Liebherr A 904 C Litronic A 904 C HD Litronic 1071 1004 Machine for Industrial Operating Manual PDF

en

Operating manual Machine for Industrial Applications A 904 C Litronic / A 904 C HD Litronic from serial number 57189

Document identification ORIGINAL OPERATING MANUAL

Id. number:

11140229

Edition:

06 / 2014

Valid for:

A 904 C Litronic / A 904 C HD Litronic from serial number 571879

Author:

LHB -Technical documentation department

Product identification Manufacturer:

LIEBHERR Hydraulikbagger GmbH

Type:

A 904 C Litronic / A 904 C HD Litronic

Type no.:

1071 / 1004

Conformity:

CE

....

0 C"II

--

8 i::::

0 :;::,

;

Address Liebherr Hydraulikbagger GmbH

~

Liebherr-StraBe 12

....I

D - 88457 Kirchdorf / Iller

J:

Machine data

Vehicle Id. No.:

Year of manufacture:

Delivery date:

MJFCIFSS

Introduction

machine operators maintenance personnel

The operating manual is an integral part of the scope of delivery of the machine. Ensure that a copy is at all times available in the storage compartment in the operator's cab.

Machine operation Maintenance Transport

Warranty and liability

MJFCIFSS

1-1

Amendments, general terms and conditions, copyright

1-2

MJFCIFSS

Table of contents 1

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

2

Safety notes, signs ........................................................................................................................................ 2-1

3

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

MJFCIFSS

4

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

MJFCIFSS

5

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

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

1 Product description 1.1 Design and overview 1.1.1

General overview

Fig. 1-1

General overview

1

2

3

4

5

6

7

1-1

1.1.2

Uppercarriage

Fig. 1-2

1-2

Uppercarriage

1 3

2 4

5 7

6 8

9 11

10

1.1.3

Undercarriage

Fig. 1-3

Undercarriage

1

2

3 5

4 6

7

8

9

1-3

1.2 Vibration emissions

Hand-arm vibration

Whole-body vibration

Weighted effective vibration in m/s² at operating conditions "light-duty" (1), "normal" (2) and "heavy-duty" (3) Machine type

Typical working cycles

x-axis 1

1-4

y-axis 2

3

1

z-axis 2

3

1

2

3

1.3 Sound emission

1-5

1.4 EC Declaration of Conformity

Fig. 1-4

1-6

Sample EC Declaration of Conformity (from year of manufacture 2010)

