work cycles, extremely high impulse frequencies, multi shift operation). e following conditions are found during inspection: cracks); shape of the hose or hose line, when under pressure or not under pressure, or in bends (e.g. separation of layers, blisters or bubbles); allation instructions; which reduce the strength of the fitting or the hose / fitting connection; h reduces function and strength;

pressure hoses, always attach the screws of half clamps or full flange on both ends of hose first and then tighten. with a bent fitting, always tighten the end with the bent fitting first when tightening the flanges, then the end with the straight fitting. and tightened thereafter. properly mounted. This prevents vibration and damage during operation. that chafing with other hoses or other structures is prevented.

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MJFCIFSS

5-5

Maintenance

Operating instructions

Maintenance access doors

the outer hose diameter to the other parts is recommended. The distance should not be less than 10 to 15 mm (1/2 inch). check before initial use, that there is not chafed area over the entire area of movement.

5.1.10

Rollover-protection features (ROPS) and falling-object protective systems (FOPS)

prevent a weakening of the roll-over protection or falling-object protective system. devices (such as fire extinguishers, headlights, or such).Welding attachment parts or drilling holes on may weaken the structure. he structure may be caused by an accident, falling objects, etc. exclusively approved by LIEBHERR will render the permit of the roll-over protection or falling-object protective system invalid.

5.2 Maintenance access doors 5.2.1

Overview of access doors

Fig. 5-1

Access doors on the machine

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Maintenance Maintenance access doors

10 Engine hood 27 Cover battery box

70 Side door, left 80 Side door, right

The machine has 4 access doors for maintenance. The locks integrated in the handles must be unlocked before starting to travel.

Access door

Lock

Engine hood

Gas pressure spring

Cover battery box

Gas pressure spring

Side door, right

Mechanical

Tab. 5-1

5.2.2

Access to:

Access doors

Door lock

Fig. 5-2

Door lock

To stop the access doors from moving unintentionally (e.g. due to wind), open them fully and allow the door lock (see arrow) to engage.

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MJFCIFSS

5-7

Maintenance

Operating instructions

Tires

5.2.3

Engine hood release

Fig. 5-3

Engine hood release

Unlock the engine hood by opening the remote control 1 behind the left side door and push up.

Before closing the engine hood, close the remote control again.

5.3 Tires

Fig. 5-4

Exploding tire

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Maintenance Tires

Danger!

Repair work on the wheels, e.g. removing tires from the rim or installing tires on the rim may only be carried out by expert personnel using the appropriate assembly tool.

If the tire inflator is operated incorrectly or carelessly, the following dangers can arise, leading to severe injury or even death:

Tires which have become flat may not be inflated. They must be repaired at a professional shop.

An incorrectly seated lock ring could burst off. Danger of injury.

When inflating the tires, use a tire inflator hose of a sufficient length with a self retaining hose valve.

When inflating the tires, stand outside of the danger zone.

Do not use different tire sizes.

5.3.1

Checking the tire pressure The air pressure in the tires has a considerable influence on the overall operational behavior of the machine. For this reason, the tire pressure should be checked regularly and corrected if necessary.

When working on the tires, ensure that the machine is positioned safely and is secured with wedges to prevent it from rolling off.

Ensure that the correct nominal tire pressure values, corresponding to the mounted tire and the machine group, are available for the tires.

Take the nominal values from the chart below.

Attach measuring equipment and correct air pressure, if necessary.

5.3.1.1

Tire pressures Size

Manufacturer

PR

bar

10.00 - 20

Continental

16

9,00

10.00 - 20

Dunlop

16

7,50

10.00 - 20

Bridgestone

14

7,00

10.00 - 20

Nokia

16

9,00

10.00 - 20

Barum

16

7,50

18.00 - 19.5

Michelin

7,00

600/40 - 22.5

Alliance

6,00

Tab. 5-2

5.3.1.2

Tire pressures

Tightening torque Tightening torque of wheel lugs: 420 Nm

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MJFCIFSS

5-9

Maintenance

Operating instructions

Lubricants and operating fluids

Note!

Retighten the wheel lugs according to the inspection and maintenance schedule after each wheel change.

5.3.2

Filling with foam Note!

The running characteristics will be influenced by filling the tires with foam. Only LIEBHERR may fill the tires with foam.

5.4 Lubricants and operating fluids 5.4.1

General information to change lubricants and operating fluids Note!

The quantities given in the lubrication and operating fluid chart as well as on the lubrication chart in the cab are only guide values.

Check the level in the corresponding component after each oil change or refill.

Note!

Adhering to regulations for lubrication, level checks and changing of operating fluids guarantees a high degree of reliability and a long service life for the machine.

It is particularly important to adhere to the oil change intervals and use the specified type of lubricant.

Observe the following when using and checking lubricants and operating fluids:

Note!

Cleanliness is of the utmost importance when changing oil.

Clean all filler plugs, filler covers and drain plugs and their surroundings before opening.

If possible, drain the oil when it is at operating temperature.

Ensure that old oils are collected and disposed of in an environmentally acceptable manner, including removable oil filter cartridges.

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A 312 Litronic / 10443914

Operating instructions

Maintenance Lubricants and operating fluids

Danger!

When checking and changing lubricants and operating fluids, ensure that the following precautions are adhered to: Unless otherwise indicated, carry out all work on the machine on level, solid ground and with the engine shut down.

Whenever you access the engine compartment, always secure the cover and side doors to prevent them from accidentally falling back or closing.

Only refuel the machine when the engine is shut down, do not smoke and avoid open flames.

Turn the battery master switch to position 0 (off) and remove the ignition key.

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5 - 11

Maintenance

Operating instructions

Lubricants and operating fluids

5.4.2

Lubrication chart

Fig. 5-5

Lubrication chart for A 312 Litronic

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Maintenance Lubricants and operating fluids

Symbol

Picture

Quantity (litre)*

Diesel engine

15.5

Hydraulic tank

300.0

Slewing gear mechanism

4.4

Transmission

3.3

Rigid axle

10.5

Steering axle

8.2

Steering axle wheel hub

3.0

General lube points Check the oil level Oil change First oil change Lubrication Operator's manual

* = approximate values

5.4.3

Lubricant table

Designation

Medium

Diesel engine

Engine oil

Symbol

Classification/Name

Viscosity

Refer to the instructions of the engine manufacturer (see Deutz manual)

Volume (litre)* 15.5

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5 - 13

Maintenance

Operating instructions

Lubricants and operating fluids

Designation

Medium

Hydraulic system (system capacity / tank capacity)

Symbol

Classification/Name

Viscosity

Volume (litre)*

Hydraulic oil

Liebherr Hydraulic Basic 68 Liebherr Hydraulic Basic 100 Liebherr Hydraulic HVI Liebherr Hydraulic Plus Liebherr Hydraulic Plus Arctic

ISO VG 68 ISO VG 100 ISO VG 46 (32-68) ISO VG 46 (32-68) VG 15-46

300 / 170

Engine oil

API - CD / ACEA - E1 (MB 226.0 and 227.0)

SAE 10W SAE 10W-30 SAE 10W-40 SAE 15W-40 SAE 20W-20 SAE 30W

300 / 170

API - CD, CE, CF / ACEA E2, E3, E4 (MB 227.5, 228.1, 228.3 and 228.5) Slewing gear mechanism (as stop brake)

Gear oil

API-GL-5 MIL-L 2105 B, C or D

SAE 80W-90 - alternatively SAE 90 LS

4.4

Slewing gear mechanism (as positioning slewing brake)

