Liebherr EP 944C 1172 1173 Hydraulic Excavator Operating Manual SN 25251 - PDF DOWNLOAD

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Operating manual Hydraulic excavator EP 944C from serial number 25 251

Document identification ORIGINAL OPERATING MANUAL Order number:

10360388

Edition:

03 / 2013

Valid for:

EP 944C from serial number 25 251

Author:

LFR - Technical documentation department

Product identification Manufacturer:

Liebherr-France SAS

Type:

EP 944C

Type no.:

1172 / 1173

Address Liebherr-France SAS 2 avenue Joseph Rey, B.P. 90287 F - 68005 Colmar Cedex

Operating manual

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

This will also be of use to you when ordering replacement parts.

Vehicle ident. number: WLHZ . . . . . ZK . . . . . .

Construction year: . . . .

First start-up date: . . / . . / . .

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EP 944C / 10360388

Introduction

This operating manual has been specifically devised for machine operators and maintenance personnel. It contains important warnings, information and tips regarding the maintenance and proper operation of the machine. It assists you in becoming familiar with the functions and features of the machine and helps prevent incorrect operation.

By strictly adhering to the instructions in the operating manual, you can significantly enhance the reliability and service life of the machine.

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.

Carefully read the operating manual before starting the machine and then regularly read it again. All persons carrying out work on or with the machine must be fully familiar with the content of the operating manual and must adhere to the instructions.

Such work include: Machine operation including tooling, troubleshooting during work, general care and cleaning, disposal of fuels and lubricants.

Maintenance including inspection, servicing and repair.

Transport or loading of the machine.

The machine owner must ensure that this operating manual is complemented with the relevant statutory regulations for accident prevention and the protection of the environment. Apart from the instructions in this operating manual and the statutory accident prevention, health and safety regulations applicable in the country of operation, all personnel working on or with the machine must adhere to best practice for safe and proper operation.

Certain sections in this manual might not apply to your specific model.

Some of the figures in this operating manual might show details or equipment that differ from those in your machine.

Some of the figures show the equipment with guards or covers removed (for better depiction).

As our products are constantly being improved, certain changes might be made to the equipment which are not referred to specifically in this operating manual.

Should you require additional information or if you have any queries, please contact the LIEBHERR customer service department.

Warranty and liability Due to the range of products (e.g. fuels, lubricants, tool attachments, spare parts) available from other manufacturers, LIEBHERR is not in a position to assess the compatibility of these products with its own machines. This also applies in relation to possible effects that third-party products have on LIEBHERR products and vice versa.

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Operating manual

It is therefore the responsibility of the machine owner to assess whether third-party products can be safely used in conjunction with the LIEBHERR machine. LIEBHERR shall not be liable for damage to or downtimes of LIEBHERR machine caused by the use a third-party products. Such damage is not covered by the LIEBHERR warranty.

LIEBHERR shall not be liable for damage caused by improper operation, insufficient maintenance or non-compliance with safety instructions.

Amendments, general terms and conditions, copyright We reserve the right to modify our products and amend the instructions in this operating manual without prior notice.

The reproduction or publication of the content of this operating manual (including figures) is prohibited. LIEBHERR reserves all rights in this operating manual, including copyright.

The warranty and liability clauses of the general business terms and conditions of LIEBHERR apply.

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Table of contents 1

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

1.2 1.3 1.4 2

Safety instructions, Signs on the machine ................................................................................................. 2-1 2.1 2.2 2.3 2.4 2.5 2.6

3

Assembly - overview.............................................................................................................................. 1-1 1.1.1 Machine with backhoe attachment ........................................................................................... 1-1 1.1.2 Machine with industrial attachment .......................................................................................... 1-2 1.1.3 Uppercarriage........................................................................................................................... 1-3 1.1.4 Elastical suspension................................................................................................................. 1-4 Vibration emissions................................................................................................................................ 1-4 Sound emission ..................................................................................................................................... 1-5 Technical data ....................................................................................................................................... 1-5

Meaning of the symbols in this manual.................................................................................................. 2-1 Use in accordance with the regulations ................................................................................................. 2-2 Safety instructions for electric excavators ............................................................................................. 2-2 Safety Instructions ................................................................................................................................. 2-4 Servicing the machine safely ............................................................................................................... 2-15 Signs on the machine .......................................................................................................................... 2-21 2.6.1 Introduction............................................................................................................................. 2-21 2.6.2 Arrangement of signage ......................................................................................................... 2-22 2.6.3 Explanation of signage ........................................................................................................... 2-23 2.6.4 Type plates on the machine ................................................................................................... 2-29

Control and operation ................................................................................................................................... 3-1 3.1

3.2

3.3

3.4

Operating and control elements............................................................................................................. 3-1 3.1.1 Controls in the op ...... 3-1 3.1.2 The joysticks............................................................................................................................. 3-3 3.1.3 Control unit ............................................................................................................................... 3-7 3.1.4 Monitoring display .................................................................................................................. 3-12 3.1.5 Main screen ............................................................................................................................ 3-14 3.1.6 Information provided in the menus ......................................................................................... 3-18 3.1.7 Glancing through the available menus ................................................................................... 3-31 3.1.8 Controls and instrumentation for optional equipments ........................................................... 3-32 Access and equipment of the cab........................................................................................................ 3-36 3.2.1 Entering or leaving the cab..................................................................................................... 3-36 3.2.2 The safety lever...................................................................................................................... 3-38 3.2.3 Operator seat ......................................................................................................................... 3-39 3.2.4 Putting on and releasing the safety belt ................................................................................. 3-42 3.2.5 Windscreen ............................................................................................................................ 3-42 3.2.6 Sunshade ............................................................................................................................... 3-43 dow ............................................................................................... 3-44 3.2.8 Interior lighting ........................................................................................................................ 3-44 3.2.9 Fire extinguisher ..................................................................................................................... 3-44 3.2.10 The heater and air conditioner ............................................................................................... 3-45 Setting the machine into operation ...................................................................................................... 3-52 3.3.1 Notes on measures to be taken before starting the machine ................................................. 3-52 3.3.2 Switching on the electrical system ......................................................................................... 3-55 3.3.3 Starting the electric motor ...................................................................................................... 3-57 3.3.4 Starting procedure for exterior temperature below -18 °C (0 °F)............................................ 3-57 3.3.5 Shutting down units ................................................................................................................ 3-57 3.3.6 Starting aids ........................................................................................................................... 3-59 Working with the machine.................................................................................................................... 3-59 3.4.1 Uppercarriage swing movements ........................................................................................... 3-59 3.4.2 Working position ..................................................................................................................... 3-62 3.4.3 Working attachment control.................................................................................................... 3-62

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Operating manual

3.4.4 Lowering the working attachment with the engine shut down ................................................ 3-64 3.4.5 Rotating, tilting, locking and unlocking a working tool ............................................................ 3-65 3.4.6 Control of the swivel rotator (option)....................................................................................... 3-67 3.4.7 Control of additional attachments via the additional pedals ................................................... 3-68 3.4.8 AHS11 proportional control (option) ....................................................................................... 3-70 3.4.9 Commutation of control for an additional attachment (option) ................................................ 3-71 3.4.10 Special control system of the joysticks ................................................................................... 3-73 3.4.11 Special control (option) ........................................................................................................... 3-76 3.4.12 Cut-off of attachment movements (option) ............................................................................. 3-76 3.4.13 Use of the excavator for lifting loads overhead ...................................................................... 3-79 3.4.14 Overload warning system (option).......................................................................................... 3-80 3.4.15 Adjustable hydraulic cab (option) ........................................................................................... 3-81 3.5 Emergency operation........................................................................................................................... 3-84 3.5.1 Emergency control circuit board E52 for electric motor & servo control ................................. 3-84 3.5.2 Emergency operation of the working pumps .......................................................................... 3-86 3.6 Attaching and dismounting equipment parts........................................................................................ 3-87 3.6.1 Removal and installation of a bucket ...................................................................................... 3-87 3.6.2 Attaching and dismounting the bucket with improved sealing ................................................ 3-89 3.6.3 Attaching and dismounting the grab on stick .......................................................................... 3-91 3.6.4 Attaching and dismounting the grab on the industrial stanchion ............................................ 3-94 3.6.5 Attaching and dismounting the stick to the boom ................................................................... 3-96 3.6.6 Mechanical quick-change adapter (option)............................................................................. 3-98 3.6.7 Hydraulic quick-change adapter (option) .............................................................................. 3-102 system (option)...................................................................... 3-109 3.7 General working methods .................................................................................................................. 3-112 3.7.1 Minimum impact working methods for your machine............................................................ 3-112 3.7.2 Preparatory activities ............................................................................................................ 3-112 3.7.3 Using a backhoe bucket ....................................................................................................... 3-113 3.7.4 Loading a transport vehicle .................................................................................................. 3-115 3.7.5 Skimming .............................................................................................................................. 3-115 3.7.6 Using a clamshell bucket (earthmoving attachment) ............................................................ 3-116 3.7.7 Using a multiple tine grapple (industrial attachment)............................................................ 3-119 3.7.8 Using an hydraulic hammer .................................................................................................. 3-120 3.8 Installing and removing counter weight.............................................................................................. 3-121 3.8.1 Safety instructions for the attachment and removal of the counter weight ........................... 3-121 3.8.2 Removing counter weight ..................................................................................................... 3-122 3.8.3 Re-attaching counter weight ................................................................................................. 3-122 3.9 Installing and removing elastic bearing in electric excavator ............................................................. 3-123 3.9.1 Safety instructions for the installation and removal of the elastic bearing ............................ 3-123 3.9.2 Installing elastic bearing ....................................................................................................... 3-124 3.9.3 Reinstalling elastic bearing ................................................................................................... 3-125 3.10 Transport............................................................................................................................................ 3-128 3.10.1 Lifting the machine with a crane ........................................................................................... 3-128 3.10.2 Secure the machine.............................................................................................................. 3-131 4

Troubleshooting............................................................................................................................................. 4-1 4.1 4.2

4.3

Error code list......................................................................................................................................... 4-2 Troubleshooting ..................................................................................................................................... 4-4 4.2.1 Hydraulic system ...................................................................................................................... 4-4 4.2.2 Travel gearbox.......................................................................................................................... 4-5 4.2.3 Electrical system....................................................................................................................... 4-5 4.2.4 Working attachment.................................................................................................................. 4-6 4.2.5 Heating and air-conditioning system ........................................................................................ 4-6 Fuses and relays.................................................................................................................................... 4-9 4.3.1 Power switch cabinet with main fuses E50............................................................................... 4-9 4.3.2 A1010 printed circuit board..................................................................................................... 4-10

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Operating manual

5

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

Access doors for maintenance .............................................................................................................. 5-1 5.1.1 Overview of access doors ........................................................................................................ 5-1 5.1.2 Door retaining rods ................................................................................................................... 5-2 5.2 Cleaning machine .................................................................................................................................. 5-2 5.3 Care for rubber components.................................................................................................................. 5-3 5.4 Lubricants and fluids.............................................................................................................................. 5-4 5.4.1 General information .................................................................................................................. 5-4 5.4.2 Filling volume and lubricant chart ............................................................................................. 5-4 5.5 Lubricants and fluids specification ......................................................................................................... 5-7 5.5.1 Lubricant for motor bearing ...................................................................................................... 5-7 5.5.2 Heating fluid system ................................................................................................................. 5-8 5.5.3 Checking heating fluid, adjusting mixing ratio ........................................................................ 5-11 5.5.4 Hydraulic oil ............................................................................................................................ 5-14 5.5.5 Lubricants for gearboxes........................................................................................................ 5-19 5.5.6 Grease.................................................................................................................................... 5-20 5.5.7 Lubricants and care products for electrical and mechanical components .............................. 5-21 5.6 Electric motor....................................................................................................................................... 5-21 5.6.1 Type plate............................................................................................................................... 5-21 5.6.2 Routine maintenance ............................................................................................................. 5-22 5.6.3 Reversible fan (option) ........................................................................................................... 5-24 5.7 Hydraulic system ................................................................................................................................. 5-25 5.7.1 Depressurising the hydraulic system...................................................................................... 5-25 5.7.2 Checking oil level in hydraulic tank; emptying and refilling tank............................................. 5-26 5.7.3 Checking and cleaning oil cooling system.............................................................................. 5-29 5.7.4 Return filter ............................................................................................................................. 5-30 5.7.5 Leak oil filter ........................................................................................................................... 5-31 5.7.6 Control oil filter ....................................................................................................................... 5-32 5.7.7 Feed line filter of the slewing gear circuit ............................................................................... 5-33 5.7.8 Control circuit ......................................................................................................................... 5-33 5.7.9 Bleeding the hydraulic pumps ................................................................................................ 5-34 5.7.10 Bleeding the hydraulic cylinders ............................................................................................. 5-36 5.7.11 Disconnecting suction hose of pump...................................................................................... 5-38 5.7.12 Breather filter on hydraulic tank.............................................................................................. 5-39 5.7.13 Bypass oil filter for hydraulic system (option) ......................................................................... 5-40 5.7.14 Return oil filter for hydraulic hammer (option) ........................................................................ 5-41 5.7.15 Servicing the hydraulic cylinder .............................................................................................. 5-42 5.7.16 Replacing hydraulic hoses ..................................................................................................... 5-43 5.8 Oil changes on components ................................................................................................................ 5-44 5.8.1 General information ................................................................................................................ 5-44 5.8.2 Swing gear - Oil level check and oil change........................................................................... 5-44 5.8.3 Pump distributor gear - oil change ......................................................................................... 5-45 5.9 Electrical installation ............................................................................................................................ 5-47 5.9.1 Electrical rotary connection .................................................................................................... 5-47 5.9.2 24 V electrical system ............................................................................................................ 5-48 5.9.3 Battery care (option) ............................................................................................................... 5-49 5.9.4 Slip ring body (option) ............................................................................................................ 5-50 5.9.5 Cabinet air pressuring system (option)................................................................................... 5-50 5.10 Heating and air-conditioning system.................................................................................................... 5-51 5.10.1 Recirculated and ambient air filters ........................................................................................ 5-52 5.10.2 Heating system....................................................................................................................... 5-53 5.10.3 Air-conditioning system .......................................................................................................... 5-54 5.11 Greasing the machine.......................................................................................................................... 5-57 5.11.1 The centralized lubrication system ......................................................................................... 5-57 5.11.2 Semi automatic and full automatic systems ........................................................................... 5-59 5.11.3 Operation of the semi automatic system ................................................................................ 5-59 5.11.4 Operation of the full automatic system ................................................................................... 5-60 5.11.5 Emergency lubrication with defective lubrication system ....................................................... 5-62

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Operating manual

5.12

5.13

5.14 5.15

5.16

5.11.6 To refill a grease container ..................................................................................................... 5-62 5.11.7 Changes in the lubrication circuit............................................................................................ 5-63 5.11.8 Greasing the grab (optional extra) .......................................................................................... 5-64 Quick-change systems......................................................................................................................... 5-65 5.12.1 Greasing the mechanical quick-change adapter (option) ....................................................... 5-65 5.12.2 Hydraulic quick-change adapter (option) ................................................................................ 5-65 5.12.3 LIKUFIX (option) ..................................................................................................................... 5-66 Check mounting bolts for tightness...................................................................................................... 5-67 5.13.1 Mounting bolts of the counterweight ....................................................................................... 5-68 5.13.2 Mounting screws of the swing ring ......................................................................................... 5-68 5.13.3 Mounting screws of the hydraulic oil and fuel tank ................................................................. 5-69 5.13.4 Mounting screws of the swing gear and motor ....................................................................... 5-69 5.13.5 Fixing bolts of catwalks around the upperstructure ................................................................ 5-70 Drive unit brakes and swing gear brakes............................................................................................. 5-70 General maintenance points ................................................................................................................ 5-70 5.15.1 Replacing working parts ......................................................................................................... 5-70 5.15.2 Checking or replacing the teeth on the bucket ....................................................................... 5-71 5.15.3 Welding work on the machine ................................................................................................ 5-73 Inspection and maintenance schedule................................................................................................. 5-73

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

1.1.1

Machine with backhoe attachment

Fig. 1-1

Machine with backhoe attachment

100

Uppercarriage

340

Bucket

300

Boom

350

Bucket cylinder

310

Boom cylinder

400

Elastical suspension

320

Stick

1000 Rotary connection

330

Stick cylinder

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1-1

Product description

Operating manual

Assembly - overview

1.1.2

Machine with industrial attachment

Fig. 1-2

Machine with industrial attachment

100

Uppercarriage

330

Stick cylinder

300 310

Industrial boom Boom cylinder

340 400

Grapple Elastical suspension

320

Industrial stick

1000 Rotary connection

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Operating manual

Product description Assembly - overview

1.1.3

Uppercarriage

Fig. 1-3

Uppercarriage

500

Electrical motor

7200 Radiator box

700 800

Swing gear installation Swing ring installation

7300 Hydraulic pumps 7600 Control valve block

1400 Centralized lubrication system 6000 Control cab

8200 Slewing platform 8700 Cab

6220 Control panel, left

8800 Cab elevation

6230 Control panel, right 7000 Hydraulic installation

9000 Electrical installation 9100 Electrical box

7100 Hydraulic oil tank

9500 Counterweight

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1-3

Product description

Operating manual

Vibration emissions

1.1.4

Elastical suspension

Fig. 1-4

Elastical suspension

2

Elastical suspension

3

Elastical element

10 Support

1.2 Vibration emissions The operator seat built into the machine by the manufacturer conforms to ISO 7096:2000, EM 6. When replacing the seat, ensure that the new seat also conforms to this standard.