1.5 Technical data

1-7

1-8

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˜

˜

˜ ˜

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•• —

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•• •• •• ••

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p t t p p p t t p p t p p

t p p p p t t p t p t p p

p p p p p p p p p p t t t t

p p p t p p

p p p p p t p t p p t t p p p t p t t t p t p p t t t p t p p t

p p t p t t p t t p p p t t t t t t p

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Š”Ÿv

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Š”Ÿv Ÿ”ž Š”žv Ÿ”Ÿ

Ÿ”Šv Ÿ”žv

Ÿ”žv

–”ƒ

–”Ÿv

Ÿ”Ÿv

–”¡

–”–v ƒ”Š –”Šv ƒ”Ÿ –”Ÿv

Ÿ”Ÿv

Ÿ”Šv Ÿ”Šv ƒ”ž

˜ ˜˜

Š”¡ –”ž Š”žv ¡¡”Š ¡Ÿ”žv ¡Ÿ”žv ¡Ÿ”žv

ž”– Š”ž ¡¡”Ÿv ¡¡”Ÿv

ƒ”– ž”ƒ ƒ”ƒ

Ÿ”¡ ž”Ÿv Ÿ”Š

Š”Ÿv Š”žv

Š”Ÿv –”ž Š”žv

–”Šv –”Šv

–”Šv –”Šv

ƒ”¡ Š”Š ƒ”¡

¡”Ÿ ƒ”Ÿ

ƒ”žv

¡”ž Š”Šv

Ÿ”– Ÿ”¡v

ƒ”ƒ Ÿ”¡v

¡”ž ƒ”Šv

ƒ”Šv

¡”Š ƒ”Š ¡”Ÿ ƒ”Ÿ ¡”Ÿ ƒ”Ÿ ¡”Ÿ ƒ”ƒv ¡”ž ƒ”Ÿv

ƒ”žv ƒ”ƒv ƒ”Ÿv

Ÿ”¡ Ÿ”ƒv

Ÿ”ƒv Ÿ”ƒv

ƒ”žv ¡”ž ƒ”–v ¡”Ÿ ƒ”Ÿ

ƒ”žv

ƒ”¡ –”–v –”žv

–”– ¡–”– ¡–”Šv ¡–”Šv

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ž”ƒ

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Š”–v ƒ”ž ž”¡v ž”¡ ƒ”¡ Š”Š

–”–v –”ƒ –”žv

ƒ”¡ –”¡v

–”¡v

Ÿ”Š

–”ƒv ƒ”ž –”Ÿv ƒ”Ÿ –”–v

Ÿ”Š Š”–v Ÿ”ƒ ž”¡v

ƒ”¡ Ÿ”ƒv ƒ”¡ Ÿ”ƒv

Ÿ”ƒv

¡”– ƒ”– ¡”– ƒ”– ¡”Ÿ ƒ”Ÿ ¡”Ÿ ƒ”Ÿ

ž”¡v

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ƒ”¡v ¡”ž ƒ”Šv

ƒ”Šv

˜

s

–

ƒ

Š”¡v Š”¡v Š”¡ ž”žv

Š”¡v Š”¡v

ž”žv ž”žv ƒ”ƒ Š”ƒv

–”– ¡–”– ¡–”–v ¡–”–v

ž”ƒ Ÿ”¡

Š”Šv ƒ”ž ž”¡v ƒ”Ÿ ž”¡ ƒ”¡ Š”Š

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Ÿ”Š Š”Šv Ÿ”ƒ ž”¡v Ÿ”ž

ƒ”ž –”Ÿv ƒ”– –”–v

Ÿ”ƒv

¡”– ƒ”Š ¡”Ÿ

¡”Ÿ ƒ”Ÿ ¡”Ÿ ƒ”Ÿ

¡”ž Ÿ”Ÿ

¡”ƒ Ÿ”¡v

ƒ”Ÿv

¡”Š –”¡v

Š”¡v Š”¡v

Š”¡v Š”¡v

Ÿ”–v

¡”Š ƒ”žv

–”¡v

ƒ”žv

ž”Ÿv ž”Ÿv Š”Šv ƒ”– ž”¡v

Ÿ”Ÿ ¡”¡v ¡”¡v ¡”žv ¡”žv

¡”¡v ¡”¡v ¡”žv ¡”žv

Ÿ”– Š”Šv Ÿ”¡ ž”¡v

–”¡v –”¡v

–”¡v

–”¡v

–”¡

–”ƒv ƒ”Š

Ÿ”ƒv Ÿ”ƒv

¡”– ƒ”– ¡”– ƒ”– ¡”– ƒ”– ¡”Ÿ ƒ”Ÿ

Š”žv Š”žv

ƒ”Šv ¡”– ƒ”Ÿ

ƒ”Šv

Š”žv Ÿ”ƒ

–”¡v ƒ”¡ Ÿ”Ÿv ƒ”¡

¡”– ¡”–

¡”¡ ¡”¡

Ÿ”– ¡”Š

Š”Ÿ

Š”žv Š”žv

– ˜–

ƒ”¡

¡”ž Š”ž –”¡v

ƒ”¡v

Ÿ”–v

–”ƒ –”žv

ƒ”¡ Š”¡ ž”Ÿv

¡”Ÿ ƒ”¡v

Ÿ”–v Ÿ”–v ƒ”¡ Ÿ”–v

–”žv

¡”ƒ

¡”ƒ ƒ”ƒ ¡”ƒ

¡”Š ƒ”¡v

¡”¡ ¡”¡

ƒ”Ÿv ƒ”Ÿv ¡”ž ƒ”Ÿv ¡”Š ¡”Š ƒ”¡v ¡”Š ¡”ž

¡”– ƒ”ƒv

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s

–

ž”¡v

ž”¡v ž”¡v –”¡

ž”Ÿv –”–

ž”Ÿv ž”Ÿv Š”Šv

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ƒ”¡ Ÿ”Šv ƒ”¡ –”ƒv

ƒ”ž Ÿ”Šv — ˜—

–”ƒv

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ž”ƒv Ÿ”¡ ž”Šv

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ž”Ÿv

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–”Šv ƒ”Š –”žv ƒ”– –”–v ƒ”–

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–”ƒv –”ƒv

ƒ”ƒ

–”ƒv

¡–”Ÿ Š”Š ¡¡”žv ¡¡”žv Ÿ”¡ ¡¡”Ÿv ¡¡”Ÿv

ž”ƒv ƒ”Š ž”ƒ ƒ”Ÿ

ž”ƒv

Ÿ”–v Ÿ”–v Ÿ”žv Ÿ”žv

Ÿ”– ¡¡”ƒv ¡¡”ƒv Ÿ”–v Ÿ”¡ Ÿ”–v ¡¡”Šv ¡¡”Šv Ÿ”žv Š”¡ Ÿ”žv Š”¡

Ÿ”žv ƒ”¡ –”¡v Š”Šv ƒ”ž ž”ƒv ƒ”Ÿ ž”¡ ƒ”ƒ

Ÿ”žv –”¡v

ƒ”Šv

ƒ”Šv

ƒ”Ÿv

Ÿ”ƒv ƒ”¡ Ÿ”ƒv

ƒ”Ÿv ¡”ž ƒ”Ÿv ¡”– ƒ”–v ¡”– ƒ”Ÿ ¡”– ƒ”– ¡”Š ƒ”ž

Ÿ”Ÿv

ž”ƒv Ÿ”ž Ÿ”Š

Š”¡v

Ÿ”Šv

Ÿ”– Š”Šv

ž”Ÿv

Ÿ”¡v

ƒ”žv ƒ”ƒ Ÿ”Šv

ž”ƒv ž”ƒv ž”ž

– ‘˜

Ÿ”Ÿv

ƒ”ž –”Šv ƒ”– –”Šv ƒ”Ÿ –”ƒv

Ÿ”Ÿv

¡”Š ƒ”Š ¡”– ƒ”–

ƒ”žv ƒ”žv ƒ”¡ ƒ”Ÿv ƒ”Ÿv ƒ”Ÿv ƒ”–v ƒ”žv

Š”¡v

˜

–”ƒ –”žv

–”žv –”žv

–”Ÿv

–”Ÿv –”Ÿv

¡”Ÿ ƒ”Š

ƒ”žv

Ÿ”Š

–”žv –”žv –”Š ž”–v

ž”–v ž”–v ž”Ÿ

Ÿ”ž –”žv Ÿ”ž –”žv Ÿ”–

Ÿ”žv Ÿ”Šv Ÿ”žv

ƒ”Š

ƒ”ž Ÿ”žv ƒ”ž Ÿ”Šv ƒ”Š Ÿ”žv ƒ”Ÿ

¡”ž

¡”Š

ƒ”–v ¡”Š ƒ”Ÿv ¡”– ƒ”ƒv ¡”Ÿ

¡”ž

Ÿ”ž Ÿ”¡

Š”Ÿ

ƒ”ƒ Š”žv

Š”žv

Š”Ÿ

Š”žv

Š”¡

Š”ƒv

Ÿ”Ÿ

–”– ¡”ƒv ¡”ƒv

¡”ƒv ¡”ƒv

ƒ”ƒ –”¡v ƒ”¡

¡”ž –”–v ƒ”Š Š”¡v

–”–v

Ÿ”–v ¡”Š

Š”¡v

– ‘—

¡”ž

¡”–

¡”ƒ ƒ”ž ¡”ƒ ƒ”Ÿv

¡”¡ ƒ”¡

¡”ž ¡”Š ƒ”–v ¡”Š

¡”– ¡”¡

¡”ž

ƒ”Ÿv

˜

•• —

—¡

’

•• •• •• ••

ƒ ŸƒŸ

•• •ƒ ƒ

¡”Ÿ ¡ ƒŸŸ

¡”Ÿ

¡”Ÿ

•ƒ •ƒ

• •• •• •• •• ••

ƒ ¡ŸŸ ¡ –ŠŸ

¡ ŠŠŸ

•• •ƒ –

–

–

–

••

“‘ ¡ƒ

¡ƒ

“‘ •• ••

–

o t t o o o t t o o t o o

t o o o o t t o t o t o o

o o o o o o o o o o t t t t

o o o t o o

o o o o o t o t o o t t o o o t o t t t o t o o t t t o t o o t

o o t o t t o t t o o o t t t t t t o

2 Safety notes, signs

2.1 Symbols used in this operating manual Danger Caution

Note

Danger!

Caution!

Note!

precondition or prerequisite procedure or activity. result

2-1

2.2 Proper use

2.3 Safety instructions 2.3.1

2-2

General safety instructions

NOTE

2.3.2

Crushing and burn prevention

2-3

2.3.3

Fire and explosion prevention

2.4 Signs on the machine 2.4.1

Safety and information signs

Danger!

2-4

Fig. 2-1

Position of the signs on the machine

1: Seat belt

2: Operating symbols

2-5

3: Payload chart

4: Information sign re. Lwa noise level

*XX

5: Operating brake (for Germany only)

6: Operating brake / parking brake

2-6

7: Accident prevention

7: Accident prevention, safety lever

7: Accident prevention, attachment

8: Lubrication chart

9: Loading and tie-down points

2-7

10: Emergency exit through rear window

11: Service manual

12: Point of danger

13: Tie-down point

14: Jump-starting

2-8

15: Lubrication chart for diesel engine

16: Attachment point for lifting

17: Prohibition sign

18: Engine shut-down

2-9

Fig. 2-2

No.

2 - 10

Sign

Location of signs (US version)

No.

Sign

No.

Sign

No.

Sign

2 - 11

No.

Sign

No.

2.4.2

2 - 12

ID tag

Sign

Fig. 2-3

ID tag of the machine

Fig. 2-4

Type ID of the machine (US version)

2 - 13

2 - 14

3 Control, operation 3.1 Operating and control elements 3.1.1

Overview of operator's platform

Fig. 3-1

Operator's platform

1

2

3

4

5 7

6 8

9

3-1

Fig. 3-2

3-2

Operator's platform as seen from the operator

1 3

2 4

5

6

7 9

8 10

11

12

13

14

15

16

3.1.2

Keypad

Fig. 3-3

Keypad

3-3

S10

Attachment headlight, roof light

S11 Windscreen washer system

S14 Windscreen wiper

S16 Parking brake

S17 Slewing gear brake

S18 Overload warning system (optional equipment)

S19 Release auxiliary function (grapple rotator)

S20 Idle automatic

S21 Creeper speed

3-4

S22 Parking light, dipped light

S35 Servo steering

S36 Special function 1 (optional equipment)

S37 Special function 2 (optional equipment)

S38 Special function 3 (optional equipment)

S39 Special function 4 (optional equipment)

S41 Beacon (optional equipment)

S42 First gear, gear switching

S85 No function

S85 Grab control

3-5

S86 Power selection (mode)

L F E P P4 Display of engine speed

S228 Increase speed

S229 Reduce speed

S354 Super Finish (flow reduction)

3-6

3.1.3

Monitoring screen

Fig. 3-4

Monitoring screen

A B

H24 P2

C

P2.1

D

P3

H2

P3.1

H12 H19

S349 S350

H20 H23

S351 S352

3-7

3.1.3.1

Area A: Monitoring the diesel engine P2 Diesel engine coolant temperature display

P2.1 P2

P3

Fuel level display

P3.1 H2

Indicator light, low engine oil pressure

H12

Indicator light, battery

H19

Indicator light, vehicle indicator lamps

H20

Indicator light, parking brake S16

3-8

H23

Indicator light, reservoir pressure (service brake)

H24 – Indicator light, steering

3.1.3.2

Area B: Screen menu control

Fig. 3-5

Screen menu control

S349 Back S350 Down S351 Up S352 Menu*

3.1.3.3

Area C: Screen To change the screen contrast: Menu

Up

Down

To alter the brightness of the main screen: Back

Up

Down

Note!

To change the brightness and contrast settings to the factory-default setting:

3-9

Up

3.1.4

Down

Main screen

Fig. 3-6 SY INF

Display: main screen EC TI

Field SY time and warning symbols

Field EC error codes*

warning symbols

3 - 10

Up

Down

Danger!

Acknowledging errors:

Back

Field INF information symbols

Field TI

3.1.5 Symbol

Information symbols on the main screen

Description Preheating

End of preheating

Forward travel

Reverse travel

3 - 11

Symbol

Description Oscillating axle locking device

Automatic oscillating axle locking

Service interval indication

Acknowledge error Back Overload warning system*

No overload warning system

Outrigger monitoring system*

Stick cylinder shut-down

Overriding stick cylinder shut-down function

Stick cylinder shut-down

Overriding stick cylinder shut-down function

Emergency operation of diesel engine

3 - 12

Symbol

Description Emergency operation of control devices: Danger

Emergency operation of control, brake

Emergency operation of servo control

3.1.6

Operator's menu Changing to operator's menu:

Fig. 3-7

Main screen

Menu

3 - 13

Fig. 3-8

Operator's menu

Scrolling through the operator's menu: UP

Select a menu:

Menu BACK

Symbol

3 - 14

Description

DOWN

Symbol

Description

Reset menu for daily operating hours counter

Fig. 3-9

Resetting the daily operating hours counter

Use this menu to reset the daily operating hours counter.