Gear oil

API-GL-5 MIL-L 2105 B

SAE 90 LS

4.4

Transmission

Gear oil

ZF TE-ML 07

SAE 10W-30 SAE 10W-20 SAE 10W-40

3.0

Rigid axle

Gear oil

API-GL-5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

10.5

Steering axle

Gear oil

API-GL-5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

8.2

Wheel hubs of the steering axle

Gear oil

API-GL-5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

3.0 each

Tracks and gearing of the slewing ring, bearing of the equipment

Grease

High-pressure grease KP2k or EP2

Consistency 2 NLGI grade

-

Hinges, joints, locks

Engine oil

-

-

-

-

Sealing rubber on doors and covering sections

Silicone spray or talcum powder

-

-

-

-

* = approximate values

5.4.4

Fuels, lubricants and process chemicals

Designation

Medium

Symbol

Fuel tank

Conventional diesel fuel with <= 0.5 % sulphur content

Volume (litre)* 215

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A 312 Litronic / 10443914

Operating instructions

Maintenance Lubricants and operating fluids

Designation

Medium

Symbol

Volume (litre)*

Coolant

Corrosion inhibitor and antifreeze agent

Windscreen washer system

Conventional windscreen cleaning agent or denatured alcohol

-

3.0

Coolant of air-conditioning system

R 134 a

-

1.7 kg

Refrigeration oil in a/c compressor

PAG ZXL 100 PG

-

0.15

15.5

* = approximate values

5.4.5

Fuels and lubricant for the diesel engine For details and specifications regarding the diesel fuel, lubricant and coolant for the diesel engine, see Deutz manual.

5.4.6

Hydraulic oil Hydraulic oils must meet the requirements outlined below.

Non-compliance with these requirements shall void all warranty and liability by LIEBHERR. Maximum water content of hydraulic oil: < 0.1 %

5.4.6.1

Hydraulic oil LIEBHERR recommends using the following hydraulic oils in its machines (depending on temperature range):

Fig. 5-6

Hydraulic oil for use as hydraulic oil (ISO classes)*

A Ambient temperature B Cold-start range with warm-up instruction C Operating range

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5 - 15

Maintenance

Operating instructions

Lubricants and operating fluids * temperature-based selection of the ISO class

Liebherr Hydraulic Plus and Liebherr Hydraulic Plus Arctic are suitable for both biological as well as prolonged operation.

Use only LIEBHERR hydraulic oils. The use of other oils is not permitted. If LIEBHERR oils are not available locally, use one of the motor oils listed in the following chapter (see 5.4.6.2) (before choosing an oil, contact our customer service department).

5.4.6.2

Engine oil If you wish to use other products, it is your responsibility to obtain a warranty declaration from the oil supplier.

Engine oils that are to be used as hydraulic oils must conform to the following specifications: Single grade oils (1):

API - CD / ACEA - E1 (MB 226.0 and 227.0)

Multigrade oils (2):

API - CD, CE, CF / ACEA - E2, E3, E4 (MB 227.5, 228.1, 228.3 and 228.5)

Tab. 5-3

Engine oils for use as hydraulic oil

Fig. 5-7

Engine oil for use as hydraulic oil (SAE classes)*

A Ambient temperature B Cold-start range with warm-up instruction

1 2

Single grade engine oil Multigrade oils

C Operating range * temperature-based selection of the SAE class ** for deviating viscosity grade: consult the LIEBHERR customer service department

5.4.6.3

Warm-up instruction The black bar B indicates that the ambient temperatures are maximum 20 °C below the operating range C. In the event of a cold start at an ambient temperature below range B, the following warm-up instruction applies to the hydraulic oil:

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A 312 Litronic / 10443914

Operating instructions

Maintenance Lubricants and operating fluids

1. Start the diesel engine and run it at approx. 1 / 2 rated speed. Carefully activate the working hydraulics. Operate the hydraulic cylinder and move them to the stop. After approx. 5 minutes, start the travel hydraulics. Warm-up time: approx. 10 minutes After a cold start at even lower ambient temperatures, the following warm-up instruction applies: 2. Before starting the engine, warm up the hydraulic oil tank. Then proceed according to the warm-up instructions in 1.

5.4.6.4

Biodegradable hydraulic oils Caution!

Risk of damage to the hydraulic unit!

When mixing ester-based biodegradable hydraulic oils with mineral oils, there is a risk of aggressive chemical reactions, which can damage the hydraulic equipment.

Do not mix biodegradable hydraulic oils from different suppliers, and never mix with mineral oils.

The use of bypass filters is mandatory.

Depending on the temperature range, LIEBHERR recommends its poly-alpha olefin (PAO, HEPR) oils that are biodegradable according to CEC-L-33-A-93: Liebherr Hydraulic Plus or Liebherr Hydraulic Plus Arctic If these oils are not available locally, use one of the following oils (before choosing an oil, contact our customer service department).

Fully saturated synthetic ester-based oils, HEES Before using biodegradable hydraulic oils, you must consult LIEBHERR. Do not use vegetable oils, as they do not possess the necessary thermal stability.

If you wish to use other products, it is your responsibility to obtain a warranty declaration from the oil supplier.

5.4.6.5

Monitoring, filter change and oil change Note!

Biodegradable hydraulic oils must be checked regularly by means of an oil analysis.

250 operating hours For mineral oils, an oil analysis is only required if the oil change interval is to be extended. hours LIEBHERR recommends contracting WEAR-CHECK** with these analyses, and to change the oil when indicated by the test results in the lab report (see also customer service and product information). * Change of oil = change from mineral oil to biodegradable hydraulic oil ** Yellow kit for machines with biodegradable oil filling (HEPR and HEES)

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5 - 17

Maintenance

Operating instructions

Lubricants and operating fluids Green kit for machines with mineral oil filling

Symbol

Description Filter change for hydraulic oil

Oil sampling

Tab. 5-4

Key to figures

Hydraulic oil in normal use:

Fig. 5-8

Oil sampling and filter change in normal use

h

Operating hours

1

First oil sample

a

Mineral oil

2

Second oil sample

b

Biodegradable hydraulic oil

3

Subsequent oil samples: every 500 operating hours

Oil change after 2000 operating hours, or when indicated by the lab report of the analysis Intervals for the change of the hydraulic oil return filter (20 / 5 µm): first change after 500 and 1000 operating hours, then every 1000 operating hours and after each hydraulic oil change.

Hydraulic oil used in dust intensive applications:

Fig. 5-9

h

Oil sampling and filter change in machines used for dust-intensive applications

Operating hours

1

First oil sample

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A 312 Litronic / 10443914

Operating instructions

Maintenance Lubricants and operating fluids

a

Mineral oil

2

Second oil sample

b

Biodegradable hydraulic oil

3

Subsequent oil samples: every 250 operating hours

Oil change after 500 operating hours, or when indicated by the lab report of the analysis Interval for the change of the hydraulic oil return filter (10 µm): first change after 500 operating hours, then every 500 operating hours and after each hydraulic oil change.

5.4.6.6

Instructions for the reduction of the contamination of the hydraulic oil in machines used for dust intensive applications If the machine is normally operated with a hydraulic hammer or under similar conditions (considerable dust generation), the hydraulic oil might become more contaminated than under normal working conditions.

In order to prevent premature wear of the hydraulic components, shorten the intervals between the oil changes (or oil samples respectively) and observe the following instructions: ilter must be replaced every 500 operating hours and after every hydraulic oil change. d of the standard 20 / 5-µm cartridges. every hydraulic oil change.

Note!

Machines delivered with hydraulic hammer attachment and retrofitted hydraulic hammer kits are already fitted with 10-µm filter cartridges in the return filter.

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5 - 19

Maintenance

Operating instructions

Diesel engine

5.4.7

Grease and other process chemicals Medium

Description / manufacturer

Grease for central lubrication system, general lube points

Liebherr recommends using the following products for the lubrication of the machine, and in particular of the slewing ring roller bearings, bolts, crown gears, axles and screws: - Liebherr Universalfett 9900 - Liebherr Universalfett Arctic (for low-temperature operation) The grease must conform to specification KP2k, consistency grade 2, NLGI grade according to DIN 51818 and DIN 51825 or EP 2 according to NF-T-60 132.