Hand-arm vibration If the machine is operated according to the manufacturer instructions, the weighted (frequency-rated) effective hand-arm vibration is below 2.5 m/s² according to ISO 5349-1:2001.

Whole-body vibration If the machine is operated according to the manufacturer instructions, the weighted (frequency-rated) effective vibration shown for specific machine applications in the table below apply. These values conform to the specifications in the technical report exposure to whole-body vibration of ri measured by international institutes, organizations and manufacturers". The method of assessment conforms to ISO 2631-1:1997. The effective values in the table for representable machines are shown with the applicable standard deviations. These deviations are classified according to the operating conditions in the classes "lightduty", "normal" and "heavy-duty". It is the responsibility of the machine owner to assess the operating conditions according to the classes, taking into account the terrain, site conditions, site organisation, material, machine equipment, working procedure and training of the operator.

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Operating manual

Product description Sound emission

As the quoted values are effective values for specific, common applications, the whole-body vibration to which the operator is exposed can only be estimated. For a more detailed assessment of the daily exposure of the operator across an 8-hour shift, please refer to the LIEBHERR brochure on whole-body vibration and the software designed for the assessment. This document and software are available from the LIEBHERR dealer and are included as standard on the documentation CD (Lipart) shipped with new machines.

For instructions how to reduce whole-body vibration during operation of mobile construction machinery, please refer to chapter "Control, operation / working with machine / safety instructions / vibration protection".

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

Crawler excavator

Mobile excavator

Typical working cycles

x-axis

y-axis

z-axis

1

2

3

1

2

3

1

2

3

Excavator

0.14

0.31

0.49

0.08

0.19

0.31

0.13

0.30

0.47

with hydraulic hammer

0.16

0.38

0.59

0.09

0.22

0.35

0.27

0.55

0.83

Use for mining

0.31

0.46

0.61

0.19

0.30

0.41

0.29

0.61

0.93

Transfer travel

0.21

0.34

0.48

0.09

0.23

0.37

0.56

0.79

1.02

Excavator

0.19

0.37

0.56

0.09

0.25

0.41

0.16

0.29

0.42

Transfer travel

0.21

0.29

0.38

0.24

0.38

0.52

0.42

0.61

0.80

The measurement uncertainty is defined in standard EN 12096:1997.

1.3 Sound emission The sound values of the machine are specified in the technical data.

The sound power level (Lwa) is determined according to Directive 2000/14/EG. The measurement uncertainty of the sound power level value corresponds to the difference between the guaranteed and the measured value.

The sound pressure level (Lpa) is determined according to ISO 6396. The measurement uncertainty is defined in the above standard.

Excavator

LwA [dB(A)]

LpA [dB(A)]

E 934 C

101

66

E 944 C

101

65

R 924 Compact Tunnel

102

80

R 944 C Tunnel

105

82

1.4 Technical data This should be taken from the accompanying technical description.

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Product description

Operating manual

Technical data

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2 Safety instructions, Signs on the machine 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 note the safety information, however, you can prevent danger and accidents. This is particularly true for those who are only occasionally in contact with the machine, eg. 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 precautions does not release you from the responsibility to take note of safety regulations which apply on site or of guidelines given by legal bodies or professional associations.

For EU countries, guideline 2009 / 104 / EC contains the minimum safety information applicable to the owner.

2.1 Meaning of the symbols in this manual Work processes and actions that could cause danger are accompanied by safety informations in these operating instructions. These safety informations describe 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 meaning: Danger!

Warning relating to a danger that carries with it 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 identifies user tips and operating and maintenance procedures whose use will guarantee a high degree of user-friendliness and longevity to the machine or which will considerably simplify working procedures.

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

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2-1

Safety instructions, Signs on the machine

Operating manual

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.

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 responsibility for following additional rules and guidelines!

Additional points that should be noted are:

2.2 Use in accordance with the regulations th work equipment (eg. hoe type bucket, grab, bucket attachment) designed to detach, lift, transport and shake off earth, stones and other materials, while the transportation of the load itself usually takes place without moving the machine. Moving the machine when it is carrying a load must be carried out while observing the appropriate safety measures (see section "Notes for safe working"). with the stipulated safety device equipped with exhaust gas reducing equipment (e.g. diesel particle filter). Always comply with the statutory regulations applicable at the location of operation. ents and possibly also special safety devices. This equipment may only be attached to the machine and used with the explicit consent of and according to the instructions of the manufacturer of the basic machine. ting persons or working in explosive atmospheres or contaminated environments is not deemed to be in accordance with regulations. The manufacturer is not liable for any damage resulting from this action. The user is solely responsible for the risk incurred. ns and the inspection / maintenance instructions is also deemed to be appropriate use in accordance with regulations.

2.3 Safety instructions for electric excavators

in the manual issued by the supplier of the electrical box installation.

Connection and commission Electrocution hazard!

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EP 944C / 10360388

Operating manual

Safety instructions, Signs on the machine Safety instructions for electric excavators

Danger of death. safety instructions:

- connecting the machine to an outside power source - installation of the electric protection device - commission of an electric excavator To manipulate switched-on wiring: uipment, in particular insulated gloves adapted to the main voltage of the machine. system is properly protected against the following:

excavator is balanced to avoid electrical malfunctions and system or component damage. (section, nominal voltage, cable or insulator type,...).

on the safety signs. y illegible, damaged or missing safety sign.

Machine operation Risk of wrenched off cable: - Use only the normal travel speed.

- Do not subject the cable to excessive traction.

- Do not use the working attachment to move the cable.

Risk of crushing under the tracks: - When driving the machine, align the uppercarriage so that you can at all times see the power cable.

Maintenance Electrocution hazard!

Danger of death.

Certain parts of the electrical circuit remain powered even after the main disconnecting switch has been actuated, after the start key is removed or after the battery (option) is disconnected. See electrical diagram of the machine. and tagged:

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2-3

Safety instructions, Signs on the machine

Operating manual

Safety Instructions

- work on the hydraulic and electrical rotary connection - work on the hoses Before carrying out any work on the machine: ication and habilitation level is sufficient for the task. edure for each cleaning, maintenance or repair work of the machine.

The following operations can only be carried out by qualified electricians: ative hazardous power sources, ng an electrical box with a tension over 50V To lock and tag the main power supply station, observe in particular the following instructions: for persons working on the electrical circuit or on the machine. elements:

at least one qualified person.

outside the machine (when possible) station outside the machine not carry out the planed work on the machine yourself.

2.4 Safety Instructions General safety instructions with the operating instructions before starting up the machine. relating to special accessories for the machine. erate, maintain or repair the machine.

The legal minimum age is to be adhered to. instructed personnel. Clearly establish which personnel are responsible for operating, setting up, maintaining and repairing the machine. Give personnel the power to refuse to carry out unsafe instructions by third parties. This also applies in relation to traffic regulations.

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EP 944C / 10360388

Operating manual

Safety instructions, Signs on the machine Safety Instructions

general training to operate on the machine under the constant supervision of an experienced member of staff. ensure that they are adhering to safe working practices, are aware of risks and are observing the operating instructions.

Avoid wearing rings, wrist watches, ties, scarves, open jackets, baggy clothing etc... There is a risk of injury from, for example, getting caught up or being drawn in. tective goggles, safety helmets, safety shoes and gloves, reflective vests and ear protection etc...). y special safety regulations for the job site from the site foreman.

joystick. Doing this could cause unintentional movement, which could result in an accident. steps, ladders, gangplanks and supporting straps provided for this purpose. two hands and one foot or two feet and one hand must always be in contact with the access system at the same time. cation of the emergency exit. and repair work: ge so that the sprockets locate at the back-end

circuits, you must also operate all pilot control devices (joystick and pedals) in all directions with the start key in contact position and with the security lever lowered, in order to reduce the actuating and dynamic pressures in the work circuits. You must then reduce the internal tank pressure as described in these operating instructions.

checking whether any warning signs are missing or illegible. st be equiped with specific safety equipments. Work only if they are mounted and functional. which may affect safety without the express permission of the manufacturer. This also applies for the installation of safety devices and valves and for welding work on load-bearing parts.

been validated by LIEBHERR for installation or extension, has not to be installed or added onto the excavator without previous written agreement of LIEBHERR. Wherefore the necessary te disposal.

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2-5

Safety instructions, Signs on the machine

Operating manual

Safety Instructions

Avoidance of crushing and burns not safely positioned on the ground or supported. ropes or chains.

correct punch for the procedure. hen the engine is on. The fan will eject or destroy these objects and will itself be damaged. exhaust system and of the hydraulic system can reach very high temperatures.

Avoid coming into contact with coolant carrying parts, with parts from the exhaust system and with hot oil or oil-bearing parts.There is a risk of sustaining burns. g cap of the expansion container has cooled to a point where it is possible to touch it. Then turn the cap carefully to let off the overpressure. d gloves when working on the battery. Avoid sparks and naked flames. by auxiliary personnel. against unintentional closing by positioning the supports provided for this purpose. ed with work equipment and has not been correctly and securely supported with hardwood beams.

Avoidance of fire and explosions refuelling and charging the batteries.

ons, blown fuses and lamps and clogged or abraded cables rectified by personnel. the tanks provided for this purpose.

abrasion and heat accumulation. or in inadequately ventilated areas. preheating or flame glow systems. There is a risk of EXPLOSION. location and operation of fire extinguishers on the machine and with local fire warning and fire abatement options. to facilitate the fight against fire in case of.

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EP 944C / 10360388

Operating manual

Safety instructions, Signs on the machine Safety Instructions

Bringing the machine safely into service it. person, is in the work and movement area of the machine.

osed, but that locks are unlocked, to facilitate the fight against fire in case of.

against unintended movement. vicinity of the machine that it is about to start by sounding the horn.

Safely getting up even, horizontal ground. Position the upper structure with the undercarriage in such a way that the steps and ladders are aligned with each other. ils (grips) are in good condition. In particular, ensure that they are free of dirt, oil, ice and snow. in all weather conditions, the door seals must be dusted with talc or silicon at least every two months or more often if required. The door hinges and locks should be greased regularly. method, i.e. two hands and one foot or two feet and one hand must always be in contact with the access system at the same time. as necessary and open it, while paying attention to remain out of its swing radius before you climb any higher. External influences, such as wind, can make it more difficult to open doors.

Because of this, always lead along the door with your hand during the whole opening motion. Ensure that the door locks in place when reaching its open position, so to prevent it can slam open and shut. he three-point support and sit down in the on as you enter the cab. lever, Close the door thereafter using the both handholds mounted to the inner face of the door frame. Only after it tilt down the safety lever, and start the machine. ur safety belt if you wish to work with the door open. l support or employed as a component of a larger installation (uppercarriage used on a pontoon, on a gantry crane,...), also consider the safety instructions in to machine relating to a safe getting up.

controls in such a way that you are able to work comfortably and safely.

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Safety instructions, Signs on the machine

Operating manual

Safety Instructions

throughout operation.

Protection from vibration - seat adjusting

and height of the operator. ensure that these seat char instructions.

Utilisation in confined spaces ventilated spaces. Before starting in closed areas, ensure adequate ventilation.

Follow the regulations which apply for the particular area of use.

Starting the machine safely l and tilt the safety lever up.

regulations given in the operating instructions. test all display and checking devices. ventilation. If necessary, open doors and windows to ensure sufficient fresh air supplies. make the control unit react sluggishly.

running and slewing gear brakes, the steering and the signaling and lighting devices.

Stopping the machine safely

it from rolling away. is possible, align the uppercarriage with the undercarriage so that the sprockets locate at the back-end. This is the only one position which enables a secured access to every maintenance locations on the uppercarriage. r structure facing the undercarriage, if available.

slewing brakes. lever up before leaving the cab. secure the machine against unpermited use and vandalis.

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Operating manual

Safety instructions, Signs on the machine Safety Instructions

Safely getting down to instal yourself. ground. The upper structure should be positioned with the undercarriage in such a way that the steps and ladders are aligned with each other. locking. Take care of weather conditions !

Unfasten the safety belt. rd the machine when getting out and use three-point support, i.e. two hands and one foot or two feet and one hand must always be in contact with the access system at the same time. Climb down until you can close the doors safely. Always use your hand for control when closing the doors. Lock the door.

Working safely with the machine with the special features of the job site and any special precautions and warning signals. Examples of particular work environments would be on-site or traffic obstructions, the load-carrying capacity of the ground and any requirements to make the job site safe from public use. ground. reduced visibility and changeable ground conditions. e location of power lines on the job site and take particular care when working near them. If necessary, inform the responsible authorities. aerial lines. Do not allow the equipment to come near cables when working near electrical aerial lines. Risk of fatality!

Inform yourself about required safety distances. the event of any transfer of electricity:

touch it, the danger zone to a sufficient distance, olutely sure that voltage in the line, which had been touched or damaged, has been turned off ! secured. regulations and if necessary, ensure that the machine has been made safe as per regulations beforehand. ns of poor visibility or darkness.

available). hat all necessary repairs are carried out immediately.

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Safety instructions, Signs on the machine

Operating manual

Safety Instructions

system in accordance with the regulations given in the operating instructions. while the machine is moving. and operated in such a way that it is stable and that there is no danger of overturning. Only known loads may be moved with the equipment; this applies particularly when using the grab. ngitudinal direction when moving and hold the load as close to the ground as possible.