UP OK Menu UP

DOWN

Menu

BACK

Fine adjustment menu

Note!

3 - 15

Fig. 3-10

"Fine adjustment" menu

Super Finish mode

SF

UP

DOWN

BACK

Menu

Slewing gear precision control

Menu UP

3 - 16

DOWN

BACK

Menu

Maximum speed of "rotate grapple" function

Menu UP

DOWN

BACK

Menu

Menu: Service interval confirmation

Fig. 3-11

Service interval menu

3 - 17

UP Menu

BACK

Tool Control menu Selection of working tool settings

Caution!

Fig. 3-12

Tool Control menu

EV1

EV2

EV6

Menu

UP

Menu

3 - 18

DOWN

To exit the submenu: BACK

Fig. 3-13

Main screen, display of selected working tool

1

2

Note!

Menu: Operating hours and machine data

Menu

Fig. 3-14

Engine operating hours menu

3 - 19

Fig. 3-15

Machine movement hours menu

Fig. 3-16

Technical data

typ, serie: ver: volt:

To exit the menu: BACK

3 - 20

Menu: Status of hydraulic pumps and electrical inputs/outputs

Fig. 3-17

Pressure and flow reduction currents menu Menu

Fig. 3-18

Power control solenoid and fan speed currents menu

Fig. 3-19

Slewing gear current

3 - 21

Fig. 3-20

Electrical inputs

Fig. 3-21

Electrical inputs

To exit the menu: BACK

Menu: errors (operating errors and electrical system errors)

Fig. 3-22

3 - 22

Errors menu

list Exxx E-elec. list S-Exxx

To select the error type: UP

DOWN

Menu UP

DOWN

Machine errors list Exxx:

Fig. 3-23

Error list (left) and occurrence of errors (right) menu list Exxx Menu

UP

DOWN

Menu

BACK

UP

BACK DOWN BACK BACK

Note! list Exxx

E5xx

3 - 23

Wire fault list E-elec.:

Fig. 3-24

Occurrence of electrical faults (left) and fault statistics (right) E-elec.

Menu

BACK

Other error list S-Exxx:

Fig. 3-25

Service operation error list menu

To exit the menu: Menu

3 - 24

Menu: Time

Fig. 3-26

Adjusting the time settings

UP

DOWN

Menu

BACK

Menu: Stick cylinder shut-down (optional equipment)

Danger!

3 - 25

Fig. 3-27

Shut-down points: Retracting stick (min), extending stick (max)

Fig. 3-28

Menu: Stick cylinder shut-down

Note!

Setting the shut-down point for retraction:

Fig. 3-29

3 - 26

Menu: Shut-down point for retraction

UP min. limit

DOWN

Menu teach min. position min. limit act. value Menu store min. value min. limit act. value Setting the shut-down point for extension:

Fig. 3-30

Menu: Shut-down point for extension

UP max. limit

DOWN

Menu teach max. position max. limit act. value Menu store max. value max. limit act. value Note! teach min. position

teach max. position

To exit the menu: BACK

3 - 27

Menu: automatic central lubrication system (optional equipment)

Mode

Use

Lubrication

H

H

N

N

L

Fig. 3-31

L

Automatic central lubrication menu

Selecting mode UP

DOWN

Menu

To exit the menu: BACK

Menu: Purge mode

3 - 28

Fig. 3-32

Purge menu Menu

3.2 Control 3.2.1

Entering and exiting the operator's cab Caution!

3 - 29

3.2.1.1

Mounting and dismounting from the machine

Fig. 3-33

Operator's cab with fixed elevation mechanism

Fig. 3-34

Operator's cab with lift frame

Emergency access:

3 - 30

3.2.1.2

Entering and exiting operator's cab

Fig. 3-35

Operator's cab without catwalk

1 2

3 4

Entering cab: 1 2

Exiting cab:

3 2

Releasing door locking mechanism: 2 4

3.2.2

Adjusting vertical position of the operator's cab (optional equipment)

3 - 31

Danger!

Danger!

Danger!

Fig. 3-36

3 - 32

Height adjustment of the operator's cab

Control by means of lever switches 1

a

b

Control by means of switches Lifting/lowering operator's cab: UP

3.2.3

DOWN

a

b

Emergency lowering of the operator's cab

Emergency lowering of the operator's cab:

Fig. 3-37

Emergency lowering valve at cab base 1

b

b Emergency lowering from outside the operator's cab: Danger!

3 - 33

Fig. 3-38

Emergency lowering valve on lift frame 1

b

b Note! b a

3.2.4

Safety lever

Fig. 3-39

Caution!

3 - 34

Safety lever

3.2.5

Operator seat Danger!

Fig. 3-40

Operator seat

1

2

3

4

5

6

3 - 35

7

8

9

10

11

12

13

14

15

16

Adjusting seat to body weight/seat height (in models with manual adjusting mechanism):

9 8

9 Adjusting seat to body weight (in models with automatic adjusting mechanism)*:

9

Adjusting seat height (in models with automatic adjusting mechanism)*:

Caution!

9 Adjusting seat depth: 12

13

Horizontal adjustment: 11

3 - 36

Horizontal adjustment with control consoles: 7

Adjusting backrest: 3

Adjusting lumbar support (in models with mechanical adjusting mechanism): 2

Adjusting lumbar support (in models with pneumatic adjusting mechanism)*: 2 Adjusting shock absorber*:

10

Adjusting horizontal cushioning*:

6

Adjusting armrests: 5

4

3 - 37

Adjusting headrest: 16

Seat heating: 1

3.2.6

Adjusting the steering column

Fig. 3-41

Steering column

2

2

3 - 38

3.2.7

Windscreen

Fig. 3-42

Windscreen

1 3

2

a b Caution!

2

Caution!

3

2

Opening windscreen: 1

1

3 - 39

Closing windscreen: 1

1

3.2.8

Sun blind

Fig. 3-43

Sun blinds for windscreen and cab roof

Windscreen 1 2 Cab roof

3 - 40

3.2.9

Emergency exit through rear window

Fig. 3-44

Emergency exit through rear window 1

2 2

3.2.10

Inside lighting

Fig. 3-45

Inside lighting

1 0 2

3 - 41

3.2.11

Fire extinguisher (optional equipment)*

Fig. 3-46

Fire extinguisher / first aid kit

3.2.12

Windshield wiper

3.2.12.1

Windshield wiper S14

Adjusting the interval time for the intermittent function S14

3.2.12.2

Windshield washing system S11

3 - 42

3.2.12.3

Windshield washing fluid container

Fig. 3-47

3.2.12.4

Windshield washing fluid container

Window wiper on the cab roof (option)

Fig. 3-48

Window wiper on cab roof S218 S218 S218

3 - 43

3.2.13

Lighting

Fig. 3-49

Positions of lighting devices

1 3

2 4

5 7

6

Parking and travel light (dipped light) S22

Attachment headlight, front roof light (optional equipment) S10

Beacon (optional equipment) S41

Rear roof light, rear light (optional equipment) S275

3 - 44

3.2.14

Radio mute mode (optional equipment) S422 S422 S422

3.2.15

Heating and air-conditioning system

Fig. 3-50

Air conditioning control unit

Control keys

3 - 45

Display screens

F1-F5 Note!

Note!

6 Switch on the control unit:

Fig. 3-51

Control unit self-test 4

AUTO (20)

3 - 46

Adjusting the cab temperature:

Fig. 3-52

Example: increase the temperature

2 3 2

1 Manually adjusting the heating performance:

Fig. 3-53

Manually adjusting the heating performance 7 23

24

23 2

3 7 23

24

Switching a/c operation on and off:

Fig. 3-54

A/C operation and REHEAT function

3 - 47

1 15

1 15 6 14

Recirculated air and fresh air, fan speed:

Fig. 3-55

Adjust the air supply and fan speed

8 13 13 Manually adjusting the fan speed: 5 22 2

3 21 5 21

3 - 48

22

Changing the air supply:

Fig. 3-56

Location of front air outlets (Fig. left) and outlets on rear cab wall (Fig. right) a

c

b

d

heating operation b

a c

a/c operation b

d

9 12

Fig. 3-57

Air outlet symbols 9 16 d 9 16 d

3 - 49

Open / close ventilation flap on control console: 10 17 b 10 17 b Open / close the ventilation flap for the windscreen and legroom: 11 18 a

19 c

11 18 a

19 c

Open / close windscreen ventilation flap: 12 18 c 10 18 c Switching the temperature display: ° Celsius

° Fahrenheit

8 3 ° Fahrenheit ° Celsius Auxiliary heater operation (option):

Fig. 3-58

Auxiliary heater operation SH

3 - 50

3.3 Operation 3.3.1

Safety instructions

3.3.1.1

Bringing the machine into service

3.3.1.2

Starting the machine

3.3.1.3

Shutting down the machine

3 - 51

3.3.1.4

3.3.2 3.3.2.1

Towing the machine

Starting machine General instructions Note!