The grease must consist of a lithium complex with a VKA value of minimum 2300 N according to DIN 51350 or ASTM D 2596 respectively.

Contact spray for slip rings

Cramolin

Lubricant for pistons, piston nuts, also used for the mounting of piston rod bearings at hydraulic cylinders

Gleitmo 800

Special corrosion inhibitor for mounting recesses for sealing elements at hydraulic cylinders

Castrol-Tarp

Tab. 5-5

Grease and other process chemicals

5.5 Diesel engine 5.5.1

Check oil level Danger!

Danger of burning.

The engine oil is hot when at or near operating temperature.

Do not allow your skin to come into contact with hot oil or components containing hot oil.

The machine must be in level position.

Shut down the engine.

Wait for a short time until the oil has collected in the oil pan.

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Operating instructions

Maintenance Cooling system

Fig. 5-10

Check oil level

Check the oil level in the engine.

The oil must leave a mark between the min and the max marks on the dipstick.

If necessary, add engine oil at the oil filler fitting (see arrow) until the level has reached the upper mark MAX.

5.5.2

Changing the oil For oil change, see the Deutz operating instructions.

Note!

Change the oil only if the engine is warm.

5.6 Cooling system 5.6.1

Checking and cleaning the cooling system

Fig. 5-11

Cleaning the cooling fins

The machine is equipped with a combination oil / water cooler.

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5 - 21

Maintenance

Operating instructions

Cooling system

Optimum cooling can only be achieved if the cooler is kept clean.

Check the engine, fan and cooler for damage and clean if necessary.

Check the cooling system according to the maintenance schedule intervals.

If required, clean the cooling fins with compressed air or a steam jet (from inside to the outside, see arrow).

Check the condition and seals of the connector hoses between the radiator and engine the as well as the coolant hoses regularly.

In case of leaks, change the pressure relief valve 1 (expansion tank lock ring).

5.6.2

Checking the coolant level Danger!

Danger of burns due to hot coolant.

The engine cooling system is hot and pressurized when at or near operating temperature.

Avoid touching coolant or coolant-bearing parts.

Check the coolant level only when the engine has cooled off sufficiently.

Fig. 5-12

Expansion tank

Turn the cover (see arrow) a half turn.

In this position, relieve any pressure that may be present. After equalizing the pressure, slowly open the cap all the way.

The coolant must be between the MIN and MAX marks.

Add coolant if necessary.

Close the cap.

After adding coolant, allow the engine to run for a short time with the heater turned on and then recheck the coolant level.

5.6.3

Anti-corrosion fluid and antifreeze The system must be filled with antifreeze year round.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Maintenance Cooling system

At delivery, the coolant contains antifreeze for temperatures up to -37 °C (this corresponds to approx. 50 % antifreeze).

When carrying out maintenance work, the mixing ratio of the coolant must be checked.

Quantity: see Lubrication Chart Note!

Do not use more than 60 % anti-corrosion fluid/antifreeze!

At a higher percentage, the cooling effect and antifreeze protection would actually be reduced.

5.6.4

Changing water filters

Fig. 5-13

Water filter

The water filter must be replaced every 500 operating hours: Close the shut off valves (arrows) on the filter housing.

Unscrew the filter element.

Lubricate the seal ring on the new filter element lightly with oil.

Install the new filter element until the seal ring is touching on the filter head.

Note!

The filter element can be damaged.

Do not use any tools to tighten the filter element.

Tighten the filter element by hand a 1/2 - 3/4 turn.

Open the shut off valves again.

5.6.5

Changing the coolant Danger!

Danger of burns due to hot coolant.

Change the coolant only when the engine is cold.

When changing the coolant, observe the following points:

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5 - 23

Maintenance

Operating instructions

Cooling system

shut off valves for the heater circuit closed.

contact position.

5.6.5.1

Draining the coolant

Fig. 5-14

Drain valve

Open the cover of the expansion tank slowly.

Remove the cover plate on the underside of the engine.

Place a suitable container underneath.

Unscrew the cover of the drain valve 1 on the underside of the water cooler (see arrow) and attach the drain hose from the toolbox.

Fig. 5-15

Water taps on the Diesel engine

Open the water taps 2.

5.6.5.2

Refilling the coolant Remove the drain hose on the underside of the water cooler and close the valve.

Open the water taps 2.

Pour coolant into the expansion tank until the coolant is visible in the filler neck.

Turn the heater on and set it to its highest level; allow the Diesel engine to warm up.

Check the coolant level and add more coolant, if necessary.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Maintenance Fuel system

5.7 Fuel system Danger!

Danger of explosion!

Avoid open flames when working on the fuel system and when refuelling.

Do not smoke.

5.7.1 5.7.1.1

Refuelling Fuel tank cap

Fig. 5-16

Fuel tank cap

Unscrew tank cap 1 Add fuel via the strainer.

5.7.1.2

Electric refuelling pump (optional equipment)

Fig. 5-17

Electric refuelling pump

The electric refuelling tank is used to refill fuel into the fuel tank of the machine.

It is located behind the side door at the fuel tank.

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5 - 25

Maintenance

Operating instructions

Fuel system

To refuel and then store away the hoses, proceed as follows: Remove the tank lid.

Connect the suction hoses 1 and 2.

Insert the free end of the suction hose 3 into the fuel container.

Open the stop cock 4.

Switch on the refuelling pump with the switch S25 (green) on the control unit 5 to pump fuel into the tank of the machine.

The pump is automatically switched off when the maximum fill level is reached.

The refuelling pump can be switched off at any time with the switch S59 (red).

Caution!

Prevent the pump from running dry!

Ensure that the fuel level does not drop below the suction height of the suction hose.

Close the stop cock 4.

Before storing away the hose, ensure that no fuel is left in the suction hose 1 (2).

Roll up the suction hose and store it away it in the storage place.

Close the flap.

Replace the tank lid.

5.7.2

Draining the water from the fuel tank The condensation in the fuel tank and fuel system should be drained daily. If conditions of use and fuel quality permit, the maintenance interval can be increased to once a week.

Note To reduce condensation in the tank, keep the fuel level as high as possible.

Fig. 5-18 1

Fuel tank

Tank cap

2

Strainer

3

Drain plug

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Maintenance Fuel system

The bottom of the tank is equipped with a drain plug 3.

Open the drain plug 3 on the underside of the fuel tank by two turns.

Drain off water until fuel emerges, close the plug again.

5.7.3

Emptying and cleaning the fuel tank To empty, remove the tank cap 1 and the drain plug 3 and allow the fuel to flow into a suitable container.

Clean the tank.

Check the tank and strainer2 regularly for contamination.

5.7.4

Fuel preliminary filter (type 1) Drain the water:

Fig. 5-19

Fuel preliminary filter

Open shutoff valve 7 Drain the water visible in the glass container into a suitable container.

Close the shutoff valve.

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MJFCIFSS

5 - 27

Maintenance

Operating instructions

Fuel system

Replace filter insert:

Fig. 5-20

Fuel preliminary filter, filter insert

Open shutoff valve 7 and vent screw 10.

Drain the fuel into a suitable container.

Unscrew screw 11 and remove cover 12 and the sealing ring.

Remove filter insert 15 and filter casing 14 Reinstall the new filter insert and spring casing.

Check seal 13, replace if necessary and screw cover 12 back on.

Close shutoff valve 7.

Operate hand pump 8 until fuel flows uninterrupted, without bubbles, out of vent screw 10.

Close vent screw 10 again.

5.7.5

Fuel preliminary filter (type 2) Drain the water:

Fig. 5-21

Fuel preliminary filter

Screw in shutoff valve 1 slightly until the water flows off via the hose.