EXCEPTION: "Safe use when loading and unloading (particularly when loading and unloading wood)" on page 11. tip the machine. Should the machine start to tip or slide sideways, however, turn the upper structure to face downhill and lower the equipment at the same time. uphill and not side on to the slope. eed or you could lose control of the machine. engine must run at maximal speed and the speed may only be reduced using the accelerator pedals. requirements are fulfilled, notably in order to protect the truck operator. devices specifically designed for the purpose. overview of and whenever necessary, ask for the assistance of a spotter. Only permit one person to give you signals. attach loads and give signals to the machine operator. The spotter must be positioned within the visual range of the operator or be in voice contact with him. he equipment combination, there is a risk of collision between the work tool and the cab, the cab protection or the boom cylinders. The greatest degree of care must be taken to avoid damage when the hoe teeth come within this area. he equipment combination, there is a risk of collision between the lift ring of the attachment and the cab or the cab protection. Before operating, ensure that there is no risk of collision, especially on excavator with cab elevation.

If necessary remove the lift ring.

the soil.

Otherwise, you must stop the excavator, turn off the radio and keep inside the closed cab until the end of the storm. functions. Always check their functions when starting up the machine. a ditch without striking the attachment on the ditch walls. attachment has been swung into a wall or any other obstacles. be used to strike the material being extracted are not permitted, even when working in a longitudinal direction.

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Operating manual

Safety instructions, Signs on the machine Safety Instructions

to damage to the steel structures and machine components. special teeth for heavy-duty or special applications are required. t with side cutters or that are during operations with rocky material. This would prolong the work cycles and may lead to damage to the bucket as well as further machine components. et position may only be employed if the working tool or the attachment does not touch the material. is not permitted. slowly back to the ground. hydraulics. This would damage the machine. is forbidden to raise the machine with the dozing blade (e.g. carving at the ceiling when tunnelling).

Safe use with a hydraulic hammer hydraulic hammer not permitted by LIEBHERR, steel structures or the other machine components can become damaged. n the machine on firm and level ground. ely for breaking stone, concrete and other breakable materials. and with the windshield closed or with a front protective grid. linder is entirely extended or retracted and that the stick is not in the vertical position. try not to break stone or concrete while performing retraction and extension motions of the hydraulic hammer. to the same place. Change the breaking point. Too long uninterrupted operation of the hydraulic hammer leads to an unnecessary overheating of the hydraulic oil. materials. Do not move obstacles with the hydraulic hammer. Misuse of this nature would damage both the hammer and the machine. hammer to lift objects

Safe use when loading and unloading (particularly when loading and unloading wood) equipment raised and the load lifted up; this applies, for example, when loading and unloading wood. y of the machine will be displaced upwards in the vertical direction. The driving characteristics of the machine will thus be influenced persistently, e.g. through reduction of the dynamic stability.

The following instructions are therefore to be observed at all times: environmental conditions. manoeuvres.

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Safety instructions, Signs on the machine

Operating manual

Safety Instructions

direction. the undercarriage is stationary.

rotated the upper structure to the driving position. when the equipment is raised. cab. ance with ISO 10262 must be attached if there is a risk of objects falling from above. such as logs, is dependent on length, diameter and specific weight. The influencing variables present in a natural product, such as moisture, must be noted. operator to receive special instruction and training. sufficient training and practical experience.

Safe use of machines with tower elevation the centre of gravity of the machine will be displaced upwards in the vertical direction. The driving and work characteristics of the machine will thus be influenced persistently, e.g. through reduction of the dynamic stability. the machine must be aligned horizontally before use. In horizontal alignment, the centre of gravity of the upper structure is over the centre of the undercarriage, which reduces the risk of tilting. tilt despite being aligned!

The following instructions are therefore to be observed at all times: When moving the machine: (transport position).

vered to ensure that the ground is solid and even.

Potholes and uneven surfaces jeopardize the stability of the machine. of gravity) and environmental conditions. manoeuvres. direction. direction in order to prevent unacceptable banking of the machine. slowly!

When loading and unloading: (slewing) the upper structure out of the transport position. act surface of the support (load carrying capacity of the substrate). A support subsiding would have disastrous

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Operating manual

Safety instructions, Signs on the machine Safety Instructions

consequences!

(Caution! swinging grab)and hold the load close to the undercarriage and above the substrate. uipment or upper structure abruptly.

Protection from vibration building machinery are mainly the result of the type and method of use. The following parameters in particular are decisive influences:

control elements when driving and working. selects the speed, gearbox ratio, working method and route himself.

This means that there is a wide range of different vibrational loads for the same machine type.

Whole-body vibrational load for the machine operator can be reduced if the following recommendations are observed: and auxiliary devices for each part of the job. (i.e. for earth-moving machinery such as hydraulic excavators, this should be a seat which corresponds with EN ISO 7096). d be adjusted depending on the weight and height of the operator. adjustment mechanisms regularly and ensure that these seat characteristics instructions. ine, particularly with respect to: tyre pressure, brakes, steering, mechanical connections etc. equipment jerkily.

working and driving in good condition:

calculate in sufficient time to carry out any work required. which reduce vibration for machines that are driven frequently.

If such auxiliary systems are not available, regulate speed to avoid "oscillating" the machine.

Attaching and removing equipment parts safely r manufacturers or those which do not have general approval from LIEBHERR for installation or attachment may not be

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Safety instructions, Signs on the machine

Operating manual

Safety Instructions

LIEBHERR must be provided with the appropriate technical documentation necessary for this purpose. on level, firm ground. not safely positioned on the ground or supported with wooden blocks. off the engine and press the start key to the contact position and both joysticks to reduce the pressure in the hydraulic system. and which have sufficient load carrying capacity. capacity. Wear work gloves when working with wire cables. tilted up. Never use your fingers to locate bores; use the correct punch for the procedure. lic lines are secured correctly and that all bolts and connections are tight. the hydraulic circuit to stop dirt entering. Only allow authorized persons in the vicinity of the machine or the lifting device used.

Removing and installing equipment bolts safely

hole conductor held by another person must be used. threaded hole and only hammer these screws. means of castle nuts and cotter pins, first drive the bolt to the stop, then screw the castle nut by hand until contact and then only pull it far enough to push in the cotter pin.

Transporting the machine safely suitable means of transport and lifting devices with sufficient load-carrying capacity.

transportation. an inclination of 30° and should have a wooden cover to prevent sliding back. ramp, clean any snow, ice and mud from the crawler / wheels of the machine.

pedals. ck to ensure against rolling back when the machine is driving up onto the flatbed.

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Safety instructions, Signs on the machine Servicing the machine safely

the equipment securely over the loading area, drive very carefully up the ramp and onto the transportation vehicle. e rear and lower the equipment. Due to restrictions during transport on hoe equipment, tilt the arm in and dismantle the bucket during transportation. d trailer, the upper structure must be secured facing the undercarriage using the stop bolts (only A devices). blocks to prevent slipping. ignition key and tilt up the safety lever.

particularly as they relate to width, height and weight restrictions. through tunnels. it was loaded. Remove all chains and blocks. Start the engine as per the operating instructions. Drive carefully the working equipment as securely as possible over the ground while doing this.

Have a spotter guide you.

2.5 Servicing the machine safely General safety instructions carried out by specially trained personnel. s given in the operating instructions for repeat tests / inspections. It is imperative that a suitably equipped workshop is available in order to carry out maintenance work. instructions defines precisely who is required / permitted to carry out what work.

Jobs listed as daily / weekly work may be carried out by the machine's driver or maintenance personnel when they have received appropriate instruction.

The remaining work may only be carried out by specialist personnel with appropriate training. the manufacturer. Original replacement parts are always guaranteed to meet these criteria. wearing of rings, wrist watches, ties, scarves, open jackets, baggy clothing etc...

There is a risk of injury from, for example, getting caught up or being drawn in.

Protective goggles, safety helmets, safety shoes and gloves, reflective vests and ear protection etc. are required for specific jobs. running.

Persons with pacemakers should not approach within 20 cm of the running diesel engine.

Do not touch voltage-carrying parts on the electrical connection of the individual solenoid injection pumps (Unit Pumps UP) while the diesel engine is running.

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Operating manual

Servicing the machine safely

maintenance work.

repair work. Designate persons in charge of supervision. the operating instructions, carry out all maintenance work on the machine on level, firm ground with the working equipment set aside and the engine switched off. every maintenance locations on the uppercarriage, is when the uppercarriage is aligned with the undercarriage so that the sprockets locate at the back-end.

The ladder situated on the undercarriage only corresponds with the vator is in this configuration. hut off the main battery switch.

counterweight must be replaced after every removal. d during set-up, maintenance and repair work, they must be immediately reinstalled and checked at the end of the work. rly visible position on the starting lock.

Pull out the start key and shut off the main battery switch. areas. Before operating these units, check ventilation. applicable local regulations.

Cleaning the machine before starting maintenance or repair work and pay particular attention to connections and screw fittings.

Do not use aggressive cleaning products and use lint-free cleaning cloths. machine for the first two months after initial set-up of the machine (or after repainting).

other cleaning materials: nections and the rim bearing to prevent water or steam entering the bearing points. ich for safety or functional reasons water or steam may not be permitted to enter.

Electric motors, electrical components, control boxes, plug connections and air filters are particularly at risk.

products during cleaning work.

The fire extinguisher could start. observe following recommendations : lower than 20 inches

use neutral cleaning agents such as

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Safety instructions, Signs on the machine Servicing the machine safely

customary car shampoos diluted to 2 or 3 percent maximum

lines for leakage, loosened connections, chafing and damage.

water or cleaning products that may have entered.

Sight field reinstalled and correctly adjusted before the initial set-up of the machine. ly the nearness area of the machine, during operation or when travelling.

to check the rear side of the machine; on some machines, this mirror is replaced or completed with a camera. ange on the machine, the sight condtions must be maintained. These conditions must otherwise be checked according to ISO 5006.

e dangers due to a restricted sight field are minimized, particularly for machines with an operating weight which is superior to 40 tons.

Crack testing perated carefully, there is a possibility of individual cases of overloading occurring, which could lead to cracks or loose connections.

The machine should therefore be checked regularly for cracks, loose connections or other visible damage to maintain operational safety. is essential that the machine is kept clean and cleaned regularly. maintenance plan:

supported, on firm, horizontal substrate, with the equipment in longitudinal and cross direction for variable loads. Current accident prevention regulations must be adhered to. g load-bearing components, particularly: nd transmission mountings, the support, the lower rim bearing support and tower and ball rim bearing. cylinder, the upper rim bearing support, the cab mount and the mount for swing gear and ballast. uipment, e. g. the boom, stay, quick change adaptor, and bucket.

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Operating manual

Servicing the machine safely

s and bolt connections, steps, ladders and mounting elements. penetration test should be carried out as a crack test on areas which do not have good visibility, such as the rim bearing support, in order to increase testing safety. parts of the earth-moving machinery, loading devices and transport devices may only be carried out by trained specialist personnel and only in accordance with the accepted rules of welding engineering. In case of doubt, contact the LIEBHERR customer support service to discuss suitable remedies.

Welding, drilling, firing and grinding work

rule is neglected, the warranty is voided. and grinding work on the machine with express authorization. Clean dust and combustible materials off the machine and its surrounding areas before welding, drilling, firing or grinding.

Ensure adequate ventilation. Risk of fire or explosion. remove the negative terminal first and reconnect it last. be done on components which may contain inflammable gases (welded counterweight, components must be previously and sufficiently ventilated with pressurized air to avoid all fire or explosion hazard e as close as possible to the welding point, so the welding current will not run through the swing ring, joints, gears, bushings, rubber parts and seals

Process materials her chemical substances, observe the appropriate current safety regulations for the product. ement parts are disposed of in a safe and environmentally acceptable manner.

(Risk of burning and scalding).

Repair work and which have sufficient load capacity. When replacing single parts and larger subassemblies, carefully secure them on lifting devices them so that they do not present a risk. Only use suitable and correctly functioning lifting devices and load take-up devices with adequate load capacity.

Do not stand or work under swinging loads. carrying capacity.

Wear work gloves when working with wire cables. operator. The spotter must be positioned within the visual range of the operator or be in voice contact with him.

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Safety instructions, Signs on the machine Servicing the machine safely

platforms which are appropriate for the job.

Do not use machine parts as climbing devices if they are not designed for this purpose.

When working at height, wear a harness to prevent falling.

Ensure that all grips, steps, rails, platforms and ladders are free of dirt, snow and ice. carefully, so that pneumatic cylinders do not hit their stops, because this could cause mechanical dammages. teeth). Prevent metal touching metal when doing this. remove a track chain unless having previously totally released the pretension of the chain tensioning unit. securely supported with wooden beams. jeopardize stability and prevent metal touching metal while doing this. trained specialist personnel. connect the upper structure to the chassis using stop bolts. equipment. ve gloves. A fine jet of liquid under pressure can penetrate the skin. tions before you have set aside the equipment, switched off the engine and depressurized the hydraulic system. After switching off the engine, with the start key in contact position and with the safety lever down into its lowest position, you must operate all pilot control devices (joystick and pedals) in all directions in order to reduce the actuating and dynamic pressures in the work circuits. You must then reduce the internal tank pressure as described in these operating instructions.

Electrical system Have all faults, such as loose connections, blown fuses and lamps and clogged or abraded cables rectified by personnel.

he event of malfunctions in the power supply. ent may only be carried out by skilled electrical personnel or by trained personnel under the supervision of an electrician in accordance with electrical regulations. the emergency-off or the main switch and overvoltage release. Cordon off the working area with a red and white safety chain and a warning sign. Only use insulated tools. voltage, briefly disconnect the supply cable at earth and electronic devices such as capacitors using an earthing rod.

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Safety instructions, Signs on the machine

Operating manual

Servicing the machine safely

that they are off circuit, earth them and then disconnect them briefly. Insulate adjacent live parts. electric arc welding on the machine.

First disconnect the negative, then the positive pole. When reconnecting, proceed in the reverse order.

Hydraulic accumulator personnel. accidents.

hydraulic system (hydraulic system including hydraulic tank), as described in these operating instructions. accumulator.

The hydraulic accumulator can be damaged by heat penetration and can be made to rupture by mechanical working. RISK OF EXPLOSION! EXPLOSION if oxygen or air is used. ged with the pressure required for the purpose of use before installation. mum pressure) are marked permanently on hydraulic accumulators. Ensure that this marking remains visible.

Hydraulic hoses and sheathed cables. ctions must be checked regularly every 2 weeks for externally visible damage and any possible damage must be immediately checked for leakage. s, use a sheet of paper or something else. and burns. subject to the natural aging process. This restricts their duration of use. common causes of failure. pertaining to hoses and sheathed cables at place of use must be adhered to. temperatures, frequent movement cycles, extremely high pulse frequencies, multiple shift usage). inspection: ure formation in hose material); sheathed cable, whether in a unpressurized or pressurized state or on bends

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Safety instructions, Signs on the machine Signs on the machine

e.g. sheath separation, blistering;

fittings or the hose / fitting connection; reduces function and tightness; , use only original replacement parts. bles correctly. Do not mix up the connections. and sheathed cables are installed free of torsion.

For high-pressure hoses, the screws from the half-clamps or full flange must always be attached to both hose ends and should only be tightened afterwards. ure hoses and sheathed cables with bent fittings, the side with the bent fitting must always be tightened first and then the side with the straight fitting tightened afterwards. attached and tightened subsequently. properly fastened. Doing this will prevent vibration and damage during operation. other hoses, sheathed cables or parts. approx. half the exterior diameter of the hose is recommended. The distance should not, however, be less than 10 to 15 mm. ables on moving parts (e.g. from the boom to the stay), check before initial start-up that there are no chafing areas in the entire area of movement.

2.6 Signs on the machine 2.6.1

Introduction The excavator comprises several types of signs: the safety plates provide warnings relating to dangers of accidents which could result in serious injury or death. the information plates indicate specific points relating to the operation, maintenance and characteristics of the machine. the nameplates are attached to components for which the machine serial 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. You will find the ordering numbers of these plates in the spare parts book of the excavator.