3.3.2.2

Tasks to be completed prior to machine start Caution!

Caution!

3 - 52

3.3.2.3

Deactivating the electronic immobiliser (optional equipment)

Fig. 3-59

Keys in different colours

1

2

Note!

Safety functions

Manipulation protection

Deprogramming keys

3 - 53

3.3.2.4

Switching on the electrical system Switch on the main battery switch:

Fig. 3-60

Battery main switch 1

Switching on the ignition:

Fig. 3-61

Ignition switch

0 2

1 P 1 1 self-test S22 self-test

Note!

3 - 54

Service interval indication

Fig. 3-62

Service interval request

service check service check

3.3.2.5

Starting the diesel engine Note!

0

Engine starting process: 2 H2

H12

H23

Starting engine at low ambient temperatures:

Pre-heating ON Pre-heating END

1 1

Pre-heating ON Pre-heating END 2

3 - 55

Starting engine at ambient temperatures below -18 °C

3.3.2.6

Warm-up phase for diesel engine and hydraulic system Diesel engine

P2 Note!

Hydraulic system

3.3.2.7

Power selection (mode) and speed adjustment

Fig. 3-63

Speed adjustment and mode functions P4

3 - 56

Selecting engine power (mode): S86 L F E P

S86

E

P L

F

Note! modes

Adjusting engine speed with the arrow keys: S258 P4 S229 P4 S86

3.3.2.8

To be observed after start-up Danger!

3 - 57

Caution!

3.3.3

Switching off the diesel engine Caution!

S229 P4

0

3.3.4

Starting aids Danger!

3.3.4.1

Fuel preheating S26 (optional extra)

S26

3.3.4.2

3 - 58

Coolant / engine oil / hydraulic oil preheating (optional extra)

Danger!

Danger!

Caution!

3 - 59

Fig. 3-64

Coolant / engine oil / hydraulic oil preheating

1

5

2

6

3 4

7 8

7

5 4 8 1 6 2

3 - 60

3.3.5

Jump start procedure Danger!

3.3.5.1

Connecting the batteries

Caution!

3.3.5.2

Disconnecting the batteries

3 - 61

3.3.6

Travelling operation

Fig. 3-65

Control elements, travelling

1

7

3 6

S30

S16 1

3.3.6.1

Gear selection

S42

S42

3.3.6.2

Creeper gear Note!

3 - 62

6

S21

S21

3.3.6.3

Travelling movement S30

3 7

Danger!

Travelling forwards: S30

a 7

Reversing: S30

b 7

3.3.6.4

Driving on gradients Caution!

S16

Danger!

S20

3 - 63

Driving on gradients steeper than 10 % Caution!

3.3.7

Travel warning device (option)

Fig. 3-66

Travel warning device 7

Deactivating the travel warning device: S55

Note!

3.3.8

Drive deactivation (optional extra)

S30

3 - 64

4

3.3.9

Oscillating axle locking device

Fig. 3-67

Oscillating axle locking device S75

S75

Function

Application

0 1 A

S35 Tab. 3-1

Functions of the oscillating axle

Danger!

S75 S35

S75

A

1 S35 S75

A

Locking oscillating axle: S75

1

3 - 65

Releasing oscillating axle: S75

0

Switching on the automatic oscillating axle locking mechanism: S35 S75

A

Note!

3.3.10

Operation of support system 1 2

Fig. 3-68

3 - 66

Machine support

Fig. 3-69

Operating the support system 5

Operating outrigger support: 5 5

(a) (b)

Outrigger support monitor (optional equipment):

Individual outrigger control (optional equipment):

Fig. 3-70

Individual outrigger control S 204- S207

S204 S205 S206 S207 S204 - S207 5

(a)

(b) Operating blade support: S335 S335

3 - 67

5

a

b

S335

3.3.11

Operation of dozer blade (optional equipment) Danger!

never

Fig. 3-71

Operating dozer blade

S335 S335

5 S335

3.4 Working with the machine 3.4.1 3.4.1.1

3 - 68

Safety Instructions Working with the machine

(a)

(b)

3 - 69

3 - 70

3.4.1.2

Use in material handling applications, specifically when travelling with raised loads and attachments

3.4.1.3

Application of machines with tower elevation

3.4.1.4

Additional notes for machines with fixed cab raiser

3.4.1.5

Protection from vibrations

3 - 71

3.4.2

Sensor controlled low idle automatic

S20

Note!

S46

S35

To set the reset time to low idle after the joysticks have been released:

3 - 72

Caution!

3.4.3

Working position

Fig. 3-72

Working position

1 S16

S30 S75

Placing the machine in working position: Caution!

S30

0

1 S16 S75

Fig. 3-73

I

Working position. The machine is supported.

3 - 73

3.4.4

Operating working attachment

Fig. 3-74

Operating working attachment

Caution!

PCSA controls

1 a

b

c

d

e g

f h

2

Moving the stick: 1 a a b b Moving the boom: 2 g h

3 - 74

Operating the grapple: Danger

e f

Operating tilting system (optional equipment)

Fig. 3-75

Operating tilting system 2 e f

Combined movements:

3.4.5

Swivelling the uppercarriage S17 1 c d

3 - 75

3.4.6

Halting the uppercarriage

Hydraulic braking: 1 1

Mechanical slewing gear brake: Caution!

S17

S17

Checking the mechanical slewing gear brake:

S17

1

Positioning slewing gear brake (optional equipment):

Fig. 3-76

3 - 76

Positioning slewing gear brake

Note!

1

3.4.7

Lowering the working attachment when diesel engine is shut off

Fig. 3-77

Lowering attachment when the diesel engine is off

1 S75

1

Note

3.4.8

Grab control

3 - 77

S85

Fig. 3-78

Grab control S85, use according to required closing force F

S85

Characteristics F

F

Danger!

3.4.9

3.4.9.1

3 - 78

Electronic stick cylinder shut-down function (optional equipment) Function and purpose

3.4.9.2

Use of stick cylinder shut-down function

Danger!

Fig. 3-79

Symbol

Shut-down points: Retracting stick (min), extending stick (max)

Description Stick cylinder shut-down

Overriding stick cylinder shut-down function

Stick cylinder shut-down

Overriding stick cylinder shut-down function

3 - 79

Symbol

Description Stick cylinder shut-down, fault

3.4.9.3

Overriding stick cylinder shut-down function Danger!

S403

3.4.9.4

Adjusting the stick cylinder shut-down function

3.4.10

Mechanical stick cylinder shut-down function

3.4.10.1

3 - 80

Function and purpose

3.4.10.2

Use of stick cylinder shut-down function

Danger!

3.4.10.3

Overriding stick cylinder shut-down function Danger!

S216 S216

3 - 81

3.4.10.4

3 - 82

Adjusting the limit switches

Fig. 3-80

Elevating operator's cab

Fig. 3-81

Stick cylinder shut-down point

Fig. 3-82

Adjusting the limit switch 1 2 3 1

3.4.11

Adjustment of attachment tool

Caution!

3.4.12

Operating the attachment tool (by pedals, push buttons) Danger!

3 - 83

Danger!

3.4.12.1

Working functions

Fig. 3-83

Operating attachment tool by pedals

Example: hydraulic hammer k

Example: sorting grapple, scrap shears k m

3 - 84

3.4.12.2

Rotating and adjusting

Fig. 3-84

Press the push button at the joystick to rotate and adjust the attachment tool

1 2 3 A B C R/L

S19

L

R

3 - 85

3.4.13

Changeover of control (optional equipment)

Fig. 3-85

Changeover of control m

k

e

S405 S405 H322 S405 H322

Function

3.4.14

0

Changeover off (0)

on (1)

e+f

m+k

m+k

e+f

Operating attachment tool (mini joystick control, optional equipment) Danger!

Danger!

3 - 86

1

f

3.4.14.1

Working functions

Fig. 3-86

Mini joystick, operating attachment tool

Example: hydraulic hammer 1

Example: sorting grapple, scrap shears 1 2

3 - 87

3.4.14.2

Rotating and adjusting

Fig. 3-87

Rotation and adjustment of attachment tool by means of mini joystick

1 2 3 L/R

L

R

3 - 88

3.4.15

Changeover of joystick control (optional equipment)

Fig. 3-88

Changeover of control 1

2

e

f S405

S405 H322 S405 H322

Function

3.4.16

1

0

Changeover off (0)

on (1)

e+f

-

1+2

e+f

Magnetic system (option) S46

3 - 89

Fig. 3-89

Operating the magnetic system S46 P4 S20

Danger!