Drain the water visible in the glass container into a suitable container.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Maintenance Fuel system

Close shutoff valve 1.

Replace filter cartridge: Unscrew electrical cable 2.

Screw in shutoff valve 1 slightly until fuel flows off.

Drain the fuel into a suitable container.

Unscrew inspection glass 4, unscrew filter cartridge 5.

Oil the seals on the filter head and inspection glass lightly (see arrows).

Screw on new filter cartridge 5 and inspection glass 4.

Close shutoff valve 1.

Screw on electrical cable 2.

Operate hand pump 3 until inspection glass 4 is filled with fuel.

Note The filter cartridge can be damaged by tightening too tightly.

Do not use tools to tighten the filter.

5.7.6

Replacing the fuel filter cartridge (fine filter)

Fig. 5-22

Fuel fine filter

Unscrew fuel filter cartridge 1.

Lubricate the rubber seal ring on the new filter cartridge lightly.

Note The filter cartridge could be damaged if it is tightened too much!

Do not use any tools to tighten the filter.

Screw on the new filter cartridge and tighten by hand.

It is not necessary to bleed the fuel system after changing the fine filter.

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5 - 29

Maintenance

Operating instructions

Dry air filter

5.8 Dry air filter Maximum engine protection against premature wear due to dust is only possible if the air filter is serviced at regular intervals.

The dry air filter is designed in such a way that it offers maximum protection at long maintenance intervals.

For safety reasons, we do not recommend to wash out filter elements.

Fig. 5-23

Dust discharge valve extractor slot

Push the extractor slot on the dust discharge valve open by hand once a week to prevent it from sticking due to humidity and dust.

Fig. 5-24

Vacuum indicator

When the maximum vacuum pressure has been reached, the maintenance indicator on the filtered air connection (see arrow) actuates and the indicator light H13 (air filter contamination) lights up.

5.8.1

Changing the main element Caution!

Only replace the main element when the maximum permissible intake underpressure has been reached, or at least once a year.

Installing and removing the main element too often could damage the seals between the filter element and the filter housing.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Maintenance Dry air filter

Only replace the safety element after every third change of the main element, or at least once a year.

Before installing a new element, carefully clean the seal and the seal contact surface in the housing.

Fig. 5-25

Changing the filter cartridges

1

Filter housing cover

4

Safety element

2

Filter housing

5

Dust discharge valve

3

Main element Remove the cover 1 with the engine shut down.

Remove the contaminated main element 3.

Clean the interior of the air filter housing and the sealing surface in the housing with a damp cloth.

Caution!

Dirt could enter the engine air intake!

Do not clean the housing by blowing it out with compressed air.

Insert the new main element and ensure that it seals and is positioned correctly.

Close the filter housing 2 with cover 1.

5.8.2

Changing the safety element Note!

Replace the safety element after replacing the main filter cartridge three times or at least once a year.

Replace the safety element immediately if a visual inspection has shown that the safety element is very dirty.

Remove the main element 3.

Remove the safety element 4.

Clean the interior of the air filter housing carefully with a damp cloth.

Clean sealing surfaces in the housing and inspect for any damage.

Insert the new safety element 4 carefully.

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5 - 31

Maintenance

Operating instructions

Hydraulic system

Insert the main filter cartridge3 and ensure that it seals and is positioned correctly.

Close the filter housing 2 with cover 1.

5.8.3

Checking the filtered air line

Fig. 5-26

Filtered air line

Check the filtered air line 1 between the filter outlet and the engine suction pipe for damage and leaks each time the filter element is replaced.

If necessary, retighten the tension clamp screws 2.

5.9 Hydraulic system Maintenance work on the hydraulic system is restricted mainly to the hydraulic tank.

All other system components do not require special maintenance.

The pipe and hose network should be checked at regular intervals for leaks.

Note!

Strict cleanliness is of particular importance for the hydraulic system.

For this reason, the intervals given

5.9.1

Checking the oil level in the hydraulic tank The oil level is checked via the sight gauges on the rear of the hydraulic tank.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Maintenance Hydraulic system

Fig. 5-27

Sight gauges on the hydraulic tank

The lower eye - MIN - shows the minimum oil level if all cylinders are fully extended.

When checking the minimum oil level, the following prerequisites must be met: The hydraulic excavator must be standing on level ground.

The attachment must be fully raised and the adjustable boom cylinder, hydraulic cylinder, stick cylinder and bucket cylinder fully extended (stick and bucket curled in).

The blade and / or outrigger support must be fully extended or lowered.

The oil level may not fall below - MIN - level.

The upper eye - MAX - shows the maximum oil level if all cylinders are fully retracted.

When checking the maximum oil level, the following prerequisites must be met: The hydraulic excavator must be standing on level ground.

The attachment is placed on level ground, the stick and bucket cylinders are fully retracted.

The blade and / or outrigger support must be fully retracted or lowered.

The oil level may not exceed - MAX - level.

Check the oil level and add more oil, if necessary.

5.9.2

Relieving the pressure in the hydraulic system Danger!

A fine stream of oil can penetrate the skin when under high pressure and cause serious injury.

Before working on the hydraulic system, always relieve the pressure.

Do not check for leaks with bare hands.

Note the following points: The machine must be in the position described above.

Shut down the engine.

Move the pilot control devices (joystick and pedals) in all directions (with the ignition key in contact position).

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5 - 33

Maintenance

Operating instructions

Hydraulic system

Danger!

The hydraulic oil is hot when at operating temperature and could be pressurized.

Do not allow your skin to come into contact with hot oil or components containing hot oil.

Fig. 5-28

Relieving the pressure in the hydraulic system

Back out the breather filter 1 by a maximum of one turn.

The pressure in the hydraulic system is relieved.

The breather filter 1 can be turned manually if the safety pin 2 is inserted. An open end spanner can be used if the filter does not open easily.

5.9.3

Emptying and refilling the hydraulic tank

Fig. 5-29 1

Draining and refilling the hydraulic oil

Breather filter

2

Return filter

3

Drain valves

If possible, always fill and empty the hydraulic system using a filler unit.

To drain the oil: The pressure in the hydraulic system must be relieved.

Back out the breather filter 1 by a maximum of one turn.

The pressure in the hydraulic system is relieved.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Maintenance Hydraulic system

Remove the cover of the return filter 2.

Install the drain hose to the drain valves 3 in the tank bottom and let the oil flow out into a suitable container.

To refill the hydraulic oil: Back out the breather filter 1 by a maximum of one turn.

The pressure in the hydraulic system is relieved.

Remove the cover of the return filter 2.

Refill the oil through the filter cartridge until the level reaches precisely the center mark on the sight gauge.

Tighten the breather filter 1.

Install the cover of return filter 2.

Caution!

After each hydraulic oil change, bleed the hydraulic pumps.

To drain the condensation: Drain the condensate regularly.

Place a suitable container underneath the tank.

Keep the drain hose on the drain valves 3 (see Fig. 5-29) until oil contains no more water.

Interval: see Maintenance schedule

5.9.4

Return filter The return filter is located on the top of the hydraulic tank.

Fig. 5-30

Return filter

1

Cover

5

Magnetic plug

2

Hex head screw

6

Filter element

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5 - 35

Maintenance

Operating instructions

Hydraulic system

3

Gasket

7

4

Bypass cage

Protective cylinder

The magnetic rod 5 of the return filter must be cleaned at fixed intervals (see maintenance chart) and the glass fiber filter element 6 replaced.

Note!

When working in dust intensive conditions, please observe the special regulations for filter change.

To clean the magnetic rod or replace the filter element: The pressure in the hydraulic system must be relieved.

Unscrew the four screws on the filter cover and lift out the cover 1 and magnetic rod 5.