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Safety instructions, Signs on the machine

Operating manual

Signs on the machine

2.6.2

Arrangement of signage

Fig. 2-1

Arrangement of signage on the machine

4

Nameplate

60

Sound / power level [truck]

15

Lubrication chart

65

Load chart

20 22

Prohibiting sign Operating symbols plate

71 73

Explosion hazard High voltage

35 36*

Loading and lashing points Waxoyl

74 75

High pressure Hazard of impact and crushing

40 45

Lashing point Lifting point

76 77

Hot machine parts Hot fluids

50

Obstruction

80

Safety belt

52 54

Egine-off Accident prevention

90* 91*

Prohibiting sign - no lifting point Counterweight removal

55 56

Safety lever Equipment

101 103

Crushing hazard Hazard of thrown out objects

250* Emergency exit - Rear window *

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Operating manual

Safety instructions, Signs on the machine Signs on the machine

Note !

In order to be in accordance with specific local safety regulations, the safety signs may be different depending on the delivery country of the machine.

For machines destined to the North American market (United States - Canada), the safety signs fitting out differs from the one of the machines delivered in other countries. The chart below distinguishes the signs applying in most of the countries in the world and the signs specific to North America.

2.6.3

Explanation of signage Serially installed signage

Signs (except for North America)

North America signs Plate 4: Machine nameplate LFR (Liebherr France) Displays the following information:

Plate 4: Machine nameplate LAM (Liebherr America) Displays the following information:

Plate 15: Lubrication chart Displays the filling and lubrication positions.

Plate 20: Prohibiting sign Entering the marked area is forbidden.

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Safety instructions, Signs on the machine

Operating manual

Signs on the machine

Signs (except for North America)

North America signs Plate 22: Operating symbols Describes the functions of the controls.

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

They are maximal values. The real values may be different.

Plate 36: Waxoyl* Indicates the corrosion protection of the pistons rods.

Plate 40: Lashing point The use of lashing points depends on the transport method. See chapter "Transport".

Plate 45: Lifting point The use of lifting points depends on the transport method. See chapter "Transport".

Plate 50: Obstruction It is forbidden to stand in the danger zone.

Plate 52: Motor-off The motor hood may only be opened when the motor is switched off.

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Safety instructions, Signs on the machine Signs on the machine

Signs (except for North America)

North America signs Plate 54: Accident prevention The accident prevention regulations given in the operating instructions must be carefully followed.

Plate 55: Safety lever Raise safety lever before le

Plate 56: Equipment Work equipment reaches as far as the cab! Caution

Plate 60: Sound/power level [truck] Indicates the sound/power level of the machine to the environment in dB(A). *XX = The applicable value for the machine is

Plate 65: Load chart* Shows the permissible loads at the end of the stick depending on the working radius.

Plate 71: Explosion hazard Indicates that it is vorbidden to smoke or to use an open flame. Explosion hazard is especially important near the batteries when they are being charged.

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Safety instructions, Signs on the machine

Operating manual

Signs on the machine

Signs (except for North America)

North America signs Plate 73: High voltage Informs that any part of the working attachment must be kept away at least 50 feet from high voltage electrical lines.

Plate 74: High pressure Warns that a jet of fluid under high pressure can cause serious injury.

Plate 75: Hazard of impact und crushing Hazard of impact und crushing during machine operation.

Plate 76: Hot machine parts Hazard due to hot machine parts, especially in the area of exhaust silencer.

Plate 77: Hot fluids Hazard due to hot fluids under pressure, especially by opening of the coolant tank.

Plate 80: Safety belt The safety belt must be fastened before starting the machine.

Plate 90: Prohibition sign - no lifting point* This sign is situated beside a lifting point. It is forbidden to use this point for lifting the complete position of the plates 45 for lifting the complete excavator.

Plate 91: Counterweight removal * Indicates the minimum angle to be respected by the loading slings when the counterweight is lifting off the machine.

The rubber weatherstrip can be loosened and removed and the rear window pushed out by pulling the clip on the inside of the rear window.

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Safety instructions, Signs on the machine Signs on the machine

* = Depends on the

Signage relating to optional equipments Standard signs

America signs Plate 101: Crushing hazard Signals of the high crushing hazard in those zones.

Plate 103: Hazard of thrown out objects Signals the hazard of injuries by thrown out objects wenn the fan is activated. (On machines fitted out with reversible cooler fan).

Positions of the signs on electrical units

Fig. 2-2

Position of the signs on the electrical machine

16

Stay clear of machine

27

Dangerous voltage! Do not open!

18

Accidnet prevention

28

Certain circuits remain powered even after the main switch has been opened.

23

Direction of rotation of electrical motors

30

Control pump cabine heating

25

Powered from below!

51

Danger from electricity

26

Powered parts!

89

Crushing hazard

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Safety instructions, Signs on the machine

Operating manual

Signs on the machine

Sign 16: Danger! Do not stand in danger zone!

Sign 16: Accident prevention The safety regulations printed in the instruction manual must be complied with at all time !

Sign 23: Direction of rotation of electrical motors During commissioning and when re-commissioning the electrical unit after major repairs, check the direction of rotation of the electrical motors. To do this, briefly start the respective motor, shut it down and check whether the direction of rotation corresponds to the direction of the arrow on the motor.

Sign 25: Caution: Powered from below!

Never touch parts that are powered - DANGER TO LIFE.

Sign 26: Caution: Powered parts!

Never touch parts that are powered - DANGER TO LIFE.

Sign 27: Caution: Dangerous voltage! Do not open!

Never touch parts that are powered - DANGER TO LIFE.

Sign 28: Caution: Certain circuits remain powered even after the main switch has been opened.

Never touch parts that are powered - DANGER TO LIFE. Sign 30: Control pump cabine heating Indicates the switch wich controls the pump of the cabine heating.

Sign 51: Danger from electricity This sign warns of a danger from electricity; extreme caution is required to prevent accidents.

Sign 89: Risk of injury from crushing This sign warns of a danger of injury from crushing between the combined cooler and the catwalk.

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2.6.4

Type plates on the machine

Fig. 2-3

Main type plates on the machine

1 2

Hydraulic pumps Electric motor

5 6

A/C compressor Travel gearboxes

3 4

Control valve block Heating device

7

Slewing gear mechanism

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Safety instructions, Signs on the machine

Operating manual

Signs on the machine

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3 Control and operation 3.1 Operating and control elements

1 4

Safety lever- Servo control Left joystick

3 5

Right joystick Pedal for left travel gear

6

Pedal for right travel gear

9

Pedal for special attachment *

10 A3

Positioning swing brake * Radio *

15 E8

Controls for optional equiments * Cigarette lighter

H1 P5

Monitoring display Hourmeter

H10 S_b

Buzzer Emergency operation with battery *

S1

Ignition key

S2

Control unit

S6L

Push button - lifting magnet

S2_1 Emergency off switch S5L Push button for rotating device left (grapple, shear, ...), S5M Horn S5R Push button - Rotating device right (grapple, shear, ...)

S55

S6M Reserve S6R Push button - Travel alarm on/off

Switch - Unlocking of cylinder cut- S57 Switch - Preselection of swing off brake operating mode

S73 Safety mode of the servo circuits S84-1 Push button - Central lubrication S180 Control heater and air conditioner U38 Control unit - Heater and air ON / OFF conditioner S181 Main motor ON S183 Main switch & control ON

S182 Main motor OFF S184 Main switch & control OFF

S207 Mains voltage ON

S208 Mains voltage OFF

*

Optional equiments

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MJFCIFSS

3-1

Control and operation

Operating manual

Operating and control elements

Fig. 3-1

Controls in the cab

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Operating manual

Control and operation Operating and control elements

3.1.2

The joysticks Control of the working movements

Fig. 3-2

Joystick right (3) and left (4)

Standard control system according to ISO The left joystick 4 controls the stick and swing movements: 4 towards a resp. b to move the stick in resp. out.

4 towards c resp. d to swing the uppercarriage to the left resp. to the right.

The right joystick 3 controls the boom and bucket or grab movements: 3 towards e resp. f to tilt the bucket in or close the grapple, resp. to tilt the bucket out or open the grapple.

3 towards g resp. h to lower resp. to lift the attachment.

Special control systems Note!

The machines are always delivered with the above described control system according to ISO standards. system (Liebherr resp. John Deere control system, ....).

The operator can activate the special control system using the switching lever situated on the floor of the cabin, under the right joystick.

See also "Special control system of the joysticks" in this chapter.

Push buttons and switches in the joysticks a) Standart execution: two positions controls for additional functions

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3-3

Control and operation

Operating manual

Operating and control elements

Fig. 3-3

Arrangement of push buttons and switches in the control levers

Button -Switch

Function

Push button S5L

Rotating device left See in this chapter " control of rotating device (rotating, tilting, locking and unlocking a working tool)".

Push button S5M

Horn

Push button S5R

Rotating device right See in this chapter " control of rotating device (rotating, tilting, locking and unlocking a working tool)".

Push button S6L

Lifting magnet See in this chapter "Lifting magnet (optional equipment)".

Push button S6M

Reserve or float position of the boom cylinders with shovel attachment See the section "working attachment control", further in this chapter.

Push button S6R

Travel alarm cut-off See in this chapter "Drive warning device (optional extra)".

Push switch S55 Tilt down

Unlocking of a movement cut-off by end position switch See in this chapter "Cut-off by end switches of attachment movements (optional equipment)" and "Mechanical stanchion cylinder shut-down (option)".

Push switch S55 Tilt up

Turning on the pressure limitation for boom cylinders for exemple when operating a grapple See also S98 in the heading "Controls for optional equipment".

Rocker switch S57

Swing brake control in semi automatic mode See in this chapter "The uppercarriage swing movements".

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Operating manual

Control and operation Operating and control elements

Caution! the functions may be different.

Always check the functions of special equipments before beginning to work with the machine. b) optional execution from May 2010: Joystick levers with proportional mini joystick for additional functions

Fig. 3-4

Control levers with push buttons, switches and mini joysticks

Button -Switch

Function

Mini joystick A185 Moved toward X+

Rotating device right See in this chapter " control of rotating device (rotating, tilting, locking and unlocking a working tool)".

Mini joystick A185 Moved toward X-

Rotating device left See in this chapter " control of rotating device (rotating, tilting, locking and unlocking a working tool)".

Mini joystick A185 Moved toward Y+

Reserve

Mini joystick A185 Moved toward Y-

Reserve

Mini joystick A186 Moved toward X+

Retraction of the cylinder of anAHS type additional user, actuation of hydraulic hammer.

Mini joystick A186 Moved toward X-

Extension of the cylinder of anAHS type additional user, respec.

Mini joystick A186 Moved toward Y+

Reserve

Mini joystick A186 Moved toward Y-

Reserve

Push button S5L

Horn

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3-5

Control and operation

Operating manual

Operating and control elements

Button -Switch

Function

Push button S5R

Reserve

Push button S6L

Lifting magnet, see in this chapter "Lifting magnet (optional equipment)". or float position of the boom cylinders with shovel attachment, see the section "working attachment control", further in this chapter. or turning on the pressure limitation for boom cylinders for exemple when operating a grapple, see also S98 in the heading "Controls for optional equipment"..

Push button S6R

Travel alarm cut-off See in this chapter "Drive warning device (optional extra)".

Push switch S55

Unlocking of a movement cut-off by end position switch See in this chapter "Cut-off by end switches of attachment movements (optional equipment)" and "Mechanical stanchion cylinder shut-down (option)".

Rocker switch S57

Swing brake control in semi automatic mode See in this chapter "The uppercarriage swing movements".

Caution!

With some specific combinations of opti the functions may be different.

Always check the functions of special equipments before beginning to work with the machine.

The operator can select an other characteristic for the proportional control of additional function.

By pressing on the touch S251 on the right side control panel, the indicator integrated in the touch lights up and the second characteristic curve for the proportional function of the left mini joystick is selected.

By pressing on the touch S252 on the right side control panel, the indicator integrated in the touch lights up and the second characteristic curve for the proportional function of the right mini joystick is selected.

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Operating manual

Control and operation Operating and control elements

3.1.3

Control unit

Fig. 3-5 M

Excavator control unit

The function of the push buttons marked with (M) are memorized when the excavator is stopped.

This means that, when turning on the excavator, the controlled function recovers the previous state (on-off, 1-2, I-C, ...) before the machine had been turned off.

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3-7

Control and operation

Operating manual

Operating and control elements

S10

Working floodlights

Press the touch. Each touch actuation will successively: turn on the uppercarriage floodlights (LED 1 illuminates), turn on the attachment floodlights (LED 2 illuminates) switch off the uppercarriage floodlights (LED 1 go out), turn on both the uppercarriage and the attachment floodlights (LEDs 1 and 2 illuminate), switch off both the floodlights on the uppercarriage and the floodlights on attachment (LEDs 1 and 2 in the touch go out).

S11

Windshield washer

Press the touch and keep it depressed: washer fluid is sprayed onto the windshield, the windshield wiper runs continuously.

Release the touch: the washer fluid spraying is stopped, the windshield wiper will stop after approx 3 seconds.

Windscreen washing fluid container

Fig. 3-6

Windscreen washing fluid container

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

Once the cover (see arrow) has been opened, the container can be refilled with ordinary windscreen washing fluid.

For the machines equipped with a cab elevation, fill the container with precaution.

Risk of tumble. Respect the local rules and safety instructions for the works in altitude.

Volume: see lubricant chart

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Operating manual

Control and operation Operating and control elements

S14

Windshield wiper

Press the touch: the windshield wiper is turned on in intermittent mode, LED I in the touch illuminates.

Press the touch again: the windshield wiper is turned on in continuous, LED C in the touch illuminates and LED I goes out.

Press the touch again: the windshield wiper is switched off, LED C in the touch goes out.

The touch S14 also allows to adjust the pause time for the intermittent mode of the windshield wiper: press the touch to select the intermittent mode and keep the touch depressed, after a few seconds the LED I starts blinking rapidly, release the touch as soon as the blinking duration has reached the desired pause time (settings from 2 - 9 seconds).

S17

Preselection of swing brake operating mode

Press the touch: LED in the touch illuminates, the swing brake is applied.

Press the touch again: LED in the touch goes out, the swing brake is switched in semi automatic operating mode. In this mode the brake is controlled depending on the position of the rocker switch S57 situated in the right joystick lever.

S18

Overload warning device (optional equipment)

Press the touch: LED in the touch illuminates, the overload warning device is activated.

Press the touch again: LED in the touch goes out, the overload warning device is deactivated.

If no overload warning device is installed or if it is not correctly initialized on the machine: the indicator symbol "No overload warning device recognized" will appear on the monitoring display at warning device activation (LED in the touch illuminates).

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3-9

Control and operation

Operating manual

Operating and control elements

S19

Rotating device (optional equipment)

The rotating device is an additional hydraulic circuit necessary to drive some specific equipments (such as rotating grapple, rotating bucket, rotating stick, quick change coupling, ...).

Press the touch: LED in the touch illuminates, the control circuit for the rotating device is activated. Now the special equipment (as an ex. the rotating grapple) can be actuated using the push buttons S5L and S5R in the handle of the left joystick unit.

Press the touch again: LED in the touch goes out, the control circuit for the rotating device is deactivated. The actuation of the special equipment via S5L and S5R is no longer possible.

S20

No function

S21

Travel speed increase

Press the touch: LED 1 in the touch illuminates, the automatic shifting from normal to increased travel speed is activated.

During travel, the oil motors mounted to the travel gears now change automatically from normal speed to increased speed each time the terrain conditions allow it, and inversely, they return to normal travel speed when ground conditions become difficult.