S6L

S55

Control in the right joystick: S6L S6L

Control in left joystick (American version): S55 S55

3.5 Installation and removal of attachment parts 3.5.1 3.5.1.1

3 - 90

Safety Instructions Installation and removal of attachment parts

3.5.1.2

Removal and installation of attachment pins

3 - 91

3.5.2

Installation and removal of digging tool

Fig. 3-90

3.5.2.1

Installation and removal of digging tools

Removing the digging tool

5

6

3

4 4

3.5.2.2

Installing a new digging tool

1 4

6 7 2

3

3 - 92

5

3

3.5.2.3

4

Bucket cylinder operation

15 a b 15 a

Note!

LIKUFIX 15

3 - 93

3.5.3

Attachment of grapple to bucket stick

Fig. 3-91

Attaching grapple to bucket stick

Danger!

3.5.3.1

Attaching grapple

1 2

3 - 94

3

Caution!

4

5 6

3.5.3.2

7

Attachment of connecting link

Fig. 3-92

Securing of connecting link 1 6 5

2 3

1

5

4

3 - 95

3.5.3.3

Changeover to grapple operation

Fig. 3-93

Valve block for tilt cylinder operation / grapple operation

a b Note LIKUFIX

b

3.5.3.4

Removing grapple 3

Caution!

3

3 - 96

2

3.5.4

Attachment of grapple to industrial stick

Fig. 3-94

Attaching grapple to industrial stick

Danger!

3.5.4.1

Attaching grapple

1 2

3

3 - 97

Caution!

4

5 6

3.5.4.2

Removing grapple

Caution!

3

3 - 98

2

7

3.5.5 3.5.5.1

Multi-coupling system (optional equipment) Overview

Fig. 3-95

Overview

1

2

3

4

5 7

6 8

9

Fig. 3-96

Securing mechanism

3 - 99

3.5.5.2

Pressure release device

Fig. 3-97

Pressure release device of the coupling

Caution!

A B

3.5.5.3

Working tool

Fig. 3-98

3 - 100

Positioning grapple

3.5.5.4

Opening coupling

Fig. 3-99

3.5.5.5

Opening pressure release device, releasing locking mechanism and moving hand lever down

Closing coupling

Fig. 3-100 Inserting the coupling plate, moving hand lever up and closing pressure release device

3 - 101

3.5.6

Industrial stick with mechanical quick-change adapter (optional equipment)

3.5.6.1

Safety information

3.5.6.2

Positioning option

Fig. 3-101 Example: Load hook in frame (bearing block)

3 - 102

3.5.6.3

Overview

Fig. 3-102 Industrial stick with mechanical quick-change adapter

3.5.6.4

1 3

2 4

5

6

Releasing and locking

Fig. 3-103 Releasing and locking A B

C D

3 - 103

3.5.6.5

Attaching working tool

Fig. 3-104 Releasing and attaching working tool

Danger!

Fig. 3-105 Locking

3 - 104

1

Caution!

Danger!

3.5.6.6

Dismantling working tool

Fig. 3-106 Releasing

1

Caution!

3 - 105

Danger!

Fig. 3-107 Disconnecting working tool

3.5.7

3.5.7.1

3 - 106

Industrial stick with hydraulic quick-change adapter (optional equipment)

Safety information

3.5.7.2

Disconnecting option

Fig. 3-108 Example: load hook in frame (bearing block)

3.5.7.3

Overview

Fig. 3-109 Industrial stick with hydraulic quick-change adapter

3.5.7.4

A

B

1

2

Operation and function control

3 - 107

Releasing and locking of adapter by means of push buttons (standard equipment):

Fig. 3-110 Releasing and locking of adapter by means of push buttons*

auxiliary function

19

S47 R

L

Locking and releasing quick-change adapter with the mini joystick (optional equipment):

Fig. 3-111 Locking and releasing quick-change adapter with the mini joystick

3 - 108

S47 R

L

3.5.7.5

Attaching tools

Fig. 3-112 Releasing adapter and attaching tool

3 - 109

Fig. 3-113 Locking

1

Caution!

3.5.7.6

Removing attachment tool

Danger!

3 - 110

Fig. 3-114 Tightening the locking screw, disconnecting the lines and releasing quick-change adapter 1

Caution!

Fig. 3-115 Disconnecting attachment tool

- alternatively -

3 - 111

3.5.7.7

Acknowledging buzzer signal (warning signal)

S349

Note!

3.5.8

3.5.8.1

3 - 112

LIKUFIX MH 40 quick-coupling system (optional equipment)

Safety information

3.5.8.2

Disconnecting option

Fig. 3-116 Example: load hook in frame (bearing block)

3.5.8.3

Overview

Fig. 3-117 LIKUFIX MH 40 quick-coupling system A

B

1

2

3 5

4 6

7

3.5.8.4

Operation and function control

3 - 113

Releasing and locking of coupling system by means of push buttons (standard equipment):

Fig. 3-118 Releasing and locking of coupling system by means of push buttons*

auxiliary function S47 R

L

3 - 114

19

Locking and releasing coupling with the mini joystick (optional equipment):

Fig. 3-119 Locking and releasing coupling with the mini joystick

S47 R

L

3.5.8.5

Attaching tools

Fig. 3-120 Releasing, lowering top section

3 - 115

Fig. 3-121 Locking

3.5.8.6

Removing attachment tool

Danger!

3 - 116

Fig. 3-122 Releasing, lifting top section

- alternatively -

3.5.8.7

Acknowledging buzzer signal (warning signal)

S349

Note!

3.5.9

Hydraulic quick-change adapter (optional equipment)

3 - 117

3.5.9.1

Safety information

3.5.9.2

Overview

Fig. 3-123 Hydraulic quick-change adapter 1

2

3

3.5.9.3

3 - 118

Operation and function control

Releasing and locking of quick-change adapter by means of push buttons (standard equipment):

Fig. 3-124 Releasing and locking of adapter by means of push buttons*

auxiliary function

19

S47 R

L

3 - 119

Locking and releasing attachments with the mini joystick (optional equipment):

Fig. 3-125 Locking and releasing quick-change adapter with the mini joystick:

S47 R

L

3.5.9.4

Attaching tools

Fig. 3-126 Positioning attachment

3 - 120

Fig. 3-127 Taking up attachment tool, step 1

Fig. 3-128 Taking up attachment tool, step 2

Danger!

Caution!

3 - 121

3.5.9.5

Removing attachment tool

Caution!

Fig. 3-129 Aligning attachment tool for release Danger!

Fig. 3-130 Placing the attachment tool on the ground

3 - 122

- alternatively -

3.5.10

Hydraulic quick-change adapter with LIKUFIX (optional equipment)

Fig. 3-131 Quick-change adapter with LIKUFIX 1

2

3

4

Note!

3 - 123

3.5.10.1

Acknowledging buzzer signal (warning signal)

S349

Note!

3.5.11

3.5.11.1

3 - 124

Mechanical quick-change adapter (optional equipment)

Safety information

3.5.11.2

Overview

Fig. 3-132 Mechanical quick-change adapter 1 3

2 4

5

3.5.11.3

Releasing and locking

Fig. 3-133 Releasing and locking A B

C D

3 - 125

3.5.11.4

Attaching working tool

Fig. 3-134 Positioning attachment

Fig. 3-135 Taking up working tool, step 1

Fig. 3-136 Taking up working tool, step 2

3 - 126

Danger!

Caution!

3.5.11.5

Dismantling working tool

Caution!

Fig. 3-137 Aligning working tool for release

3 - 127

Danger!

Fig. 3-138 Placing the working tool on the ground

3.6 General working methods 3.6.1

3 - 128

Tips for the proper operation of the machine preventing damage and wear

Caution!

Fig. 3-139 Permissible working range for hydraulic cylinders 1

2

3

4

5

3 - 129

3.6.2

Preparation

Fig. 3-140 Safe working: observe machine range and danger zones Danger! r

Caution!

3 - 130

3.6.3

Working with grapples Danger!

3.6.4

Excavating and moving material with grapples

Fig. 3-141 Clamshell bucket: align stick, close jaws, lift excavated material Align stick (1):

Closing jaws (2): Danger!

3 - 131

To lift excavated material (3):

Fig. 3-142 Releasing excavated material

3.6.5

Loading operation Danger!

Fig. 3-143 Taking up the load

3 - 132

Note!

Fig. 3-144 Loading operation

Danger!

Caution!

3.6.6

Load lifting operation

3 - 133

Danger!