Carefully clean the magnetic rod to remove any dirt particles.

Remove the used filter cartridge 5 using the bracket.

Vertically insert the new filter cartridge into the tank, using the bracket and press down lightly. Then place the bracket on the side on the tank ring.

Caution!

Ensure that the filter cartridge is vertically positioned in the tank.

Center the cover unit and bypass cage 4 on the filter element 6 and set it on top.

When doing this, ensure that the gasket 3 is positioned correctly and is in good condition.

Note!

The filling hole of the hydraulic tank is equipped with a protective cylinder 7. This prevents objects from getting into the hydraulic tank. The protective cylinder can be removed from the filling hole, if required.

Note!

Each time you replace the filter element 6, also replace the pressure filter integrated in the servo oil unit.

5.9.5

Servo oil filter The pressure filter 10 is part of the servo oil unit 1 which is located on the rear of the hydraulic tank.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Maintenance Hydraulic system

Fig. 5-31

Servo oil unit

1

Servo oil unit

12

Filter element

2 10

Mounting stud Pressure accumulator

13 14

Filter element seal ring Filter housing

11

Pressure filter

15

Filter housing seal ring

Note!

It is not permitted to clean the filter element.

Change the filter element each time the filter housing is opened.

To replace the filter element: The pressure in the hydraulic system must be relieved.

Unscrew the filter housing 14 from pressure filter 11 and remove filter element 12.

Clean the filter housing.

Oil the thread and sealing surfaces on filter housing 14 and on servo oil unit 1 as well as seal rings 13 and 15 with hydraulic oil.

Push the filter element 12 carefully onto the mounting stud 2.

Screw filter housing 14 on completely and tighten by hand.

Note!

When replacing the filter element 12, also replace the filter element seal ring 13.

5.9.6

Servo circuit The joysticks do not require special maintenance.

Inspect the pipe network as well as connections on all components (pressure accumulator, pressure limiting valve, pressure filter etc.) regularly for leaks.

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5 - 37

Maintenance

Operating instructions

Hydraulic system

Danger!

The pressure accumulator 10 (see Fig. 5-31) ensures that the servo circuit has enough pressure for a few movements, even after the Diesel engine has been shut down.

Before working on the servo circuit, the control pressure must be relieved as follows: Place the attachment on the ground.

Shut down the engine.

Operate both joysticks (with ignition key in contact position).

5.9.7

Bleeding the hydraulic pump

Fig. 5-32

Hydraulic pump

After working on the pump or after changing oil in the hydraulic system, the hydraulic pump must be bled.

Loosen the fitting of the leak oil hose 1 slightly and allow the air to escape.

When hydraulic oil flows out, retighten the fitting.

Before using the pump for the first time or after repairs or replacement, the pump housing must be filled with hydraulic oil via the same connection.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Maintenance Hydraulic system

5.9.8

Servicing the hydraulic cylinder

5.9.8.1

Checking the piston rod bearing

Fig. 5-33

Piston rod bearing

Note When a leak occurs on the piston rod bearing of a hydraulic cylinder (arrow), then the seal kit must be replaced by a LIEBHERR mechanic.

5.9.8.2

Protecting the piston rods

Fig. 5-34

Machine with piston rods retracted

When the machine is out of service for more than 4 weeks and particularly for transport by sea, the following measures must be taken: Position or transport the machine in such a way that the piston rods are fully retracted.

Cover any exposed piston rods with a thick layer of acid free anti-corrosion grease.

For sea transport, check the preservation of the piston rods again after loading.

Cover piston rods with anti-corrosion grease also if a cylinder is used with a low stroke for certain applications, and the piston rod is not regularly covered with hydraulic oil (e.g. cylinder on basic boom when working above ground).

Regularly check the condition of little moved hydraulic cylinders.

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5 - 39

Maintenance

Operating instructions

Changing the oil on components

5.9.9

Replacing hydraulic hoses

Fig. 5-35

High pressure hose with SAE fitting

Danger!

A defective hydraulic hose can cause accidents and injuries.

Replace defective hydraulic hoses (bubbles, moisture, damaged top edge etc.) immediately.

Install new hydraulic hoses without torsion.

Ensure that the hydraulic hose is not twisted when mounting.

Installed high pressure hoses with SAE connections have a nominal diameter of 16, 20 or 25.

Tighten the mounting screws of SAE fittings with the following tightening torques. :

Screw

Grade

Torque

M10

10.9

68 Nm

M12

10.9

117 Nm

M14

10.9

185 Nm

Tab. 5-6

Tightening torques for SAE fittings

5.10 Changing the oil on components 5.10.1

General notes The machine must be in level position.

Shut down the engine.

Wait for a short time until the oil has collected in the oil pan.

If possible, drain the oil when it is at operating temperature.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Maintenance Changing the oil on components

5.10.2

Swin gear - oil change

Fig. 5-36

Changing the oil on the swing gear

1

Drain valve

3

Oil container

2

Drain hose

4

Cap

To drain the oil: Remove the cap 4.

Unscrew the cover of the drain valve 1 via the opening on the base plate of the swing platform.

Screw the provided drain hose 2 on the drain valve and allow the oil to flow into a suitable container.

Remove the hose 2.

Reinstall the cover of the drain valve 1.

To add the oil: Add the oil via the tank 3 until the level reaches the MAX mark.

Reinstall cover 4.

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Maintenance

Operating instructions

Changing the oil on components

5.10.3

Transmission - oil change

Fig. 5-37 1

Changing the oil in the transmission

Oil drain plug

2

Oil filling and oil filler plug

To drain the oil: Remove the oil filler plug 2.

Remove the oil drain plug 1.

Drain the oil into a suitable container.

Install the oil drain plug 1.

To add the oil: Add the oil until the oil level reaches bore 2.

Install the oil filler plug 2.

5.10.4

Steering and rigid axle - oil change

Fig. 5-38

Changing the oil on the steering axle and rigid axle

1

Oil drain plug

3

Oil level monitor

2

Oil filler plug

To drain the oil: Remove oil filler plug 2 and oil drain plug 1.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Maintenance

Drain the oil into a suitable container.

To add the oil: Screw in oil drain plug 1.

Remove plug 3.

Add the oil until the oil level reaches bore 3.

Screw in oil filler plug 2 and plug 3.

5.10.5

Steering axle, wheel head - oil change The steering axle and its wheel heads have the same oil circuit.

The oil is changed centrally (on the axle itself).

The steering axle and its wheel heads have the separate oil circuit.

As a result, the oil in the wheel heads of the steering axle must be changed separately.

Fig. 5-39

Changing the oil on the wheel head (draining the oil, Fig. left, adding the oil, Fig. right)

To drain the oil: Turn the wheel head until the plug is located exactly vertically beneath the center of the wheel.

Remove the plug and drain the oil to flow into a suitable container.

Reinstall the plug.

To add the oil: Turn the wheel head until the level mark line is exactly horizontal.

Add the oil up to the bottom edge of the bore.

Reinstall the plug.

Check the wear on the multi-disk brake at least once a year.

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5 - 43

Maintenance

Operating instructions

Electrical system

The wear on the multi-disk brake can be checked without removing the planetary carrier or disks (see Service manual).

Check brake wear also in case of the following problems:

5.12 Electrical system 5.12.1

Notes for electrical system Danger!

Danger of injury due to spark formation.

Avoid sparks and open flame when charging batteries or working on the batteries.

Always wear safety glasses and protective gloves. correct function at regular intervals.

Burnt out fuses and bulbs must be replaced immediately after the cause of the defect has been rectified.

Fix any problems, such as loose connections, chaffed wires or incorrectly attached clamps immediately.

Disconnect the batteries when working on the electrical system or when carrying out electric arc welding on the machine.

Danger!

Danger of injury due to spark formation.

Disconnect the negative terminal (-) first and connect it last.