Press the touch again: LED 1 in the touch goes out, the automatic shifting between normal and increased travel speed is deactivated. The travel motors remain permanently in the normal travel speed position.

S22

Auxiliary floodlights (optional equipment)

Press the touch: LED in the touch illuminates, the auxiliary floodlights are turned on.

Press the touch again: LED in the touch goes out, the auxiliary floodlights are switched off.

S36

No function

S41

Rotating beacon (optional equipment)

Press the touch: LED in the touch illuminates, the rotating beacon is turned on.

Press the touch again: LED in the touch goes out, the rotating beacon is switched off.

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Operating manual

Control and operation Operating and control elements

S56

Working pressure increase (optional equipment)

Press the touch: LED in the touch illuminates, the relief pressure of the primary relief valves increases, the maximum possible forces at the working attachment are raised.

Press the touch again: LED in the touch goes out, the relief pressure of the primary relief valves is reduced to its initial value.

S85

No function

S86

No function (Operating mode preselection

P4

No function (Engine RPM indicator)

S228

No function (Engine RPM increase)

S229

No function (Engine RPM decrease)

S354

No function

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3 - 11

Control and operation

Operating manual

Operating and control elements

3.1.4

Monitoring display

Fig. 3-7

Monitoring display

A C

Area of analog-value gauges LCD screen

B D

Area of indicator lights Menu control keys

H2

Indicator light, engine oil pressure H12

H19

Function not used

H20

Indicator light, battery charge (option) Function not used

H23

Function not used

H24

Function not used

S349 Back key

S350 Down key

S351 Up key

S352 Menu key

Area of analog value gauges A : Not used Area B :Indicator lights B

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Operating manual

Control and operation Operating and control elements

H12

Indicator light, battery charge (option)

The indicator light illuminates to alert the driver that yhe batteries are being unloaded (electrical charging system is not energized or defective).

Area D : Menu control keys

Fig. 3-8

Menu control keys

The screen can be operated using the following four keys: S349: Back key S350: Down key S351: Up key S352: Menu key These keys are used to jump from the main menu to the submenus or to move from page to page, to scroll inside a menu, ....

Area C: LCD Screen To change the contrast of the LCD screen: Press the Menu key and the arrow key Up (higher contrast) or Down (lower contrast) simultaneously.

The contrast will be changed.

When releasing the both keys the set value of the contrast is memorized.

To change the brightness of the LCD screen: Press at the same time the Back key and the arrow key Up (brighter) or Down (darker).

The brightness will be changed.

When releasing the both keys the set value of the brightness is memorized.

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Control and operation

Operating manual

Operating and control elements

Note A light sensor built in to the top left of the monitoring screen adapts the illumination on the main screen to the brightness of the environment. The adaptation takes place from the saved brightness value. Illumination will be automatically reduced in conditions of low environmental brightness and inversely.

To change the brightness and the contrast setting to the initial setting: Turn off the ignition.

Press and hold the Up and Down keys simultaneously.

Turn on the ignition again.

After completion of the automatic display check release the both keys.: the settings for the brightness and for the contrast of the LCD screen retrieve their initial values set at machine delivery.

3.1.5

Main screen The main screen appears when the machine has been switched on and remains on display until the screen is changed over to the menu selection screen using the Menu key.

Fig. 3-9

Main screen - Division into four fields

EC

Error codes of electrical SY errors

Symbols of operating faults, clock

INF

Information symbols

Display of hour meters, flow limitations, ...

TI

Constitution of the main screen SY field The upper field of the screen shows the warning symbols for the actual operating faults and also the clock.

Should more than two symbols be shown, so the clock is not displayed any more and up to four symbols can be shown at the same time in the field SY. If more than 4 symbols must be shown, then every 10 seconds, the symbols move to the left by one symbol.

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Operating manual

Control and operation Operating and control elements

See the list of the possible symbols in section "Warning symbols in the SY field", further in this chapter.

EC field The EC window displays the error codes for electrical faults which occur in the excavator's electronics system (line errors, sensor errors etc.). A maximum of 7 error codes are displayed simultaneously. If there are more than these 7 errors present, an arrow which points to where the other error codes are located will be displayed next to the error code window.

Press the Up or Down button.

The error code list is shifted in the selected direction.

See the complete list of the error codes in section "Error codes charts", in chapter 4.

INF field The INF field displays temporary information in graphic form.

If more than 3 symbols are to be displayed, the symbols will shift one symbol to the left approx. every 10 seconds.

The information is displayed in graphic or text form and indicates specific operating states on the machine (also see the section "Information symbols in the INF field", further in this chapter).

TI field The machine operating hours and the daily operating hours counter are displayed in this field at the bottom right of the screen. During the start-up phase, the operator will be alerted about a possible up-coming service time, by a graphic symbol and an hour indication displayed instead of the machine hour-meter during about 8 seconds.

The symbol ® is displayed when an external flow limitation is activated (see the description of the menu "Info In/Outputs", further in this chapter).

The symbol " " indicates that no external flow limitation is actually activated. But an internal flow limitation (travel, swing,...) may be activated.

In this field can also be indicated the denomination (for example HM2000) of the option which is actually assigned to the external flow limitation input I1 (see the description of the menu "Set option", further in this chapter).

Control of the screen at error recognition In case a new operating fault displayed in the field SY is recognized, the presentation will return to the main screen, and the relevant symbol is displayed.

Depending on the fault (level of urgency), the buzzer will sound either continuously or in short consecutive bursts. At the same time the symbol "acknowledge error" will be displayed in the INF field.

Danger!

If the displayed fault is not remedied immediately, this could lead to persons sustaining injury or the machine being damaged.

Immediately remedy the occured error or get it remedied.

Press the Back key.

The error will be acknowledged, this means that the buzzer signal alerting to the upcoming of this fault is stopped.

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Control and operation

Operating manual

Operating and control elements

Warning symbols in the SY field A) Warning symbols for operating faults fault occurs, the corresponding symbol is displayed in the field SY of the screen. The error code is not displayed in the field EC, but the error is memorized under this error code in the error list.

E 504

Low hydraulic oil level

This symbol appears if the oil level in the hydraulic tank drops below the minimum level.

Simultaneously, the buzzer sounds and the debit of the hydraulic pumps is reduced to the minimum.

Switch off the engine as quickly as possible.

Find the leak.

Depressurize the hydraulic tank.

Carry out the necessary repairs.

Only refill the hydraulic oil using the return-line filter.

E 505

Hydraulic oil overheat

This symbol appears if the hydraulic oil temperature in the tank exceeds 99 °C. Immediately bring the engine to low idle.

Switch off the engine after a few seconds.

Find out and remedy the fault (radiator dirty, ...).

E 506

Splitterbox oil overheat

This symbol appears if the oil temperature in the splitterbox exceeds 100 °C. Immediately bring the engine to low idle.

Switch off the engine after a few seconds.

Localise and remedy the fault.

E 511

High voltage of batteries

This symbol appears if the operating voltage of the batteries exceeds 30 volts for at least 0.5 seconds.

This symbol lights up when the maximum admissible temperature in the stator windings has been reached.

If the temperature continues to increase, the engine is shut down automatically.

E 550 - Overheating of the bearings of the electric engine This symbol lights up when the maximum admissible temperature for the bearings of the electric engine has been reached.

Have the bearings verified (grease quantity, grease quality, vibration level, ...) as indicated in the attached maintenance manual of the manufacturer of the engine.

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Operating manual

Control and operation Operating and control elements

B) Warning symbols for special operating states and system errors The symbols of the list below appear in the SY field of the screen to warn the operator that certain operating sequences or system errors are occurring.

Quick change adapter (option) This symbol appears during the unlocking procedure or when the locking pins of the quick change adapter are not completely out.

No error code is linked to this symbol.

Information symbols in the INF field Error in measurement of hydraulic pressure This symbol informs of the emergence of a trouble in the circuit for measurement of the servo control pressures.

As a result of the incorrect pressure measurement(s), all the functions of the power regulation of the concerned movement(s) can no longer be ensured, these movements are controlled in a downgraded mode.

At the same time the related error codes will be displayed in the EC field of the main screen to specify which are the incriminated movements and pressure transmitters. ment (pressure transmitter B160)

See also the error codes chart in chapter 4 "malfunctions".

Service due This symbol indicates that the moment for carrying out the next recurring service work has nearly arrived. During this span of time, and each time when the electrical system of the machine is turned on, this symbol and the hours for the next service falling due will be displayed for approx. 10 seconds in place of the current operating hours.

Get the the service work carried out within the prescribed delay,or report the falling due to your supervisor.

The symbol will go out after the execution of the programmed service work has been confirmed, see the menu "set service" thereafter.

Acknowledge error This symbol appears if an operating fault of the machine (E5xx type error code) has occurred and the buzzer sounds simultaneously.

It informs the operator that he can, after having recognised the occured fault, press the back key to stop the buzzer.

This symbol alerts the operator that the servo-pressure circuits have been turned into safety mode (switch S73 is tilted in safety position).

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Control and operation

Operating manual

Operating and control elements

Swing brake not operative This symbol alerts the operator that the swing brake control circuit is out of function due to the turning into safety mode of the servo-control via switch S73.

Servo control operation changed This symbol appears if switch S73 is tilted into the safety mode position.

Overload warning device (optional equipment) For a machine fitted with the optional equipment "overload warning device", and if this equipment has been turned on via the switch S18, this symbol alerts the operator that the load limit of the machine has been reached At the same time the buzzer sounds to alert the operator to this fact.

No overload warning device recognized This symbol appears if switching on the overload warning device via switch S18 though no overload warning device has been installed and/or correctly initialised on the machine.

Warm up procedure This symbol appears during a warm up procedure of the hydraulic oil.

Working pumps swivelled back to minimum delivery

3.1.6

Information provided in the menus Menu selection from main screen:

Fig. 3-10

Main screen

To change to the list of menus, the main screen must be visible.

With the main screen visible, press the Menu key of the display.

The list of accessible menus is displayed.

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Operating manual

Control and operation Operating and control elements

Fig. 3-11

List of menus

To select a menu: Press arrow key Down or Up. The following or previous menu will be displayed on the screen with a black background.

If the desired menu is displayed with a black background, as an example here the Reset daily operating hours menu: Press the Menu key again.

The sub-menu for the function selected is displayed.

Press the Back key again.

The sub-menu will be aborted.

Symbol of menu

Denomination of menu

Role of the menu

Reset Data

Reset of daily operating hours counter

Set Service

Confirmation of the execution of a recurring service work

Set Option

Selection of the flow and pressure limitations relating to the mounted working tool (e.g. hammer)

Info - Hours

Display of the operating hours of the machine components and general machine data.

Info - In/Outputs

Information about the status of the hydraulic pumps and of the electrical inputs and outputs

Info - Errors

Memory of the stored operating faults and electrical system errors

Set Clock

Setting of the clock

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Control and operation

Operating manual

Operating and control elements

Menü "Reset Data" - reset of daily operating hours counter The daily operating hours counter can be reset to 0 using this menu.

Fig. 3-12

Resetting the daily operating hours counter

Press the Up arrow key.

The OK which is not crossed out will be displayed with a black background.

Press the Menu key.

The operating hours will be reset to 0.

The arrow key symbols Up and Down and the Menu symbol will no longer be displayed.

To exit the menu: Press the Back key.

The sub-menu will be aborted.

Menu "Set Service" - confirmation of the execution of a service work This menu gives information about the falling due of the next service work and allows to confirm the execution of the service work after it just has been carried out.

Fig. 3-13

Menu "Set Service"

An upcoming service work can be confirmed a maximum of 50 operating hours before the service interval is due.

When this time period has been reached a query will appear to ask whether the service work has been carried out.

If the service work has been carried out.

Press the Up arrow key.

The choice "OK not crossed out" will be displayed with a black background.

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Operating manual

Control and operation Operating and control elements

Press the Menu key.

The current operating hour will be stored as the time for the last carrying out of a recurring service work.

The operating hours indicating the next service due will be increased by the duration of a service interval (as an example they augment from 500 to 1000 working hours).

If the service work has not been carried out.

Press the Back key.

The sub-menu will be aborted.

Menu "Set option" - selection of the flow and pressure limitations This menu allows to allocate flow and pressure limitation options to external input I1 (choice of the maximum oil flows and system pressure depending on the mounted working tool).

In this menu, the operator can choose between 10 predefined options. For each option a pressure limitation and a flow limitation is assigned. When an option is chosen, the limitation values assigned to this option are effective as soon as the command of the optional tool is actuated (actuation of the foot pedal for hammer or grapple for example).

A

Caution!

Selecting a wrong option for a tool can damage it (for example: hydraulic hammer) or cause its restricted operation (for example: milling tool).

Fig. 3-14

Menu "Set option"

EV1 = Regulation solenoid valve for oil flow limitation on pump P1

EV2 = Regulation solenoid valve for oil flow limitation on pump P2

EV6 = Regulation sol. valve for pressure limitation in hydraulic system The black field represents the active option.

In the left figure, the option 1 is active for the input I1. This means, if the external hardware input I1 is activated, then the nominal pump values allocated in option 1 for the excavator control are given as maximum nominal values.

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Control and operation

Operating manual

Operating and control elements

Note!

The values EV1 and EV2 determine the flow limitation of the main pumps when the special attachment is actuated.

The value EV6 determines the maximum allowed pressure level for the actuation of the special attachment.

If another option must be allocated to input I1 (as an example due to replacement of the working tool), Press the Up or Down key to select another attachment in the vertical symbol range.

Press the Menu key.

The selection is confirmed. The new active option is displayed on a black background (in the example above, right figure the Option 10).

At the same time the denomination that has been assigned to the option is displayed in the bottom right corner of the screen (in this example "HM2000").

To exit the menu: Press the Back key.

The sub-menu will be aborted.

In the main screen the denomination of the chosen option (HM200) is also displayed.

The tool will be supplied with the reduced pressure and the reduced flow predefined for the option 10.

Fig. 3-15 1

Main screen, the choosen option is displayed

Denomination of the active option

2

The symbol "R" indicates that an external flow limitation is active

Note!

The standard denominations of the options are "Option 1", "Option 2"...

The Liebherr after sales department can assign a more concrete name to each option, for example "HM2000" or "Grapple", ...

Menu "Info-hours" - operating hours of components, duration of processes, ..

In this menu the screens 1/... to 3/... provide an overview of the operating hours of specific components, of duration of processes and operating types.

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Operating manual

Control and operation Operating and control elements

Fig. 3-16

Menu "Info Hours" operating hours of electric motor

Press the Menu key. the screen 2/... is displayed.

The screen 2/... provides the operating hours for: and increased travel speed.

Fig. 3-17

Menu "Info Hours" duration of the various movements

Press the Menu key again. the screen 3 ... is displayed.

The screen 3 provides the operating hours for: ent (operated via the foot pedals) Press the Menu key again. the screen 4/... is displayed.

Fig. 3-18

Menu "Info Hours" general machine data

The menu General Data, provides information on:

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Control and operation

Operating manual

Operating and control elements

re-Versions for, respectively, the monitoring display, the control unit and the pump regulator BST. The areas provided on the second line are neither employed nor active on electric powered machines.

actually), actually), actually), Press the Menu key again.

The screen 1/... is displayed.

To exit the menu: Press the Back key.

The sub-menu will be aborted.

Menu "Info In/Outputs"- Status of hydraulic pumps and of electrical inputs and outputs The screens 1 to 3 provide information on the regulation parameters for the hydraulic pumps.