Lifting tackle that allows for the safe attachment of a load (optional equipment)

Overload warning system (optional equipment)

Pipe fracture safety valve at the boom cylinders

– Load lift chart in the operator's cab If one or more of the above requirements is not met, the machine may not be used for load lifting operations.

3.6.7

Use of quick-change adapter for load lifting operation

Fig. 3-145 Lifting operation with load hook 1 3 A

3 - 134

2

Danger!

1 1 A

3.6.8 3.6.8.1

Overload warning system (optional equipment) General

Note!

3 - 135

Note!

3.6.8.2

Operating principle

3.6.8.3

Start-up Danger!

S18

3.6.8.4

3 - 136

Functional test

3.7 Parking and exiting machine

Fig. 3-146 Parking 1 S16

S30

S30

0

S16

1

Fig. 3-147 Boom: Energy recovery cylinder and lockable hoist cylinder 1

2

3 - 137

3

a

b 3

3.8 Transport 3.8.1

Safety instructions

3.8.2

Transportation on low-loader

3.8.2.1

Preparation

max. 10°

3 - 138

Fig. 3-148 Loading ramp

3.8.2.2

Loading machine onto a low-loader

S16

Secure the machine:

Fig. 3-149 Securing the machine

Danger!

3 - 139

3.8.3

Loading with crane Danger!

Danger!

Fig. 3-150 Attachment of the machine

S16

3 - 140

3 - 141

3 - 142

4 Malfunctions

Note!

4.1 Error code list General error codes Error code

Effect

Cause

Remedy

4-1

General error codes Error code

4-2

Effect

Cause

Remedy

General error codes Error code

Effect

Cause

Remedy

4-3

General error codes Error code

4-4

Effect

Cause

Remedy

General error codes Error code

Effect

Cause

Remedy

Error codes combined with symbols / indicator lights Error code

Symbol *

Effect

Cause

What you can do

4-5

Error codes combined with symbols / indicator lights Error code

4-6

Symbol *

Effect

Cause

What you can do

Error codes combined with symbols / indicator lights Error code

Symbol *

Effect

Cause

What you can do

SY Quick-change adapter symbol

4-7

4.2 Faults and remedies 4.2.1 Faults / errors

4-8

Diesel engine and fuel system Cause

Solution

Faults / errors

Cause

Solution

4-9

Faults / errors

Cause

Solution

Note!

4.2.2 Faults / errors

Note!

4 - 10

Hydraulic system Cause

Solution

Faults / errors

Cause

4.2.3 Faults / errors

Solution

Travelling Cause

Solution

S16

S16 S30

4 - 11

Faults / errors

Cause

Solution

S42

S42

S21

S21

S354

4.2.4 Faults / errors

Brakes Cause

4.2.5 Faults / errors

S354

Solution

Electrical system Cause

Solution

S20 S20 S71

S72

B12

S20

4 - 12

S20

Faults / errors

Cause

Solution S73

4.2.6

Heating and air conditioning system

Faults / errors

Cause

4.2.7

Solution

Working attachment

Faults / errors

Cause

Solution

4.3 Fuses and relays Danger!

4 - 13

0

4.3.1

Fuse box E50

Fig. 4-1

F19 F20 F22 F31 F33 F34 F35 F36 F36-2 F37 F109 F110 F115 F116 F117 F122 F133 F253 K127 K128 K288 K302 K415

4 - 14

Fuse box E50

4.3.2

ESP02 printed circuit board

Fig. 4-2

Fuses and ESP02 relay board

F1 F2 F3 F4 F5 F6 F7

4 - 15

F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F250 F251 K332

4.4 Emergency operation 4.4.1

Purpose

Emergency operation

4 - 16

Purpose

Emergency operation

Purpose

Danger!

4.4.2

Identifying solenoid valve

4.4.3

Emergency mode control

4 - 17

Fig. 4-3

Control panel in the right control console

Fig. 4-4

Control panel for emergency control

S71

S72

S73

H11

H60

4.4.3.1

Emergency operation of diesel engine

S71 H11 n-min/MANU

4 - 18

Note!

H60 E 525

4.4.3.2

Emergency speed adjustment S86 S228

S229

S72

Note!

4.4.3.3

Emergency operation of control devices

4 - 19

Danger!

Fig. 4-5

Emergency control screen

S73

4.4.4

Emergency operation of hydraulic pump

Fig. 4-6

4 - 20

Control oil unit, hydraulic pump emergency operation

1

Y50 2

3

4.4.5

Emergency operation of electric stick cylinder shut-down function Danger!

Fig. 4-7

Stick cylinder shut-down, solenoid valves

Y212

4.4.6

Y231

Emergency gear shifting

4 - 21

Fig. 4-8

Solenoid valve of the gear shifting system Y6

4.4.7

Towing the machine

Note!

Danger!

4 - 22

4.4.8

Disengaging transmission (emergency release) Danger!

and

Emergency release:

Fig. 4-9

Transmission

Fig. 4-10

Pressing in grease with the adapter

1

2

3

A

B B

A 1

4 - 23

3

?Caution!

Deactivating emergency release: 2

2

4 - 24

5 Maintenance 5.1 Safety instructions 5.1.1

General safety instructions

5.1.2

Checking for cracks

5-1

5-2

5.1.3

Welding

5.1.4

Fuels, lubricants and process chemicals

5.1.5

Repair

5.1.6

Electrical system

5.1.7

Pressure accumulator

5-3

5.1.8

5-4

Hydraulic hoses and lines

5.1.9

Cab protection (FOPS)

5.2 Maintenance access doors 5.2.1

Overview of access doors

Fig. 5-1

Access doors on the machine

Caution!

5-5

No.

Access door

1

2

3

4

5

Tab. 5-1

5.2.2

Door locking mechanism

Fig. 5-2

5-6

Access doors

Door locking mechanism

Access to:

5.2.3

Engine hood locking mechanism

Fig. 5-3

Engine hood locking mechanism 1

Caution!

2

5.3 Cleaning machine

Note!

Before cleaning the machine:

Cleaning:

5-7

After cleaning:

5.4 Care for rubber components

5.5 Tyres

5.5.1

Checking tyre pressure

Fig. 5-4

5-8

Checking tyre pressure, safety distance

Danger!

Type

Tab. 5-2

Manufacturer / Size

bar

Tyre pressures

5-9

5.5.2

Foam tyres Note!

5.5.3

Checking wheel lugs for proper fit 460 Nm Danger!

Fig. 5-5

Tightening wheel lug

5.6 Fuels, lubricants and process chemicals 5.6.1

5 - 10

General information

5.6.2 5.6.2.1 Designation

Filling volumes, lubricating chart Recommended lubricants Recommended lubricant

Symbol

Volume [litre]*

5 - 11

5.6.2.2 Designation

5 - 12

Recommended fuels and chemicals Recommended fuel

Symbol

Volume (litre)*

5.6.2.3

Lubrication chart

Fig. 5-6

Lubrication chart for type 1004

5 - 13

Fig. 5-7

5 - 14

Lubrication chart for type 1071

Symbol

Tab. 5-3

Description

Key to lubrication chart

5.7 Specifications for fuels, lubricants and process chemicals 5.7.1

Diesel fuels

5.7.1.1

Specification

5.7.1.2

Sulphur content, lubricity

5 - 15

5.7.1.3

Cetane number

5.7.1.4

Low temperature operation

Caution!

5.7.2 5.7.2.1

5 - 16

Lubricating oil for the diesel engine Quality

Designation

Tab. 5-4

5.7.2.2

Specification

Lubricating oil specifications

Viscosity

Fig. 5-8

Temperature-based selection of the SAE class

Liebherr Motoroil 10W-40 Liebherr Motoroil 10W-40 low ash

Liebherr Motoroil 10W-30

5.7.2.3

Adverse operating conditions affecting the oil change intervals

5 - 17

adverse factors

Adverse factor

Oil quality CH-4, CI-4

Operating conditions

Sulphur content of fuel

Adverse factor

h *

5 - 18

5.7.3

Coolants for diesel engine

5.7.3.1

General recommendations

E4 / E7*

Interval

Oil quality

5.7.3.2

Water (fresh water)

Do not use sea water, brackish water, brine or industrial wastewater.

Designation

Tab. 5-5

Value / unit

Fresh water quality

Designation

Tab. 5-6

5.7.3.3

Value / unit

Fresh water quality with use of DCA 4*

Mixing ratio for coolant all times of the year Mixing ratio Outdoor temperature to Water %

Corrosion inhibitor/antifreeze agent %

%

%

%

%

Tab. 5-7

Permissible mixing ratio (for all seasons)

Fig. 5-9

Temperature-based mixing ratio of water + corrosion inhibitor / antifreeze agent

5 - 19

A B

5.7.3.4

Permissible corrosion inhibitors/antifreeze agent Note!