5.12.2

Battery master switch Caution!

Be especially careful with machines with built-in auxiliary heater.

Turn the battery master switch only off when the auxiliary heater's after-run is completed.

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MJFCIFSS

A 312 Litronic / 10443914

Operating instructions

Maintenance Electrical system

Fig. 5-40

Battery master switch

Before starting any work on the electrical system, including welding work on the machine, switch the battery master switch to position 0.

When washing the machine, cover the electrical components (particularly the alternator, generator, wiring, electronic components and transmitters) to prevent moisture penetrating.

When cleaning the engine with a water / steam jet, do not hit electric sensors such as oil pressure switches directly with water or steam.

Otherwise moisture could penetrate and lead to contact corrosion and the failure of the transmitters.

Oil pressure switches are not watertight due to the necessary membrane ventilation.

Note!

Battery can discharge if the machine is out of service for longer periods of time.

Before a longer down time, switch the battery master switch to position 0 (off).

5.12.3

Battery care The battery must always be kept clean to ensure proper function.

Especially the pole ends and battery terminals A must be cleaned regularly and then covered with a thick layer of acid free grease (see Fig. 5-41).

Danger!

Bent rubber hoses of central degasification increase the risk of explosion!

The hydrogen created in the batteries may not be allowed to build up in the battery compartment and must be able to escape through the rubber hoses. The hoses of the central degasification must be routed without kinks.

Check the condition of the hoses B regularly, especially after installing a battery (see Fig. 5-41).

The fluid level in the cells should be 10 to 15 mm above the top of the plate. Use only distilled water when refilling.

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5 - 45

Maintenance

Operating instructions

Electrical system

Fig. 5-41

Battery care

From time to time, use an acid tester C to measure the acid concentration.

When the battery is fully charged, the unit weight is 1.28 kg/l (31.5° Bé).

If the acid tester displays a lower value, then the battery is more or less discharged and must be recharged, if necessary.

5.12.4

Slip ring assembly (option)

Fig. 5-42

Slip ring assembly

Slip ring assemblies are sensitive to moisture. An oxide layer can form on the conductive surfaces, which restricts the flow of current. Electrical users in the undercarriage will no longer be supplied sufficiently with current, which can lead to malfunctions.

To prevent this, it is recommended that the following work is carried out every 500 operating hours.

Unscrew the lock nuts 1.

Remove the slip ring housing 2.

Clean the oxidation off the slip ring assembly (use a cleaning spray if necessary).

Replace damaged (corroded) wire lugs.

Spray "Cramolin" contact spray on all slip ring elements.

Replace the housing 1.

Fasten the housing 1 evenly with lock nuts 2.

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A 312 Litronic / 10443914

Operating instructions

Maintenance Heating system / heating and air conditioning system (option)

5.13 Heating system / heating and air conditioning system (option) 5.13.1

Fresh air filter

Fig. 5-43

Fresh air filter

The air flow in the heating and air conditioning system is reduced when the fresh air filter is dirty, which frequently results in the system icing up or shutting down. rking in dust intensive conditions. without these filters, since the heat exchanger will be blocked quickly.

Remove the reservoir of the windshield washing fluid and deflector 2.

Remove the fresh air filter 1.

Note!

Never wash the filter elements with hot water or a steam jet.

If damaged or in a bad condition, replace the filter elements.

Blow out the fresh air filter 1 with compressed air or clean in cold or luke warm water.

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Maintenance

Operating instructions

Heating system / heating and air conditioning system (option)

5.13.2

Heating system

Fig. 5-44

Water taps on the Diesel engine

If the heater remains off for an extended period of time (e.g. in summer), the water taps (see arrows) on the Diesel engine should be closed.

Carry out the following maintenance work on the heating system annually before the start of the heating period: oolant circuit, the hose connections on the heat exchanger, the seals on the shut off valves and the hose clamps. anti corrosion fluid and antifreeze in the coolant.

Fig. 5-45

Heating / air conditioning unit

To check the heat exchanger / evaporator: Check the fins on the heat exchanger 1 and evaporator 2 (air conditioning system) annually for damage.

Blow out with compressed air if dirty.

Align the fins, if necessary.

5.13.3

Air conditioning system (option) Switch on the air conditioning system for approx. 10 minutes every 2 or 3 weeks, regardless of the season.

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Operating instructions

Maintenance Heating system / heating and air conditioning system (option)

During the operating period, the following maintenance work must be carried out every 500 operating hours:

Fig. 5-46

Condenser

To check the condenser: If heavily contaminated, overpressure forms in the air conditioning circuit and the air conditioning system turns off automatically.

Remove cover 1.

Check the condenser 2 for contamination.

If necessary, blow out the condensor 3 with compressed air from the front through the mesh guard 4 of the fan motors. Remove the fan motors, if necessary.

Make sure that the condenser fins are clean.

To check the A/C compressor:

Fig. 5-47

A/C compressor

Tighten the mounting screws of the A/C compressor (see arrow) and retainer on the Diesel engine.

Check the condition of the compressor V-belt.

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Maintenance

Operating instructions

Heating system / heating and air conditioning system (option)

Fig. 5-48

Dryer-accumulator unit

To check the dryer-accumulator unit: With the Diesel engine running and the air conditioning system turned on, check the refrigerant level in the sight gauge a of the dryer accumulator unit 5.

Note!

If there is insufficient refrigerant, the white floater ball 6 is at the bottom of the sight gauge.

If the cooling effect is diminishing, have the system refilled by a refrigeration technician.

Determine the degree of moisture of the desiccant in dryer accumulator unit 5.

To do this, check the color of the indicator pearl 7 in the sight gauge a.

If the pearl is blue, the degree of moisture in the air conditioning circuit is OK. If, however, the pearl is pink, then the dryer-accumulator unit is saturated with moisture.

Change dryer-accumulator unit 5 immediately.

Check the condition of the of dryer accumulator unit visually.

If you notice that the refrigerant collector is rusty or damaged (e. g. on the panel mounting, on the hose connection), replace the refrigerant collector (pressure tank).

In the last two cases and at least once a year, the dryer-accumulator unit 5 must be replaced by a technician trained in air conditioning systems.

The A/C circuit must be emptied, checked for leaks and refilled. Check the hose lines for abrasion, replace and, if necessary, retighten the hose connections.

Fig. 5-49

Fan motor on the heating /air-conditioning unit

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A 312 Litronic / 10443914

Operating instructions

Maintenance Lubricating the machine

Additional maintenance work: The following maintenance work must also be carried out at least once a year by a technician trained in air conditioning systems: Check the function of the fan motor M65.

Check the function of the air flaps in the heating / air-conditioning system.

Check the electrical connections for tight seating (good contact).

Check the electrical lines for abrasions.

Check the defrost thermostat B295 (for function, correct positioning and for damage).

Check the function of the pressure switch B294 on the dryer-accumulator unit 9 (see Fig. 5-48).

5.14 Lubricating the machine Note!

When lubricating the machine with a manual grease gun, the required effort is reduced significantly if the grease is pumped in slowly.

5.14.1

Lubricating the swing gear

Fig. 5-50

Central lubrication, swing race / gears

Lubrication is carried out at the grease bar. The grease bar is located under the swing platform. Lubrication must be carried out daily in multi-shift operation.

To grease the swing race a, use the manual grease gun to pump two strokes of grease into grease fittings 1 and 2.

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Maintenance

Operating instructions

Lubricating the machine .

Fig. 5-51

Pinion on swing gear

A housing (see arrow) which surrounds the swing gear pinion provides a virtually sealed grease reserve for gear lubrication on the swing ring. Lubrication ensures partial replacement of this reserve.

For partial replacement of the grease reserve, pump 20 strokes of grease into grease fitting 3 with the manual grease gun.