Fig. 3-19

Menu "Info In/Outputs" Active flow and pressure limitations

The screen 1/... displays: active flow limitation option and which percentage of the maximum flow is set (solenoid valves EV1 and EV2). essure limitation for the hydraulic system and which percentage of the maximum pressure is set (solenoid valve EV6). regulation solenoid valves..

On the left picture, an external limitation (Hardware input I1, option 2) is activated.

The currents supplying the flow limitation solenoid valves EV1 and EV2 limit these flows to 55% of their maximal values. The current supplying the pressure limitation solenoid valve EV6 limits the pressure to 80% of its maximal value.

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On the right picture, an internal limitation (Pressure increase ) and an external limitation (Hardware input I1, option 1) are activated at the same time.

Due to the internal limitation, the flow of the pump P1 is limited to 50% of its maximum value via the solenoid valve EV1.

Due to the external limitation, the flow of the pump P2 is limited to 70% of its maximum value via the solenoid valve EV2 and the pressure in the hydraulic system to 60% of its maximal value via the solenoid valve EV6.

When several limitations are activated at the same time, only the one with the smallest percentage value is decisive for each regulating solenoid valve.

Note!

An external limitation becomes active for example when a pedal controlling an additional equipment is actuated.

The three internal limitations which are the most currently used are the followings: is activated when travelling. is activated when the pressure increase is actuated (button S56 on the control unit). ted when actuating the shovel flap on machines with shovel attachment.

Press the Menu key again.

The screen 2/... is displayed.

The screen 2 shows the instantaneous LR current (current flowing to the solenoid valve for power regulation).

Fig. 3-20

Menu "Info In/outputs" Currents to the solenoid valves LR and EV5

Press the Menu key again.

The screen 3/... is displayed.

This screen shows the instantaneous current flowing to the regulation solenoid valve EV5 which determines the RPMs of the hydrostatic driven cooler fan.

Press the Menu key again.

The screen 4/... is displayed.

This screen shows the instantaneous current flowing to the regulation solenoid valve EV3, which determines the power reduction for the swing movement.

Notice: this screen is displayed only since the software version V4.4 of the display.

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Control and operation

Operating manual

Operating and control elements

Fig. 3-21

Menu "Info In/Outputs"- Current to the solenoid valve EV3

Press the Menu key again.

The screens 5, 6, 7 and 8/... are successively displayed.

Fig. 3-22

Menu "Info In/outputs" Status of electrical inputs and outputs

The screens 5/... to 8/... provide an overview of the status of the different electrical inputs and outputs.

been deactivated in the software.

The duration indicated in the last line of the screen 4/7, under M4/Time corresponds to the pause time for the windshield wiper in intermittent mode.

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Operating manual

Control and operation Operating and control elements

Menu "Info In/outputs" Status of electrical inputs and outputs the motor is running. movements amounts to at least 7 bar (pressure transmitter B159). movements amounts to at least 7 bar (pressure transmitter B160). movements amounts to at least 7 bar (pressure transmitter B167). movements amounts to at least 7 bar (pressure transmitter B162). movements amounts to at least 7 bar (pressure transmitter B163).

To exit the menu: Press the Back key.

The sub-menu will be aborted.

Menu "i-errors" - operating faults and electrical system errors

Fig. 3-23

Menu "i-errors" Display of the memorized errors

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Control and operation

Operating manual

Operating and control elements

There are 3 possible choices in this menu: list Exxx, all the operating faults detected by the switches and sensors monitoring the machine parameters are listed. list E-elec, all the electrical system errors (cable errors, sensor errors, ...) detected during the operation of the machine are listed. list S-Exxx, all the operating faults are listed, just as with the selection list Exxx, but this time only faults which appeared when the service connector was connected .

To select the desired error type: Press the Down or Up arrow key: the previous, respec. the next error typ is preselected Press the Menu key.

The sub-menu on a black background will be displayed.

If more than 6 error codes are listed, use the arrow keys Down or Up to scroll in the list. "list Exxx": Operating faults

Fig. 3-24

List of the operating faults (fig. left) and occurrences of a fault (fig. right)

Select list Exxx.

Press the Menu button: the first page of the sub-menu appears.

All the operating faults are listed with their error code and number of occurences.

Select the desired error code using the Down or Up arrow key.

Press the Menu key again: the second page of the sub-menu appears.

A screen appears with the operating hours and the duration for the ten first and the ten last occurrences of the selected error.

Press the Back key: the first page of the sub-menu appears.

Press the Back key again, to select another error type, or press the Down or Up arrow key, to preselect another error code.

The asterisk "*" shows that the error was also indicated by the buzzer and then acknowledged using the Back key. .

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Operating manual

Control and operation Operating and control elements

Note!

Only operating faults with an error code E 5xx are displayed in the list Exxx menu.

Press the Back key.

The first page of the sub-menu appears.

Press the Down or Up key to select a new error code or press the Back key again to select another error type . "list E-elec.": Errors of the electrical system

Fig. 3-25

List of the electrical errors

Select "list E-elec.".

Press the Menu key: the sub-menu is entered.

The screen displays the list of all electrical errors with their error code. deletion.

The hour information "reset test at x Hrs" (e g. 12 Hrs) indicates the operating hour in which the "Test" column was the last time deleted.

Press the Back key to return to the first page of the sub-menu.

Press the Down key and then the Menu key to confirm the new choice. "list S-Exxx": Operating faults in service mode

Fig. 3-26

List of operating faults appeared in service mode

No information will be displayed in this menu if the service connector is not connected.

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Control and operation

Operating manual

Operating and control elements

When a service connector is pluged in: The submenu list S-Exxx lists all the operating faults, just like the submenu list Exxx, but this time only faults appeared in service mode, i. e. when a service connector was connected.

The sub-menu allows to separate the faults occuring during maintenance works,in particular during the troubleshootings.

For each error, an overview is shown and can be paged in just like for the "list Exxx" selection.

When exiting the service mode, the memory "list S-Exxx" is reset, the service mode operating faults are not stored.

Menu "set clock" - Time setting Via this menu the clock displayed in the upper right corner of the main screen can be set.

Fig. 3-27

Setting of the clock

After function start, the presently set time will appear in the lower section of the screen with the digit completely right inversely displayed (unity digit of the minutes).

Press the UP or DOWN key to adjust the selected digit.

Press the MENU key: the immediately more left digit is now inversely displayed.

Repeat the procedure until all the digits have been set.

Press the Enter key:

Fig. 3-28

Confirmation of the storage of the new time

The confirmation message ear momentarily on the screen and the new time is stored.

The menu "set clock" is closed and the main menu is displayed on the screen.

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Operating manual

Control and operation Operating and control elements

3.1.7

Glancing through the available menus

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Control and operation

Operating manual

Operating and control elements

3.1.8

Controls and instrumentation for optional equipments

Fig. 3-29

Controls for optional equipments

The location of these controls may be different, depending on the type of the other installed optional equipments.

On machines fitted with the special equipment "cooler fan reversible", this control light lights up to indicate that the fan has been changed over to rotation in opposite direction via the push button S160, see also the section "Reversible cooler fan (Optional equipment)" in the chapter "maintenance".

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Operating manual

Control and operation Operating and control elements

When actuating this touch a pressure signal is send to the reversing hydraulic hammer, causing the hammer to change over to the second cycle frequency. for special equipment If an hydraulic actuator ( cylinder, hydraulic motor, ) of a special equipment requires a constant oil flow, the speed of the remaining attachment movements can be reduced by depressing the push button S45 (control light inside the button must light).

The necessary oil flow for the hydraulic actuator is maintained, even in case of simultaneous actuation of other attachment movements.

The push button S47 turns on the control circuit for the quick change adapter for the working tool. See also the section "Hydraulic quick change adapter for working tools (optional equipment)" in this chapter.

Actuating this touch makes alive an additional control circuit for a special equipment.

The green indicator light in the touch lights up to show that the additional servo control circuit is under pressure.

On some special working attachments, or on attachment showing particular cinematic capacities (as example on industrial attachment), certain movement(s) may be stopped automatically by electrical end switches. The main purpose of this movement limitation is to prevent possible damages due to components frequently reaching their end stops.

See "Cutoff by end switches of attachment movements (option)" in this chapter.

This touch controls the travel parking brake on the machines fitted with a special undercarriage, or on machines mounted on a loading bridge, a wagon, ...

When the red indicator light in the touch lights up, the travel brake is applied.

On machines with a standard undercarriage, the travel brakes are controlled directly via the travel pedals and the touch S76 does not exist.

When the touch is depressed, the green indicator light in the touch lights up and an air fan is started to maintain a slight pressurization inside the driver's cab.

The entering of dust or not filtered air into the cab is then almost prevented.

Should a certain user (cylinder, hydraulic motor, ...) has to be fed with a constant oil flow during the actuation of a special attachment, so the necessary oil flow can be reserved to give priority to this user while depressing the touch S79.The indicator light in the touch is then lighting up.

The velocity of the other simultaneously actuated working movements is correspondingly reduced.

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Operating and control elements

This push button is mounted serially.

The pause time of the intermittent mode of the cab roof window wiper can be adjusted by turning this button. (The window wiper is switched on and off using the touch S218).

If the touch S98 is actuated, the pressure protection value for lowering the attachment (circuit for retraction of the boom cylinders) is reduced, so to limit the possible downward thrust exerted by the working attachment onto the materials to be dug out.

This safety device must be turned on, as an example, when unloading a boat or a barge, so to avoid damage to its bottom.

Thanks to this switch, the operator can control the movement of the additional user of an add on kit AHS either using the double pedal destined for this purpose (key switch in position "pedal")., or via the right joystick (key switch in position "joystick").

See also "Commutation of the control for the user of add on kit AHS" in this chapter.

On machines fitted with the special equipment "cooler fan reversible", the direction of revolution of the cooler fan can be inverted while actuating the push button S160.

In some particular working conditions, this inversion of the direction of the fan rotation allows an easy cleaning of the radiator core and of suction area of the fan.

See also the section "Reversible cooler fan (Optional equipment)" in the chapter "maintenance". n when operating a super long working attachment When using a long reach attachment (super long working attachment with a smaller digging tool), this device allows to limit the working pumps oil flows to a value admissible for all the hydraulic cylinders of the working attachment.

Turn the key switch S168 to the right, in po movements of the working attachment. draulically adjustable cab See the section "Hydraulically adjustable cab (option)" in this chapter.

When the ignition key is in contact position, pressing the switch S218 activates the cab roof window wiper.

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Operating manual

Control and operation Operating and control elements

This touch switch on and off the additional floodlight.

This touch switch on and off the additional floodlight.

S357

Touch / Lifting the attachment while the grapple is being closed

With this function, the working attachment is lifted slightly while the grapple is being closed. This reduces the risk of damage to the surface on which the grapple is used.

Example: Protection of loading areas, ship bottoms and similar surfaces.

Note! This function is an auxiliary tool designed to assist the machine operator. Even if the function is activated, the surface can still be damaged due to lack of care.

The button turns on the electric cab roof window washer system. Washer fluid will be sprayed to the window and the cab roof window wiper will be actuated as long as the push button S362 is depressed.

S422 - Radio muting

See the section "Safety access to electric machines for industrial applications with self-stabilising tower superstructure" in this chapter.

The additionnal standstill heater is only working when the main switch ist switched off (S184). Its performance is 1,1 kW. Two modes of operation are possible: /off the additionnal standstill heater independdently of the programmation of the automatic mode day slot.

Only an authorized personn can change the programmation of the additionnel stanstill heater.

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Control and operation

Operating manual

Access and equipment of the cab

3.2 Access and equipment of the cab 3.2.1

Entering or leaving the cab Climbing up Caution!

Entering or leaving the cab incorrectly could lead to injury.

Proceed with the same attention on exit or entry of the cab, as while climbing the machine.

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

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

Face the machine when getting in or out and always use three-point support, i.e. two hands and one foot or two feet and one hand must always be in contact with the access system at the same time.

Do not hold onto the controls to steady yourself.

Never jump from the machine.

Cab:

Fig. 3-30

Climb up using the handholds

Getting in

Fig. 3-31

Door - exterior

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Operating manual

Control and operation Access and equipment of the cab

1

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 180° and secure in the latch 2.

Climb in with your face towards the machine and sit Adjust the seat and steering column if necessary.

Getting out Caution!

Entering or leaving the cab incorrectly could lead to injury.

Proceed with the same attention on exit or entry of the cab, as while climbing the machine.

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

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

Face the machine when getting in or out and always use three-point support, i.e. two hands and one foot or two feet and one hand must always be in contact with the access system at the same time.

Do not hold onto the controls to steady yourself.

Never jump from the machine.

Fig. 3-32 3

Door - interior

Door handle on door lock

4

Lever for the latch

Switch off the machine and push the safety lever up.

Push the door handle 3 on the lock down.

Open the door fully and secure it in the latch 2.

Climb out with your face towards the machine.

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Control and operation

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Access and equipment of the cab

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

Move the lever 4 next to the cab frame outwards.

The door is now unlocked.

Close the door.

3.2.2

The safety lever

Fig. 3-33

Safety lever

The safety lever is mounted to the left controle console and is designed so to obstruct the way to the cab when tilted down in lower position.

Caution !

The operator must move this safety leve The operator may only push the lever down when he is again seated in the

interrupt the servo control circuit: no working movements are possible if the joysticks or pedals are accidentally actuated while entering or leaving the cab, the swing brake applies automatically (the LED in the touch S17 is lighting), the swing brake can no longer be released using the touch S17.

After you are seated again and before you begin operating the machine, push the lever down in lower position: the swing brake recovers the previous state (applied or released) before the lever had been pulled up, the pilot control devices (joysticks and pedals) become active again.

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Operating manual

Control and operation Access and equipment of the cab

3.2.3

Operator seat Danger!

The adjustment of the operator seat could result in an inadvertent actuation of control elements, moving the machine or the attachment.

This can lead to injury to persons or damage to property.

Do not adjust the operator seat while driving the machine.

Move the safety lever up.

Fig. 3-34

Operator seat

1

Operator seat heating

2

Mechanical / pneumatic lumbar support*

3

Backrest adjustment

4

Armrest height adjustment

5 7

Armrest adjusting wheel Horizontal adjustment with control consoles

6 8

Horizontal suspension* Display for weight settings*

9

Manual/automatic adjustment 10 Shock absorber* for body weight and seat height*

11 Horizontal adjustment 13 Seat inclination

12 Seat depth 14 Safety belt

15 Armrests

16 Headrest

* Model variant

Adjusting seat to body weight/seat height (in models with manual adjusting mechanism): Sit down on the seat.

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Control and operation

Operating manual

Access and equipment of the cab

Adjust the seat height/body weight by pulling or pushing the lever 9 to the stop.

Check the display 8.

If necessary: Adjust the settings by pulling or pushing the lever 9 to the stop.

Adjusting seat to body weight (in models with automatic adjusting mechanism)*: Before adjusting the body weight settings, set the shock absorber* to "soft".

Sit down on the seat.

Pull the lever 9 briefly upwards.

The seat is automatically adjusted to suit the body weight of the operator.

Adjusting seat height (in models with automatic adjusting mechanism)*: Before adjusting the height, set the shock absorber to "soft".

Caution!

Risk of damage to compressor.

Do not run the compressor continuously for more than 1 minute.

Adjust the seat height by pulling or pushing the lever 9 to the stop.

Adjusting seat depth: Lift the button 12.

Sit on the seat and move it horizontally to the desired position.

To adjust the angle of inclination of the seat, press the button 13.

Sit on the seat and move it to the desired angle.

Horizontal adjustment: Pull up the lever 11.

Adjust the operator seat in horizontal direction.

Release the lever. Ensure that the lever engages properly in the desired position (audible click).