Concentrate Product name

Manufacturer

Ready-mixed corrosion inhibitor/antifreeze agent (premix) Product name

5.7.3.5

Manufacturer

Approved corrosion inhibitors without antifreeze agent Note!

exceptional circumstances above the freezing point

5 - 20

ambient temperatures that are always

Product name

5.7.4

5.7.4.1

Manufacturer

Hydraulic oil

Liebherr hydraulic oil

Fig. 5-10

Liebherr hydraulic oil, viscosity grade selection based on temperature

A B C Liebherr Hydraulic Plus

Liebherr Hydraulic Plus Arctic

5 - 21

5.7.4.2

Engine oils for use as hydraulic oils

Single-grade oils (1) Multigrade oils (2)

Tab. 5-8

Classification of products, engine oils for use as hydraulic oils

Fig. 5-11

Engine oil for use as hydraulic oil, viscosity grade selection based on temperature*

A B

1 2

C

5.7.4.3

Warm-up instruction B C B 1.

2.

3.

5 - 22

1

5.7.4.4

Biodegradable hydraulic oil Caution!

Liebherr Hydraulic Plus

Liebherr Hydraulic Plus Arctic

Caution!

5.7.4.5

Oil change, oil analysis and filter change Oil change Note!

Liebherr recommends carrying out regular oil analyses (see chapter , "Oil analysis" on page 24).

5 - 23

Oil change Oil type

Not for use in environmentally sensitive areas without oil analysis

with oil analysis* (optional)

LIEBHERR mineral oil

Liebherr-PAO**

Third-party product Third-party product

Tab. 5-9

Oil change intervals

Use in environmentally sensitive areas

Oil analysis

5 - 24

For use in environmentally sensitive areas (only permissible with oil analysis*)

Oil sampling / operating conditions normal operating conditions

extremely dusty conditions

Tab. 5-10 Symbols: Oil sampling depending on operating conditions

Oil sampling Not for use in environmentally sensitive areas (oil analysis optional)

For use in environmentally sensitive areas (oil analysis mandatory)

Oil type

LIEBHERR mineral oil

Liebherr-PAO*

Third-party product

Third-party product

Tab. 5-11 Oil sampling depending on operating conditions

5 - 25

Filter change Filter change / operating conditions normal operating conditions

extremely dusty conditions

Tab. 5-12 Symbols: Filter change depending on operating conditions

Change of return filter (use only LIEBHERR filters)

Tab. 5-13 Filter change depending on operating conditions

Change of bypass oil filter LIEBHERR filter

Filters from other manufacturers

Tab. 5-14 Filter change depending on operating conditions

5.7.4.6

5 - 26

Dust-intensive applications, reduction of oil contamination

5.7.5 5.7.5.1

Lubricants for axles and gearboxes Quality Recommended lubricant

Specification

Tab. 5-15 Lubricating oil specifications

5 - 27

5.7.5.2

Viscosity

Fig. 5-12

Temperature-based selection of the SAE class

A 1 2 3 4 *

5.7.6

Lubricating oil for transmission Recommended lubricant

5 - 28

Specification

5.7.7

Grease

5.7.7.1

Quality Recommended lubricant

5.7.7.2

Specification

Operating temperature

Fig. 5-13

Operating temperature for Liebherr greases

A * **

5.7.8

Lubricants and care products for electrical and mechanical components Medium, purpose

Product (manufacturer)

5 - 29

5.8 Diesel engine 5.8.1

Checking the oil level in the diesel engine Danger!

Fig. 5-14

Oil level markings on the dipstick

MIN

5.8.2

Changing the diesel engine oil Note!

5 - 30

MAX

Fig. 5-15

Drain valve on the oil pan, oil filter cartridges, oil filling nozzle

Drain the oil (A):

1

To change the oil filter cartridges (B): Danger!

Note!

by hand Fill with oil (C):

5 - 31

5.8.3

Ribbed V-belt for A/C compressor and alternator installation

Fig. 5-16

Replacing the ribbed V-belt

To replace the ribbed V-belt:

Note!

5.8.4

Crankcase bleeding point

Fig. 5-17

5 - 32

Replace the filter element

Replace the filter insert:

5.8.5

Grease the starter tooth ring

Fig. 5-18

Grease the starter tooth ring

1 2

4 5

3

Note!

3

1 4 4 2

5

4.

1

5 - 33

5.9 Cooling system 5.9.1

Checking and cleaning the cooling system

Fig. 5-19

Cooling system

1

5.9.2

Checking the coolant level

Fig. 5-20

5 - 34

Expansion tank

Danger!

1

5.9.3

Changing the coolant Danger!

Fig. 5-21

Cooling circuit shutoff valves

5 - 35

5.9.3.1

Draining the coolant

Fig. 5-22

Draining the coolant

To drain the coolant at the radiator: 1

To drain the coolant at the diesel engine: 2

5.9.3.2

Refilling the coolant and bleeding the coolant circuit 1 2

5 - 36

Caution!

5.9.4 5.9.4.1

Checking coolant, adjusting mixing ratio Coolant with corrosion inhibitor/antifreeze agent

5 - 37

Fig. 5-23

Determining refill volume - example for -15 °C:

1

3

2

4

Determining refill volume - example for -15 °C / 50 litres of coolant: 2

4 1

5 - 38

Correcting mixing ratio

5.9.4.2

Coolant with corrosion inhibitor (without antifreeze agent) When using DCA 4:

When using Caltex / Chevron / Havoline / Total:

Fig. 5-24

Gefo refractometer 2710

Refractometer:

Measuring procedure:

5 - 39

Fig. 5-25

Determining refill volume - example for 1 % Brix.

1

3

2

4

Determining refill volume - example for 1 % Brix / 50 litres of coolant: 2 4 1

Correcting mixing ratio

5 - 40

5.10 Fuel system Danger!

5.10.1

Refuelling Note!

Fig. 5-26

Tank lid 1.

5.10.1.1

Electric refuelling pump (optional equipment)

Fig. 5-27

Electric refuelling pump

5 - 41

3 To refuel and then store away the hoses, proceed as follows:

1 2

B S25

S59 Caution!

2

A 1 1

5.10.2

Dewatering fuel tank

Fig. 5-28

Dewatering fuel tank

The fuel tank must be dewatered daily: 1

1

1

5 - 42

Note!

P3 P3.1

5.10.3

Emptying and cleaning fuel tank

Fig. 5-29

Fuel tank

1

3

1 2

2

5 - 43

5.10.4

Maintenance of fuel filter

Fig. 5-30

Overview of fuel filter

1

5.10.4.1

2

Dewatering fuel pre-filter:

Fig. 5-31

Fuel pre-filter

a b a

5.10.4.2

5 - 44

Replacing filter cartridges

Changing the fuel pre-filter:

Fig. 5-32

Fuel pre-filter

1 4

2 5

3 6

7 b

8

a

5

6

4

a

2 3

2

3 7

a 8 2 1 5

6

4

5 - 45

Changing the fuel fine filter:

Fig. 5-33

5.10.5

Fuel fine filter

Bleeding fuel system

Note!

Bleeding fuel filter:

Fig. 5-34

5 - 46

Bleeding fuel filter

1 2 1 2 3 2 3 2 Bleeding crankcase:

Fig. 5-35

Bleeder screw at the crankcase 1 2 1 2

Starting diesel engine in PURGE mode: Note!

PURGE

PURGE

5 - 47

Fig. 5-36

PURGE menu Menu

5.11 Dry air filter

Fig. 5-37

Vacuum indicator 9

5 - 48

10

11

Fig. 5-38

5.11.1

Dust discharge valve extractor slot

Changing the main element Caution!

Fig. 5-39

Changing the filter cartridges

1

4

2

5

3 1

5 - 49

3

Caution!

2

5.11.2

1

Changing the safety element Note!

3 4

4 3 2

5.11.3

1

Checking the filtered air line

Fig. 5-40

Checking the filtered air line 8 7

5 - 50

5.12 Hydraulic system

Note!

5.12.1

Preparations

Fig. 5-41

5.12.2

Machine position for checking the oil level in the hydraulic system

Checking the oil level in the hydraulic tank

Fig. 5-42

Hydraulic tank oil level

5 - 51

MAXI MINI

MINI

5.12.3

Depressurizing the hydraulic system Danger!

S75

0.

Danger!

Fig. 5-43

Depressurizing the hydraulic system, breather filter 1 1

5 - 52

maximum 2

5.12.4

Replacing the breather filter 1

2

Note!

5.12.5

Emptying and refilling the hydraulic tank

Fig. 5-44

Draining and refilling the hydraulic oil

1

2

3

To drain the oil:

1 2 3

To refill the hydraulic oil: 1 2

1 2

5 - 53

Caution!