5.14.2

Lubricating the attachment Each lube point on the attachment must be lubricated every 10 to 50 operating hours (depending on use and multi-shift, daily or for each shift).

5.14.3

Lubricating the axles Lubricating the steering knuckle bearings:

Fig. 5-52

Lube points of steering knuckle bearing

Caution!

Do not use too much grease on the steering knuckle bearings.

Grease each bearing point with two strokes.

Grease the bearing points via the grease fittings with a manual grease gun.

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A 312 Litronic / 10443914

Operating instructions

Maintenance Lubricating the machine

Lubricating the oscillating bearing: The bearing of the oscillating axle has two lube points.

Fig. 5-53

Lube points of oscillating bearing

Use a manual grease gun to grease the oscillating bearing via the grease fitting, until clean grease emerges on the bearing points.

5.14.4

Lubricating the digging tool / bucket tilt device The lubrication points on the digging tool or change over lever / connector link must be lubricated regularly. The corresponding lube points are marked in red.

Fig. 5-54

Lubrication of digging tool

In normal use, each lube point must be greased weekly until clean grease emerges on the corresponding bearing point.

In severe applications, for example when handling material that causes wear, when working under water or in multiple shifts, the lubrication must be made daily or for each shift.

5.14.5

Lubricating the grapple (option) The grapple must be lubricated regularly. The corresponding lube points are marked in red.

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Maintenance

Operating instructions

Quick change systems (option)

Fig. 5-55

Lubrication of grapple

In normal use, each lube point must be greased daily or per shift until clean grease emerges on the corresponding bearing point.

In severe applications, the lubrication interval should be shorted accordingly.

5.15 Quick change systems (option) 5.15.1

Lubricate the mechanical quick change adapter The mechanical quick change adapter is not lubricated via the central lubrication system. The bearing points must be greased using the grease gun.

Fig. 5-56

Lubrication of mechanical quick change adapter

Grease the bearing points via the grease fitting with a grease gun.

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A 312 Litronic / 10443914

Operating instructions

Maintenance Quick change systems (option)

Note!

If the mechanical quick change adapter is greased when the pin is extended, the hollow area between the locking pins fills with grease and the pins can no longer be retracted.

Make sure that the locking pins are retracted during the lubrication procedure.

5.15.2

Hydraulic quick change adapter Lubricating the quick change adapter: The hydraulic quick change adapter is not greased via the central lubrication system.

The bearing points must be greased using the grease gun.

Fig. 5-57

Lubricating the quick change adapter

Grease the locking pins 1 via the grease fitting with a grease gun.

Note!

The hydraulic quick change adapter cannot be sufficiently greased if the locking pins are extended.

Make sure that the locking pins are retracted during the lubrication procedure.

Cleaning the strainer:

Fig. 5-58

Cleaning the strainer

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Maintenance

Operating instructions

Quick change systems (option)

The filter disc 12 in the fittings between the connecting hoses and the hydraulic cylinder must be checked for blockages and cleaned, if necessary, every 2000 operating hours.

Remove the cover 20 and the screws 21 from the quick change adapter.

Remove the fittings and hydraulic hoses from the hydraulic cylinder 10.

Screw out the outer mounting assembly 13 using a suitable tool (e g. a tack).

Remove the filter disc 12, check it and clean or replace it, if necessary.

Place the filter disc 12 on the inner mounting assembly 11 and mount the outer mounting assembly 13.

Connect the fittings and hydraulic hoses to hydraulic cylinder 10.

Attach the cover 20 with the screws 21 on the quick change adapter.

5.15.3

Hydraulic coupling

Fig. 5-59

Hydraulic coupling plug

The LIKUFIX hydraulic coupling system and the multi-coupling system are equipped with hydraulic coupling plugs (see arrows).

The coupling plugs are maintenance-free. We recommend cleaning the system regularly. This prevents caking of dirt and icing up in winter. With regular cleaning, the seals of the system have a long service life.

Cleaning: Remove dirt and clean all coupling parts and sealing surfaces with a clean cloth and oil.

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A 312 Litronic / 10443914

Operating instructions

Maintenance Quick change systems (option)

Changing seal ring:

Fig. 5-60

Changing seal ring

Caution!

The hydraulic lines are under pressure.

Before changing the seal ring, depressurise the system using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick).

In the event of leakage at the coupling plugs (A), change the seal rings.

Hold down the seal washer of the coupling plug with a screwdriver and lever out the defective seal ring using a pointed tool (B).

Squeeze the new seal ring and place it with its open side facing downwards onto the seal washer (C).

Push the washer into the groove, place the screwdriver onto the centre of the seal ring and remove your hand (D).

Let the seal ring expand into the groove (E).

Remove the screwdriver (F).

The seal washer must move upwards.

If this is not the case, push the seal ring into the groove until the seal washer can move.

5.15.4

LIKUFIX electric coupling The LIKUFIX hydraulic coupling system is equipped with an additional electric coupling (e.g. for the operation of a magnet system). This coupling must be regularly inspected and cleaned.

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Maintenance

Operating instructions

Parking and swing gear brake

Fig. 5-61 1

Electric couplings

Electric coupling top section

2

Electric coupling bottom section

Switch off the magnet system (if installed).

Remove the working tool, if required.

Switch off the diesel engine.

Check the contacts for corrosion and wear (e.g. burn marks).

Clean the contacts of the electric couplings 1 and 2 with a dry cloth and apply contact spray (Cramolin), if necessary.

Check the electric couplings and the screwed connections for proper fixture.

Check the contacts of the top section 1 for play: it must be possible to push in the contacts against the spring force.

Check whether the seals at the contacts of the electric couplings (see arrows) are properly installed and undamaged.

Repair any damage and replace defective parts.

5.16 Parking and swing gear brake Both the parking brake on the transmission and the swing gear brake are negative acting, wet multi-disk brakes.

They are vented hydraulically and are fully sealed and integrated in the transmission or swing gear.

Their usage purely as parking brakes makes them wear-free and therefore maintenance free.

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Operating instructions

Maintenance General Maintenance points

5.17 General Maintenance points 5.17.1

Replacing wear parts In addition to the normal maintenance and service work, which have to be carried out in the given intervals, the following repairs can also be made by the machine operator or maintenance personnel: the pipe and hose system and on connections of hydraulic components (but not on pressure relief valves which are sealed with a lead seal at the factory). system can be replaced.

It should be noted that only original LIEBHERR spare parts are to be used.

This is particularly true for hoses and hydraulic lines, which must be preassembled at the factory. For all other repairs, particularly when removing the counterweight, factory or dealer mechanics must be consulted.

5.17.2

Replacing the teeth on the digging tool Determine the degree of wear of the teeth visually.

With heavily worn teeth, considerably greater force will be required for the digging tool to penetrate the digging material. The teeth must be replaced in time to prevent damage to the tooth adapter.

Do not work with the machine if teeth on the digging tool are missing or are heavily worn.

To attach and remove teeth with wedge retainers:

Fig. 5-62

Replacing the teeth

Use a hammer and driver 1 to knock out the wedge 2 (A ).

Remove the old tooth.

Place a new rubber wedge retainer 3 on the tooth retainer (B).

Push the new tooth on the adapter.

Use the hammer to knock in the wedge 2 (C).

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Maintenance

Operating instructions

Inspection and maintenance plan

To attach and remove teeth with tension pin retainer:

Use a hammer and driver 1 to knock out the tension pin 2 (A).

Remove the old tooth.

Push the new tooth onto the adapter (B).

Knock in the tension pin 2 with the hammer (C).

5.17.3

Welding work on the machine Welding work on all main components serving for power transmission (such as the undercarriage frame, swing platform, attachment parts etc.) may only be carried out by the manufacturer or by an authorized workshop.

Disconnect the battery before starting any electric arc welding work on the machine.