Carry out the following check: After locking, it must be impossible to move the operator seat to a different position.

Horizontal adjustment with control consoles: Pull up the lever 7.

Adjust the operator seat together with the control consoles in horizontal direction.

Release the lever. Ensure that the lever engages properly in the desired position (audible click).

Carry out the following check: After locking, it must be impossible to move the operator seat to a different position.

Adjusting backrest: Pull up the lever 3.

Sit on the seat and move the backrest to the desired position.

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Operating manual

Control and operation Access and equipment of the cab

Release the lever. Ensure that the locking lever engages in the desired position.

Carry out the following check: After locking, it must be impossible to move the backrest to a different position.

Adjusting lumbar support (in models with mechanical adjusting mechanism): Adjust the height and curve of the lumbar pad by turning the hand wheel 2 at the back of the seat.

Adjusting lumbar support (in models with pneumatic adjusting mechanism)*: Adjust the curve of the upper and lower section of the backrest upholstery by pressing the two switches 2 at the rear of the seat.

Adjusting shock absorber*: The shock absorption level can be adjusted to suit the actual road or terrain conditions.

Turn the handle 10 to the desired position and release it.

Adjusting horizontal cushioning*: Under certain operating conditions, you can improve the operator comfort by adjusting the horizontal cushioning mechanism. This helps reduce impact stress in travel direction on the operator as these impacts are better cushioned by the seat.

Move the handle 6 to the desired position.

After the handle has been moved to position 1, ensure that is engages properly in this position: push the seat back until you hear an audible click.

Adjusting armrests: Turn the hand wheel 5 until the armrests are in the desired position.

If required, the height can be adjusted individually for each armrest: Remove the cover cap 4 from the seat covering.

Loosen the hex (wrench size 13 mm).

Set the armrest to the desired position.

Tighten the hex nut (25 Nm).

Replace the cover cap on the hex nut.

Adjusting headrest: Adjust the headrest 16 by pulling it from the engaging mechanism.

Adjust the headrest angle by pushing it forward or back.

To remove the headrest, move it to the upper stop and then pull it with force from the seat.

Seat heating: Actuate the switch 1 to switch on the seat heating.

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Control and operation

Operating manual

Access and equipment of the cab

* Model variant

3.2.4

Putting on and releasing the safety belt 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 without delay.

Fig. 3-35

Safety belt

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

Pull the belt and buckle 2 out of the roller mount 1.

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

Push the buckle into the belt lock 3 until it fastens.

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

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

3.2.5

Windscreen

Fig. 3-36

Locked positions of the windscreen

The windscreen can be locked in two positions.

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Operating manual

Control and operation Access and equipment of the cab

a the windscreen is closed. b the windscreen is fully opened (locked in place on the roof of the cab) Caution!

It is not allowed to work with the machine when the windscreen is in an intermediate position!

To change the position of the windscreen Pull the lever 1 in and down to unlock the windscreen.

Move the windscreen using the handle 2, secure it in one of the two positions a or b and relock using the lever 1.

3.2.6

Sunshade

Fig. 3-37

Sunshades at windscreen and at cab roof

The cab is provided with two sunshades, located at the windscreen and at the cab roof window.

Manoeuvring the sunshade at the windscreen Using the strengthening tongue 1, pull the sunshade down to the desired position.

Press the red button 2, the sunshade will roll itself up.

Manoeuvring the sunshade at the cab roof Pull out the sunshade and secure it in the holders designed for the purpose.

To retract the sunshade, take it out of the holders and let it roll up slowly.

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Control and operation

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Access and equipment of the cab

Fig. 3-38 In case of emergency, remove the rubber seal 2 from all around the rear window by pulling the clip 1 on the inner side of the rear window. Thereafter push the window out.

Note!

For the machines equipped with a cab elevation, steps, ladders and hand-rails (grips) are installed to secure the descent.

3.2.8

Interior lighting

Fig. 3-39

Dome light for cab interior lighting

The dome light is controlled via the button 1.

Push the button 1 to the right to switch on the light 2.

Push the button 1 to the left.to switch on the spot 3.

Push the button 1 into central position to switch the dome light off.

3.2.9

Fire extinguisher The interior of the cab of your machine is fitted with fixing points allowing the mounting of a fire extinguisher. These fixing points are on the right side wall of the cab, in the front area for machine models up to R954C, or in the rear corner for machine models R964C and above.

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Operating manual

Control and operation Access and equipment of the cab

Fig. 3-40

Possible locations for fixing the fire extinguisher

The fire extinguisher is only mounted as an option.

Note!

It is the responsibility of the owner of the machine to decide if it must be fitted with a fire extinguisher or not, considering the operating conditions and the local laws and regulations applying where the machine is used.

You can order a kit for retrofit adaptation comprising a fire extinguisher and its mounting bracket at any time at the LIEBHERR customer service.

Caution!

If your machine is fitted with a fire extinguisher: Always comply with the operating guide on the body of the extinguisher.

Make sure that all the necessary inspections of the fire extinguisher prescribed by local laws and safety regulations are carried out.

3.2.10

The heater and air conditioner The cab is equipped with a heating and air conditioning system as standard. The heating and air conditioning system is used to heat, cool and ventilate the cab.

Danger!

Close to operating temperatures, the elements of the heater system and the hydraulic system can reach extremely high temperatures. Do not touch any parts containing fluids or oil. There is a risk of injury from burns.

Check the heater fluid level only after the lid of the expansion vessel has cooled down so that it can safely be touched by hand. Turn the lid carefully to relieve the overpressure.

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Control and operation

Operating manual

Access and equipment of the cab

Prior to commissioning

Fig. 3-41 1 10

Expansion tank in heating box

Expansion tank Heating box

20 Plug S206 Button

Filling expansion tank 1 with corrosion inhibitor and antifreeze agent: Open the plug 20.

Fill the expansion tank 1 with corrosion inhibitor and antifreeze agent: Close the plug 20.

Filling heating system: Press and hold the button S206.

The booster pump is working.

The heating system is filled.

When corrosion inhibitor or antifreeze agent flows to the centre piece of the undercarriage: Release the button S206.

Preparation of heating system

Preparation of heating system Set the switch S206a to position 1.

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Control and operation Access and equipment of the cab

Switching off heating system Set the switch S206a to position 0.

Switching heating system on/off

Fig. 3-42

Left console

Switching on heating system Press the button S180.

The indicator light in the button is on.

The heating system ist now powered on.

Switching off heating system Press the button S180.

The indicator light in the button is off.

The heating system is powered off.

Control unit of the heating and air conditioning system

Fig. 3-43

Control unit of the airco system

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Control and operation

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Access and equipment of the cab

Control keys

Indications at the LCD display

automatic

OPEN legroom CENTER legroom OPEN

CLOSED OPEN / CLOSED operation) CENTER / CLOSED manual operation) CENTER / OPEN output

Note!

If the control unit recognizes a sytem error in the air conditioning circuit, a flashing error code number F1-F5 is displayed, see the section "faults and remedies", further in this manual.

Turning the control unit on

Fig. 3-44

Turning the control unit on and setting the cab temperature

Turn the system on using the key 4.

The software version will be displayed for approx. 12 seconds while the control unit carries out a self test.

The heating and the ventilation of the cab are operating. The heating output and the fan speed will be controlled automatically if the AUTO symbol (20) is displayed.

Setting the desired cab temperature The four-digit segment indicator 25 shows the desired cab temperature.

Use the key 2 to increase the temperature.

Use the key 3 to reduce the temperature.

The adjusted temperature will remain until the next change via keys 2 and 3 is made.

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Operating manual

Control and operation Access and equipment of the cab

Manual setting of the heating output

Fig. 3-45

Setting of the heating output and of the fan speed

Press the key 7 to adjust the heating output manually. the heating symbol 23 is displayed and will flash for 5 seconds. the bar graph 24, showing the adjusted heating output, is displayed.

As long as the heating symbol 23 is flashing, the heating output can be increased or reduced manually using the keys 2 or 3.

Press the key 7 again, to return to automatic operation. the symbols 23 and 24 will go off, the symbol 20 is displayed again.

Manual setting of the fan speed Press the key 5 to adjust the fan speed manually. the fan symbol 22 is displayed and will flash for 5 seconds. the bar graph 21, showing the adjusted fan speed, is displayed.

As long as the fan symbol 22 is flashing, the fan speed can be increased or reduced manually using the keys 2 or 3.

Press the key 5 again, to return to automatic operation. the symbols 22 and 21 will go off, the symbol 20 is displayed again.

Air conditioning operation

Fig. 3-46

Air conditioning operation and Reheat-operation

Press the key 1 turn on the air conditioning operation. the symbol 15 is displayed. the control unit now turns the airco compressor on and off automatically. the control unit automatically adjusts the fan RPM. Press the key 1 again, to turn off the air conditioning operation. the symbol 15 is no longer displayed, the airco compressor remains off.

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Control and operation

Operating manual

Access and equipment of the cab

Note!

In case of high outside temperature, and especially if the cab has been heated up by the sun, decrease the temperature inside the cab as far as possible before turning on the air conditioner.

Open the windows and the door for a few minutes and adjust the blower fan to maximum RPM via the keys 5 and 2.

Reheat-operation In order to achieve a quick dehumification of the cab, as an example on morning, when setting the machine into operation, it may be advisable to briefly turn on the air conditioning operation even when the heater is allready operative.

Press the REHEAT-key 6: the symbol 14 is displayed, the compressor is constantly working, the fan of the heater and airconditioner is running at maximum RPM, the air flaps at the front window and at the legroom are open, as necessary the control unit switches on the heating so to maintain the adjusted cab temperature.

As soon as the windows are completely demisted, the Reheat-operation may be exited while pressing the REHEAT-key 6 again.

Note!

To avoid overloading the starter motor and the batteries, turn on the air conditioning operation and the REHEAT-operation only after the engine is running.

The REHEAT-operation is turned off automatically after 60 minutes.

If the machine is used for a longer period of time without using the air conditioner, press the REHEAT key 6 about every 2 weeks so to turn on the airco compressor.

Recirculated air and fresh air operation

Fig. 3-47

Recirculated air and fresh air operation

The heating and air conditioning system can work either in recirculated air operation or in fresh air operation.

Pressing the key switch 8 will alternately change from recirculated air operation into fresh air operation: in recirculated air operation: 13 is displayed, in fresh air operation:

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Control and operation Access and equipment of the cab

13 is no longer displayed, ll is open and an amount of fresh air is admitted into the cab (about 10%, depending on the contamination of the filters 31 and 32).

Note!

The best heating, resp. cooling effect is reached in recirculated air operation!

Air repartition The adjustment of the air flow in the cab is achieved via the keys 9 to 12 and via the partly closing and revolving louvers 8a to 8d: 8a on the seat console 8b on the right control panel 8c on the front windshield 8d on the rear wall of the cab

Fig. 3-48

Air repartition in the cab

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Control and operation

Operating manual

Setting the machine into operation

To reach a maximal feeling of comfort: For heating the air flow must be blown into the cab via the louvers 8a, 8b and eventualy 8c. This is obtained while actuating the keys 10, 11 and eventualy 12 .

For air conditioner operation the air flow must be blown into the cab via the louvers 8d and eventualy 8b. This is obtained while actuating the keys 9 and eventualy 12.

Note!

To defrost or dehumidify the windshield quickly, blow the whole air flow only out of the louvers 8c at the front windshield and 8b on the right control panel.

In case of very high outside temperature, preferably close the louvers 8c to avoid an unnecessary warming up of the inside air along the windshield.

Changing the temperature from °Celsius to °Fahrenheit

Fig. 3-49

Switching over °Celsius - °Fahrenheit

Press the key 8 and keep it depressed. Press the key 3 at the same time. the display of the adjustet cab temperature is changed from °Celsius into °Fahrenheit.

Pressing again the keys 8 and 3 at the same time will cause the temperature to change back into °Celsius.

3.3 Setting the machine into operation 3.3.1

Notes on measures to be taken before starting the machine Tasks to be carried out prior to commissioning Remove the padlocks attached to the switch cabinet door for the transport of the machine.

Insulating resistors During commissioning and after prolonged standstills of the machine, and also before connecting the excavator to the power mains, check the following insulating resistors: resistors between the winding and the stator housing)

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Operating manual

Control and operation Setting the machine into operation

The measured values must always be higher than those specified in the operating manual of the motor manufacturer.

As a rule, the minimum value is 1000 ohm per 1 V operating voltage: e.g. 0.5 mega ohm for a 500 V motor and 6.6 mega ohm for 6.6 kV motor.

If the insulating values are lower, preheat the respective units using the installed auxiliary heater until the value of 1000 ohm per 1 V is reached.

If necessary, and if the mains voltage cannot be directly switched to the excavator (e.g. due to insufficient insulating resistors of the electric rotary connection), the auxiliary heaters can be powered by a separate 220 V or 380 V power source.

The connection to the external source and the important changes of the electrical system must be carried out by a qualified electrician.

Direction of rotation of the electrical motors During commissioning and when re-commissioning the electrical system after major repairs, check the direction of rotation of the electrical motors.

To do this, briefly start the respective motor, shut it down and check whether the direction of rotation corresponds to the direction of the red arrow on the part between the motor and the pump distributor gear.

If the motor is powered through U1, V1, W1 or 1U, 1V, 1W from a direct mains L1, L2, L3, it rotates clockwise when looking at the shaft end.

By exchanging the 2 phases, the direction of rotation is reversed (before doing this, ensure that the motor is designed for operation in both directions of rotation).

Earthing terminal and earthing The earthing terminal is located on a separate mount inside the terminal box; in certain models, it is located on a base or a cooling fin (motors of round design). It is marked with the following symbol: Caution Earthing the motor is compulsory. The earth connections must be established according to the applicable regulations (to protect workers).

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Control and operation

Operating manual

Setting the machine into operation

Other checking After commissioning and then again after approx. 50 operating hours, check the mounting bolts of the motor and the coupling element for correct tightening (see chapter 5 "Checking mounting bolts for proper fixture").

Check that the emergency off switch is operating correctly.

Immediately after starting, check that no abnormal vibrations are occuring at the bearings of the motor. Make sure that the ball bearings of the electrical motor have been properly greased. If necessary, complete the grease charge of the bearings, following the lubrication procedure in the manufacturer maintenance manual.

Tasks to be completed prior to machine start Caution!

A fire can only be extinguished, if it is accessible.

Before starting the machine, open all locks of the hydraulic excavator panels.

In the event of a fire, these doors can than be opened without delay to extinguish the fire.

Positions of the locks: see chapter "Maintenance".

Caution!

When the tasks listed below are completed while the machine is already at operating temperature, there is risk of injury from scalding by hot oil.

Before completing the tasks described here, read the respective sections in chapter "Maintenance".

Daily before starting the machine Check the oil level in the hydraulic tank, see the chapter "Maintenance".

If required, remove any ice and snow from the motor hood, from the grate above the hydraulic oil cooler and from the cooling air aspiration mouth of the electric motor.

Check that all doors and covers are correctly closed, but not locked.

Check that the doors of the electrical enclosures are closed.

Before first start after a longer standstill of the machine Check the insulation resistance values of the stator windings of the electric motor as described in the chapter "Maintenance".

Before first start after the machine was diconnected from the power supply, resp. after important repairs at the machine Immediately after starting, check that the sense of rotation of the motor is correct, this means that it coincides with the sense of the arrows on the motor housing.

Otherwise the motor must be stopped immediately.

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Operating manual

Control and operation Setting the machine into operation

3.3.2

Switching on the electrical system Ignition key and buttons

Fig. 3-50

Ignition

Fig. 3-51

Button in right armrest

0

Neutral position

1

Contact position

2 3

No function No function

P

No function

Switching on the electrical system The doors of the main switch cabinet must be closed.

