Liebherr Crawler Excavators R924 Litronic Operation and maintenance manual

Operation and Maintenance Manual

Litronic

FOREWORD This manual is primarily for the operator and the maintenance crew and contains information which is vital to the correct and secure operation and proper maintenance of the LIEBHERR excavator.

It includes: Accident Prevention Guidelines Operating Instructions Maintenance Instructions.

This Operation and Maintenance manual should be given to the OPERATOR and any other person, who might work on the machine. It is very important that should read the manual carefully before operating or working on the LIEBHERR excavator and at regular intervals thereafter, for example: - Operation, including installing and removing the attachments, trouble

shooting during operation, removing production residue, care, disposing of operating and auxiliary fluids, - Maintenance work (maintenance, inspection, repair), - Transportation.

The manual will make it easier for the operator to get accustomed to the hydraulic excavator and to prevent any problems due to improper handling.

All maintenance personnel should follow the operating and maintenance instructions and your LIEBHERR excavator will give you constant and reliable service with excellent performance, reducing repair costs and down time.

In addition to the operating and maintenance guidelines is this manual, additional local and national accident prevention guidelines and environmental regulations might be applicable and must be observed.

The Operation and Maintenance Manual is part of the machine and should be left in the glove compartment of the operator's cab.

Please take notice that we cannot honor any claims which could arise due to careless handling, improper operation, inadequate maintenance, use of unauthorized oils or lubricants, non-observance of the safety instructions, etc.

LIEBHERR reserves the right to cancel any warranty claims, service contracts etc. without prior notice if any other than Original LIEBHERR parts or parts sold

by LIEBHERR are being used for maintenance and repairs.

This Operation and Maintenance manual contains all necessary information to operate and maintain your Litronic track type excavator. However, should you need additional information or explanations, please contact LIEBHERR's Technical Documentation, Service school or Customer Service Department.

0.1

INDEX Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Information to the operation and maintenance manual

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0. 1 0.3 0.5

MACHINE DESCRIPTION, TECHNICAL DATA Machine description, technical data Digging envelope Lift capacities

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SAFETY INFORMATIO N Destined use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Crushing and burn prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Fire and explosion prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Machine start up safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Engine start up and operating safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 Machine operating safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 Machine parking safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Machine transporting safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Machine towing safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Machine maintenance safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Additional safety guidelines for excavators fitted with a cab elevation . . . . . . . . . . . . . . . . . . . . . . . . 2.1 O 2.14 Signs on the hydraulic excavator . .............. . .. ..... .

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CONTROLS AND INSTRUMENTATION The operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Controls and instrumentatio n in the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 3.6 Monitoring display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Informations provided in the menus of the LCD screen . . . . . . .

3.19 Controls and instrumentatio n for optional equipments . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outfit of driver's cab . . . . . . . . . . .

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OPERATING PROCEDURES Pre starting inspection ... .. .............. . .. .... .. .... . .. . .. . ....... . ..... . .. .

Machine start up safety ....... .... . ..... . .. . ... . .... ... ... . ..... .. .

Diesel engine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. ... .. .. .. . . . ...

External starting procedure . . . . . . . . . . . . ... . . ..... .... .. . . .. .. . .. . . . . . .. .. .. .... . . . . . . . . . . . . . . operation safety pumps Hydraulic Machine operating safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location of the two joysticks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control of the swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attachment control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The heater and air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting the excavator on flatbed trailers or railway cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Towing the excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal and installation of attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Guidelines for hydraulic excavators when they are used for lifting loads The overload warning device .. .... .............. .. . ........... .. ... .

0.3

4.1 4.3 4.4 4.7 4.7 4.8 4.9 4.10 4.12 4.12 4.14 4.14 4.18 4.21 4.22 4.23 4.30 4.31

5/

LUBRICATION General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricant and fuel chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricant and fuel specification s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication chart . .. .......... . .. .

Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing the oil in the travel gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing the oil in the swing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil in the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .

Swing ring lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication of attachment bearing points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Centralized lubricating system {Optional equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grapple lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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5.1 5.2 54 5.10 5.11 5.15 5.15 5.16 5.19 5.20 5.21 5.25

MAINTENA NCE Machine maintenanc e safety . ... .... ... ... .. ... . .. . . .. . . . . ....... .. . . . .... . ... . ... . .. ... .. .

The fuel system . ...... ... . . ..... .... . .. . . . . . ..... . .. . . . . . .. . . .. . .. . . . ... . .. . ........... . . .

The diesel engine . .. .. ......... .. . . .. .. .. . . ... .. ... .. ... . . . ... . . .... . ...... . ... . . .. .... . . .

The track components .. .. ... . ... ... . . . . . ... .. . . .... . . . ...... .. .. . ..... . . . . . .. .... . . .. . .

The hydraulic system .. ... . . . .. . .... ... . .. ..... . .... . .. . . . .. . ......... . ...... . . .. ... ... .. .

The swing and travel brakes . . . . ... . .. . ...... . ... . .. . . . .. . . . .. . ......... . . . . . . . . .. . . . . .. .. .

Checking mounting screws for tightness . . ... .. .. . . . . . ..... . . ... .. ... . . .. . . ... . ...... . . . .. .

The air filter ... . . . .. ... . ... .. .... . .... . . .. . .. . . .... ..... . ..... . .. .. ... . ...... .. ..... . .. . .

The electrical system . . .... . . .. . ... .. . . ...... . ..... . . .. ... . ... . ... . .......... .

The heater and air conditioner ... .. ....... .. .. . . . . .. .

Replacing the bucketteeth ... .. . . .. . ...... .

Replacing wear and tear items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenanc e schedule

6.1 6.4 6.6 6.8 6.10 6.14 6.15 6.16 6.18 6. 20 6.22 6.23 6.2 3 6.25

7/ This chapter intentionna lly blank . .. .... . .. . . . ... . . . . . . . .. . . .. . . . . . .. . . . . ... . . . ........ . . . . .

8/

OPTIONAL ATTACHM ENT 8.2 .1 Hydraulic quick change adapter 8.2.9 Mechanical quick change coupler .. .. ... . .. . .

8.3 Swing brake semiautoma tic controlled 8.6 . . .. . ..... . . . . . . .

Bypass oil filter for hydraulic circuit . . . .

8.7 Use of environmen tally friendly hydraulic fluids . . . .. . .. . . .. . ....... . ...... . . . ... .. .

Refueling pump .. . . .. ... . .. . ..... . ..... . .. .... . . . . . ..... . ....... . ... . ... . . . . .. . . .. ... . .. . . 8.8

0.4