To drain off condensed water (only for mineral oils):

3

5.12.6

Return filter

Fig. 5-45

Return filter

1

5

2 3

6 7

4 5 6 Note!

Cleaning the magnetic rod and replacing the filter element:

1 5

5 - 54

5

6

Caution!

1

4 3

6

Note!

7

Note!

6

5.12.7

Control oil filter

Fig. 5-46

Control oil unit

1

5

2

6

3

7

4

8 2

1

Note!

5 - 55

To replace the filter element:

6

2

4

6 5

4 6

5.12.8

Control circuit

Danger!

8

5.12.9

Bleeding the hydraulic pump

Fig. 5-47

5 - 56

1

7

Hydraulic pump

2

Unscrew the suction hose to the pump: a b b

a

5.12.10

Bypass oil filter (optional equipment).

Note!

Fig. 5-48

Bypass oil filter

1 2

3 4

1

5 - 57

Checking filter contamination:

Replacing filter element:

2 3 4

3

5.12.11 5.12.11.1

Maintenance of hydraulic cylinders Checking piston rod bearing

Fig. 5-49

Piston rod bearing

Note

5.12.11.2

5 - 58

Preservation of piston rods

2

5.12.12

Replacing hydraulic hoses

Fig. 5-50

High pressure hose with SAE fitting

Danger!

Screw

Grade

Torque

Tab. 5-16 Tightening torques for SAE fittings

5.13 Changing the oil on components 5.13.1

General notes

5 - 59

5.13.2

Swin gear - oil change

Fig. 5-51

Changing the oil on the swing gear

1 2

3 4

To drain the oil: 4 1 2 2 1 To add the oil: 3 4

5 - 60

MAX

5.13.3

Transmission – oil change

Fig. 5-52

Changing the oil in the transmission

1

2

To drain the oil: 2 1

1 To add the oil: 2 2

5.13.4

Steering and rigid axle - oil change

Fig. 5-53

Changing the oil on the steering axle and rigid axle

1

2

To drain the oil: 2 1

5 - 61

1 To add the oil: 2 2

5.13.5

Wheel head – oil change To drain the oil:

Fig. 5-54

Changing the oil on the wheel head (draining the oil, Fig. left, adding the oil, Fig. right)

To add the oil:

5 - 62

5.13.6

Pump distributor gear - oil change

Fig. 5-55

Oil change in the pump distributor gear

1

3

2 Draining oil: 1 2 2

2 Filling oil: 1

5.14 Checking brake pads for wear

5 - 63

5.15 Electrical system 5.15.1

Notes regarding the electrical system

5.15.2

Battery main switch Caution!

Caution!

Fig. 5-56

Battery main switch 0

5 - 64

Note!

0

5.15.3

Battery care Danger!

Danger

Fig. 5-57

Battery care

B

B

A C density is 1.28 kg/l (31.5° Bé)

5 - 65

5.15.4

Slip ring body (optional equipment)

Fig. 5-58

Slip ring body

2 1

1 2

5 - 66

5.16 Heating and air-conditioning system 5.16.1

Recirculated and ambient air filter

Fig. 5-59

Recirculated air filter

Fig. 5-60

Ambient air filter

Cleaning or replacing the recirculated and ambient air filters: 1 2 1 4 3 Note!

5 - 67

1 3

5.16.2

Heating system

5.16.3

air-conditioning system

Inspection of the condenser:

Fig. 5-61

A/c condensers

1

2

1 1

5 - 68

Maintenance of a/c system:

5.17 Automatic lubrication of the machine 5.17.1

Semi-automatic central greasing system

Fig. 5-62

Central greasing pump, semi-automatic

5 - 69

1

4

2

5 6

3

6

Starting the greasing process: S84

S84

Note!

S84

Fig. 5-63

Monitoring pin on the main distributor

5

4

5 - 70

To refill the grease container:

Note!

2 6 2 6 3

Automatic:

Manually:

5.17.2

S84

4

Fully automatic central greasing system (optional extra)

Fig. 5-64

Central greasing pump, fully automatic

5 - 71

1

4

2

5 6

3

6

S84

S84 S84

E514

5

E514 S84 4 To refill the grease container:

Note!

2 6 2 6 3

Intermediate greasing: Automatic:

Manually:

5 - 72

S84

4

Adjusting grease quantity:

operator's menu

5.18 Manual lubrication of the machine

Note!

5.18.1

Steering axle

Fig. 5-65

Lubricating oscillating bolts

Fig. 5-66

Lubricating steering knuckle bearings

5 - 73

Caution!

5.18.2

Central lubrication system of steering axle (optional equipment)

Fig. 5-67

5.18.3

Digging buckets / bucket tilting device

Fig. 5-68

5 - 74

Central lubrication system of steering axle

Lubricating bucket tilting device

5.18.4

Attachments (optional equipment)

Fig. 5-69

Lubricating attachment (example of grapple)

5 - 75

5.18.5

Industrial stick with mechanical quick-change adapter

Fig. 5-70

Lubricating the mechanical quick-change adapter

Note!

5.18.6

Industrial stick with hydraulic quick-change adapter

Fig. 5-71

Note!

5 - 76

Lubricating the hydraulic quick-change adapter

5.18.7

LIKUFIX MH 40 quick-coupling system

Fig. 5-72

Lubricating MH 40 (with removable protective cover)

Fig. 5-73

Lubricating MH 40 (with housing)

2 1

Note!

5.18.8

Hydraulic quick change adapter

5 - 77

Fig. 5-74

Lubricating the quick change adapter

Note!

5.18.9

Mechanical quick-change adapter

Fig. 5-75

Note!

5 - 78

Lubricating quick-change adapter

5.19 Couplings of the quick-change adapter systems (optional equipment) 5.19.1

Hydraulic coupling

Fig. 5-76

Hydraulic coupling plug

Cleaning:

Changing seal ring:

Fig. 5-77

Changing seal ring

5 - 79

Caution!

A B C D E F

5.19.2

LIKUFIX electric coupling

Fig. 5-78 1

Electric couplings 2

1

5 - 80

2

1

5.20 Parking and swing gear brake

5.21 General maintenance tasks 5.21.1

Replacing wear parts

5.21.2

Replacing teeth on digging tool

5 - 81

U system:

Fig. 5-79

U system – replacing teeth on digging tool 2

1 A

B 2

C

Z system:

Fig. 5-80

Removing teeth from digging tool - Z system

1

2

3 5

4 6 1

2 A 3

a B

4 Note!

5 - 82

5

6 C

Fig. 5-81

Mounting teeth on digging tool - Z system 6

5 D

E b F 2a

5.21.3

6a

Welded parts on the machine

Caution!

5 - 83

5.22 Maintenance and inspection schedule Note!

Note!

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 904 C Litronic, type 1003 / 1004 / 1005 / 1071 by maintenance personnel (machine operator)

DIESEL ENGINE

5 - 84

together with authorised specialist technicians

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 904 C Litronic, type 1003 / 1004 / 1005 / 1071 by maintenance personnel (machine operator)

together with authorised specialist technicians

RADIATOR

FUEL SYSTEM

AIR FILTER

ELECTRICAL SYSTEM OF THE DIESEL ENGINE

5 - 85

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 904 C Litronic, type 1003 / 1004 / 1005 / 1071 by maintenance personnel (machine operator)

together with authorised specialist technicians

DIESEL ENGINE - EXHAUST GAS SYSTEM WITH PARTICLE FILTER (optional equipment)

HYDRAULIC SYSTEM

ELECTRICAL SYSTEM

5 - 86

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 904 C Litronic, type 1003 / 1004 / 1005 / 1071 by maintenance personnel (machine operator)

together with authorised specialist technicians

SLEWING GEAR MECHANISM

SLEWING RING

TRANSMISSION

AXLES

If travel accounts for more than 30 % of the total operating hours:

5 - 87

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 904 C Litronic, type 1003 / 1004 / 1005 / 1071 by maintenance personnel (machine operator)

STEERING

OSCILLATING AXLE SUPPORT

BRAKE SYSTEM

OPERATOR'S CAB + HEATING

AIR-CONDITIONING SYSTEM

5 - 88

together with authorised specialist technicians

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 904 C Litronic, type 1003 / 1004 / 1005 / 1071 by maintenance personnel (machine operator)

together with authorised specialist technicians

UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENTS

HYDRAULIC QUICK CHANGE ADAPTER

5 - 89

WORK TO BE CARRIED OUT A 904 C Litronic, type 1003 / 1004 / 1005 / 1071

Maintenance/inspection at operating hours

by maintenance personnel (machine operator)

together with authorised specialist technicians

MECHANICAL QUICK CHANGE ADAPTER

GENERAL

1 2 3 4

5 - 90