Always disconnect the negative terminal (-) first and reconnect it last.

Turn the battery master switch off!

Caution!

If high currents flow through the bearings or sealing elements, they could be burnt.

Move the grounding cable of the welding tool as close as possible to the welding area, so that the welding current cannot flow over parts, such as the swing ring, joints, bearings, bushings, rubber elements or seals.

5.18 Inspection and maintenance plan Caution!

Careful maintenance can only be carried out when the machine is clean. In particular, visual checks such as crack testing are only possible on a clean machine.

Clean the machine before you start maintenance work (see also the chapter

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Operating instructions

Maintenance Inspection and maintenance plan

Note!

The daily maintenance work carried out by the equipment operator comprises a functional check of the brakes (slewing gear brake, service brake and parking brake), steering and the electrical and hydraulic systems.

In addition, a daily inspection must be performed to check for leaks from the engine, hydraulic system, transmission and axles.

Maintenance / inspection during operating hours

WORK TO BE CARRIED OUT A 312 / A 314 / A 316 Litronic by maintenance personnel (machine operator)

by authorized specialist personnel

first and only interval repeat interval special interval every 250 hours

Note

first and only interval repeat interval

DIESEL ENGINE Check oil level and oil pressure in engine Check coolant level and coolant temperature Check air filter on maintenance display Check and drain water separator on fuel filter Drain off water and sediment in fuel tank Empty dust collection container on air filter (shorten or extend interval as required) Check and clean cooler, pressure relief valve, coolant hose, ventilator Replace lubricating oil filter cartridge Replace engine oil

1)

Check oil-, cooling- and fuel system for leaks and its overall condition Replace water filter cartridge (at least 1 x yearly) Check and set engine speed adjustment Check anti-corrosion fluid / antifreeze in coolant (replace coolant every 2 years) Check condition and tension (using a testing device at operating temperature) of the V-belt (replace every 2 years) Check / adjust valve play, replace valve cover seal Check engine bracket and oil sump mounts, clamps etc.

Check flexible fuel leakage oil line (change at least every 2 years) Check intake and exhaust system for leaks and verify its overall condition Replace fuel fine filter cartridge (or as required)

4)

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Maintenance

Operating instructions

Inspection and maintenance plan

Maintenance / inspection during operating hours

WORK TO BE CARRIED OUT A 312 / A 314 / A 316 Litronic by maintenance personnel (machine operator)

by authorized specialist personnel

first and only interval repeat interval special interval every 250 hours

Note

first and only interval repeat interval

Replace preliminary fuel filter cartridge (or as required)

4)

Replace main air filter element (according to maintenance display / annually) Replace air filter safety element (every third change of main element / annually)

Never clean!

Check clean-air line (during filter maintenance) Check / adjust injection valves every 3000 op. hours (when performance diminishes) HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod in return-line filter (daily during first 300 op. hours) Replace filter insert in return-line filter (first time at 500 op. hours)

2)

Replace filter element in bypass flow filter (every 250 op. hours for dust intensive applications) Replace filter insert on control oil unit Check component mounts Clean hydraulic oil cooler (and as required) Drain off water in hydraulic tank (when using environmentally-friendly fluids, max. 0.1 % water content permitted, insert bypass flow filter, take oil sample) Check hydraulic system for leaks and its corrent function Check / adjust servo pressures, secondary pressures and pressure cut-off Replace hydraulic oil in tank (or optimise interval using oil analyses)

2), 3)

Replace ventilation and vent filters on hydraulic tank

2)

ELECTRICAL SYSTEM Check indicator lights and display devices when switching on Check lighting Check acid concentration and level, cable terminals and terminal posts on batteries, as well as all plug connections Spray slip rings on slewing gear connection (if present) with Cramolin contact spray

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A 312 Litronic / 10443914

Operating instructions

Maintenance Inspection and maintenance plan

Maintenance / inspection during operating hours

WORK TO BE CARRIED OUT A 312 / A 314 / A 316 Litronic by maintenance personnel (machine operator)

by authorized specialist personnel

first and only interval repeat interval special interval every 250 hours

Note

first and only interval repeat interval

Check function of entire system and its components SLEWING GEAR TRANSMISSION Check oil level and tightness against leaks Check function and operation of slewing gear brake Check transmission and oil motor mounts Replace transmission oil (first time at 500 op. hours) SLEWING RIM Renew lubrication on gearing Renew lubrication on ball race Check if mounting screws are tight and check contact of slewing gear pinion AXLE TRANSMISSION Check oil level and tightness against leaks Check function of gear change and parking brake Check transmission, oil motor and drive shaft mounts Replace transmission oil (first time at 500 op. hours) AXLES Check oil level and tightness against leaks. Also check that wheel nuts are tight.

Check axle mounts Lubricate steering knuckle bearings (weekly / monthly according to use) Lubricate oscillating axle bearing (weekly / monthly according to use) Replace oil from axle housing and planetary drive, front and rear (first time at 500 op. hours) Check wear on multi-disc brake (1 x yearly or as required) STEERING Check function and tightness against leaks

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Maintenance

Operating instructions

Inspection and maintenance plan

Maintenance / inspection during operating hours

WORK TO BE CARRIED OUT A 312 / A 314 / A 316 Litronic by maintenance personnel (machine operator)

by authorized specialist personnel

first and only interval repeat interval special interval every 250 hours

Note

first and only interval repeat interval

Check component and steering part mounts OSCILLATING AXLE SUPPORT Check function and tightness against leaks Check cylinder mounts BRAKE SYSTEM Check system for leaks Check function and operation Check accumulator pressure and brake pressure as well as monitoring switches CAB + HEATING Check / refill washing fluid in windscreen washer system container Check heating function (before start of winter) Check heating system for leaks Check door and window hinges and locks Check function of water inlet valve. Check for dirt and clean if necessary AIR-CONDITIONING SYSTEM Regularly switch on air-conditioning system (at least 1 x every two weeks) Check condenser for contamination, blow out if required Check mounting screws and compressor drive belt Check dryer-collector unit (moisture, filling and condition), replace if required (at least every 2 years) Clean fresh air filter (at least 1 x monthly, weekly for dust intensive appliations) Replace fresh air filter (shorten change interval for dust-intensive applications) Check air-conditioning system mounting, hose connections and electrical contacts (at least 1 x yearly)

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A 312 Litronic / 10443914

Operating instructions

Maintenance Inspection and maintenance plan

Maintenance / inspection during operating hours

WORK TO BE CARRIED OUT A 312 / A 314 / A 316 Litronic by maintenance personnel (machine operator)

by authorized specialist personnel

first and only interval repeat interval special interval every 250 hours

Note

first and only interval repeat interval

UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENT Lubricate bearing points on working attachment Visually check wear condition of teeth Lubricate bearing points on undercarriage (depending on use; daily for multiple shift operation) Check parts for cracks Check ballast weight and tank mounts Check that line and screw connections are tight Check trim panel hinges, quick-release fasteners and gas pressure springs on hatches Indicate appropriate use of equipment Have device lubricated according to lubrication chart and checked for operating errors by machine operator.

HYDRAULIC QUICK-CHANGE ADAPTER Check function of visual and acoustic warning devices Visually check extended position of locking pins Check condition of hydraulic hoses and cable kit Lubricate locking pins Cleaning the sieve filter MECHANICAL QUICK-CHANGE ADAPTER Visually check extended position of locking pins Lubricate locking pins Tab. 5-7 1 2 3 4

Inspection and maintenance plan

Engine oil change intervals can be shortened depending on temperature, fuel and oil quality.

Observe shortened maintenance intervals in dust intensive application.

When using environmentally friendly hydraulic fluids, the maintenance interval is to be determined by regular analysis.

Shorten the maintenance interval depending on the application (e.g. dust intensive application, barrel refuelling).

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