Turn the ignition key to contact position 1.

Press and then release the button S207.

The main switch is switched on.

Note The main switch is automatically switched off when the electrical box door is opened or when the emergency off switch is engaged. The electrical system has ti be reset by poushing during 5 seconds on S208.

Danger If the main switch is off (S208 is switch on), certain components of the electrical system are still powered!

The electrical rotary connection, the switch cabinet heating, ventilation and lighting system, the operator's cab standstill heating, the hydraulic oil preheating system and the motor preheating system remain powered.

Switching on control system Press and then release the button S183.

The indicator light in the switch is on.

Immediately after switching on the system, the keyboard and the monitoring display complete a self-test.

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Control and operation

Operating manual

Setting the machine into operation

Note!

If no self-test of the keyboard and the monitoring display is performed when the key is set to contact position, check that the machine equipped with an immobiliser and has this immobiliser been activated (see section "Immobiliser" in this group)?

When switching on the machine, check all indicators and similar instruments for proper functioning.

All indicator lights, with the exception of the LED of the switch S22 (auxiliary light) must be briefly on.

The LIEBHERR logo must be shown on the monitoring display.

Display of service tasks that are due

Fig. 3-52

Service interval request

After the self-test is completed, a graphic symbol might be displayed, indicating that a pre-programmed routine service task is due.

The display usually showing the operating hours now shows the hours after which the next service task is due.

The service task symbol disappears after about 8 seconds.

Emergency operation (option)

Fig. 3-53

Battery main switch

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Operating manual

Control and operation Setting the machine into operation

Set the battery main switch S9 (on the heating box behind the operator's cab) to position 1.

3.3.3

Starting the electric motor Note !

A wrong start can cause damages for the electric motor !

Only operate the green switch S181 when the motor is stped.

If the motor is cold: Do not operate more than 3 following starts.

Do not operate more than 6 starts per hour.

If the motor is hot: If the motor does not start after 2 starts, wait at least 10 minute before attempting to restart.

Starting procedure Operate S181 The light in the green switch is on.

The light H10 switch on when the hydraulik system is ready to work.

3.3.4

Starting procedure for exterior temperature below -18 °C (0 °F).

To improve the starting ability of the motor at temperatures below -18 °C, we recommend to equip the machine with one or several of the original LIEBHERR cold starting kits (see Starting aids).

Hydraulic oil The power of the main pumps is automatically limited when the hydraulic oil is cold (temperature below 8 °C).

As soon the hydraulic oil temperature rises above 8 °C, the full power of the machine is available.

Note !

The warm up phase for the hydraulic circuit can be activated and deactivated while programming the display.

During a warm up phase for motor or hydraulic oil, the symbol "current warm up phase" will be displayed on the screen.

3.3.5

Shutting down units Shutting down electric motor Press the button S182.

The motor and the indicator light in the button S181 are switched off.

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Control and operation

Operating manual

Setting the machine into operation

Switching off control circuit Press the button S184.

The indicator light in the button S183 is off.

Switching off main switch Press the button S208.

The indicator light in the button S207 is off.

Danger!

If the main switch is off (S208 is switch on), certain components of the electrical system are still powered!

The electrical rotary connection, the switch cabinet heating, ventilation and lighting system, the operator's cab standstill heating, the hydraulic oil preheating system and the motor preheating system remain powered.

Emergency shut-down of the units Engage the emergency-stop switch S2-1.

The power circuit is switched off.

Caution!

The emergency shut-down procedure must only be used in the event of an emergency.

After actuation of the emergency-stop switch S2-1, the switch remains locked and must first be released before the motor can be restarted.

To release the emergency-stop switch, press in the release button and turn the switch clockwise.

Caution!

The electrical system has ti be reset by poushing during 5 seconds on S208.

After an emergency shut-down, you must wait at least 10 minutes before restarting the electric motor.

Fig. 3-54

Emergency-stop switch on the control console

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Operating manual

Control and operation Working with the machine

3.3.6

Starting aids Hydraulic oil preheating (optional extra) The hydraulic oil can be preheated before starting using hydraulic oil preheating. It is working when the power supply is switched on.

The hydraulic oil preheating switches off when the control circuit is activated with the switch S183.

3.4 Working with the machine 3.4.1

Uppercarriage swing movements The swing movements of the uppercarriage are controlled by the left joystick 4.

Fig. 3-55

Rotating the uppercarriage

Caution!

The joystick functions described below refer to the normal control, fitting out the machine at delivery.and according to ISO-standards, On machines equiped in addition with a special control system, and if this special control system is activated by the operator, the joystick functions correspond to the information on the label which is sticked on the side window of the cab and is specific to the installed special control system.

Push the left joystick 4 to the left c: the uppercarriage rotates to the left.

Push the joystick to the right d: the uppercarriage rotates to the right.

Braking the uppercarriage The machine is equipped as well with an hydraulic as with a mechanical swing brake.

The hydraulic swing brake

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Control and operation

Operating manual

Working with the machine

Let the left joystick 4 move back to neutral position.

The hydraulically swing braking of the uppercarriage takes place. In normal working conditions, the braking efficiency is sufficient to bring the uppercarriage to a standstill rapidly.

Move the left joystick 4 in the opposite direction.

The maximum hydraulic braking action of the uppercarriage is achieved.

The mechanical swing brake The mechanical brake is a negatively acting multidisc brake which is integrated in the swing gear. It allows to stop the uppercarriage in any desired position (for parking, when working on a slope, ...).

Press the touch S17. the red LED beside the touch is lighting. the swing brake is applied.

Press the touch S17 again. the red LED beside the touch goes out.

The swing gear brake is in mode semi-automatic and can now be controlled as follows by the rocker switch S57: Tilt down the rocker switch S57 on the joystick handle, the brake is applied when the uppercarriage is at standstill, respectively it applies as soon as the uppercarriage speed gets lower than a limit value.

Tilt up the rocker switch S57, the brake remains released permanently.

Note!

The red LED beside the touch S17 is lighting in any case when the brake is applied.

If this light does not go out when the rocker switch S57 is tilted up, the button S17 must first be pushed to pre-select the semi-automatic mode.

Caution!

The brake only applies when the uppercarriage is near standstill and if no swing motion is actuated via the joystick!

In order to stop the uppercarriage when working on a slope, tilt the switch S57 down and reduce the uppercarriage speed by braking with joystick 4.

Move the joystick 4 back to «0» position only after the brake has applied.

Ermergency stop of the uppercarriage swing motion The swing brake can be applied independently of the uppercarriage RPM by switching the button S17 from position «semi-automatic» into position «applied».

Caution Perform this braking via button S17 only exceptionaly, i. e. in emergency cases, since it causes fast abrasion of the brake discs.

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Operating manual

Control and operation Working with the machine

To check the mechanical swing gear brake: When the uppercarriage is stationary.

Press the touch S17. the swing brake is applied. the LED in the touch is lighting.

Push the left joystick 4 to the right and then to the left as far as the stop.

If the swing brake function is OK, the uppercarriage does not start swinging.

The positioning swing brake (option) The positioning swing brake is used for progressive and sensitive braking of the upper carriage.

Fig. 3-56

Positioning swing brake pedal

Note!

Increased wear.

Do not use the positioning swing brake purely as a service brake, but only as a stop and parking brake.

Using this brake to stop the uppercarriage running at the full swing RPM is not permissible since this would result in a quick abrasion of the brake discs.

In any case, first use the hydraulic braking to greatly reduce the speed of the uppercarriage Depress the pedal 10 when the uppercarriage is near standstill The uppercarriage can be stopped precisely and progressively in the desired position.

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Control and operation

Operating manual

Working with the machine

3.4.2

Working position Every time it is possible, work on a level, flat and firm ground.

If necessary arrange the working place and free it of obstacles.

As a general rule, work with the attachment over the idler wheels.

Fig. 3-57

Working position of the machine

Note!

Drive backwards when you are working lengthwise with a backhoe bucket attachment.

3.4.3

Working attachment control Caution!

The joystick functions described below refer to the normal control, fitting out the machine at delivery.and according to ISO-standards, On machines equiped in addition with a special control system, and if this special control system is activated by the operator, the joystick functions correspond to the information on the label which is sticked on the side window of the cab and is specific to the installed special control system.

Control of the stick cylinder The stick cylinder is operated using the left joystick 4.

Fig. 3-58

Stick cylinder control

Pull the joystick 4 back (a).

The stick is moved in.

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Operating manual

Control and operation Working with the machine

Push the joystick 4 forwards (b).

The stick is moved out.

Control of the boom cylinders The boom cylinders are operated using the right joystick 3.

Fig. 3-59

Boom cylinders control

Pull the joystick 3 back (g).

The working attachment is raised.

Push the joystick 3 forwards (h).

The working attachment is lowered.

Float position of the boom with shovel attachment When operating a machine fitted with a shovel attachment, it is possible to turn on the float position of the boom cylinders. Therefore: push the right joystick 3 foreward h. press the touch S6M at the top of the handle of the right joystick 3 and keep it depressed. the float position of the boom cylinders is now engaged, the working attachment can move up and down freely, depending on the backlash opposed by the excavated materiel.

Fig. 3-60

Float position of the boom cylinders with a shovel attachment

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Control and operation

Operating manual

Working with the machine

Note!

Turning on the float position of the boom cylinders can, depending on the kind of the material, facilitate the penetration of the shovel in the heap to be hollowed.

When leveling out the working area, the bucket follows automatically the solid ground contour during the stick extension ( movement "b" controlled by the left joystick 3), and the shoveling up of the loosen material is made easier.

Control of the bucket or grapple cylinders The bucket cylinder as well the grapple cylinders are controlled by the right joystick 3.

Fig. 3-61

Operation of the bucket or grapple cylinders

Push the joystick 3 to the left e.

The bucket is tilted in, or the grapple closes.

Push the joystick 3 to the right f.

The bucket is tilted out, or the grapple opens.

Danger Never allow anybody to guide the grapple by hand!

Combined movements A diagonal movement of the joystick combines the corresponding movements of the working attachment. This makes it possible for all attachment movements to be actuated at the same time.

3.4.4

Lowering the working attachment with the engine shut down In an emergency, the attachment can be lowered also when the engine is not running.

Note The attachment can be lowered thanks to a pressure accumulator mounted to the control oil unit. Due to the small volume of this accumulator only a limited number of movements can be actuated by the pilot control devices.

Only operate the joysticks in the directions for lowering the attachment.

Only the movements resulting from the own weight of the attachment parts are possible.

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Operating manual

Control and operation Working with the machine

Fig. 3-62

Lowering the attachment with shut down engine

Turn the ignition key to contact position 1.

Actuate the desired movement(s) while deflecting the joysticks (eventually also the foot pedals in case of special attachment) until the equipment has lowered to the required position.

3.4.5

Rotating, tilting, locking and unlocking a working tool An additional hydraulic circuit must be activated to operate some specific working tools such as:

The medium pressure circuit is activated via the touch S19 on the main control unit.

Fig. 3-63

Activation of the medium pressure circuit (S19) and actuation of the working tool (S5L/S5R)

The working tool is then actuated via the both push buttons S5L and S5R mounted at the top of the handle of the left joystick 4.

Press the touch S19.

The medium pressure circuit is activated.

The LED of the touch is lighting.

Press the left push button S5L and keep it pressed.

The working tool is actuated to the left (the grapple is rotated to the left, or the bucket is swivelled to the left, or the locking pins of the hydraulic quick-change adapter are driving out, ...).

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Control and operation

Operating manual

Working with the machine

Fig. 3-64

Actuation of working tools

Press the right push button S5R and keep it pressed.

The working tool is actuated to the right (the grapple is rotated to the right, or the bucket is swivelled to the right, or the locking pins of the hydraulic quickchange adapter are retracted, ...).

The movement of the working tool is stopped as soon as the push button S5L or S5R is released.

Press the touch S19 again.

The medium pressure circuit is deactivated and the working tool can not be actuated any more.

The LED of the touch goes out.

Note!

With the option "Left joystick with proportional control" installed, the working tool can be actuated in a proportional way, while deflecting the mini joystick A185 on the left joystick to the left "X-" (resp. to the right "X+").

Caution!

On machines destined to the North American market, and which are fitted with a lifting magnet, the rotating device is controlled by the push buttons S6L and S6R in the handle of the right joystick 3.

Also see the section "joysticks" in this chapter.

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Operating manual

Control and operation Working with the machine

3.4.6

Control of the swivel rotator (option) Rotation, swivel, locking and unlocking of the swivel rotator :

Fig. 3-65

Swivel rotator

The push buttons on the right and left manipulators controls the swivel rotator.

Fig. 3-66

Push buttons on maniopulators 3 and 4

Press siwtch S19. the swivel rotator is activated.

LED in switch illuminates.

Swivel the rotator : Press push button S5L and hold it. rotator swivels to the left.

Press push button S5R and hold it. rotator swivels to the rightr.

Turn the rotator : Permutate between those modes using push button S6R. Press push button S6R and hold it.

Swivel mode permutates into rotation mode.

Press push button S5L. rotator turns to the left.

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Control and operation

Operating manual

Working with the machine

Press push button S5R. rotator turns to the right.

Remarque !

To lock and unlock, see chapter "Mechanical quick-change adapter" into the operating instructions.

3.4.7

Control of additional attachments via the additional pedals If necessary, select the mounted additional attachment in the menu "Set Option".

This selection determines pressure and oil flow adjustment in the hydraulic circuit, depending on the function and the size of the auxiliary user. A wrong selection could lead to damage or unsatisfactory operation of the additional attachment.

Note!

The selection of the attachment does neither have an influence upon the allocation of the pedals, nor lead to the switching-off of pedal function.

Danger!

Additional pedals may have many functions. They are describe on the operating sign in the cab, on the window on attachment side. u start up a machine fitted with additional attachments.

Control of the other additional attachments The additional pedal 9m/9k allows to control optionaly mounted additional attachments. These additional attachments are, for example: A B C D When two of these additional attachments are mounted simultaneously on the machine, the first is controlled by the left double pedal 9m/9k, and the second is controlled by the right double pedal 9n/9p.

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Control and operation Working with the machine

Push down the foot pedal 9m (or 9n).

The cylinder of the additional user is retracted.

Push down the foot pedal 9k (or 9p).

The cylinder of the additional user is extended.

Control of a bottom dump shovel

For the excavators R934C - R944C - R954: Push down the foot pedal 9p.

The shovel flap closes.

Push down the foot pedal 9n.

The shovel flap opens.

For the excavators R964C - R974C: Push down the foot pedal 9n.

The shovel flap closes.

Push down the foot pedal 9p.

The shovel flap opens.

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Control and operation

Operating manual

Working with the machine

Control of the hydraulic hammer

Select the mounted hydraulic hammer in the menu "Set Option" The designation appears in the lower right corner of the screen (for example HM 2000).

In case of a doubt, contact your supervisor to obtain this information.

Push down the foot pedal 9m.

The hydraulic hammer is activated.

Note!

If the machine is used frequently or for long periods for hammer work, the hydraulic oil will be more contaminated than in usual conditions.

Adapt the maintenance intervals for hydraulic oil and for return filter cartridges to the work in heavy dust conditions.

3.4.8

AHS11 proportional control (option) With the special equipment "AHS11 proportional control", installed on customer's request and according to customer's wishes, the AHS11 control on the left double pedal is permanently transfer on the axes X(-) and X(+) of the mini joystick on the right joystick.

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Control and operation Working with the machine

Fig. 3-67

Mini joystick on the right joystick

Danger!

Risk of accident due to an unintentional movement by an uninformed machine operator!

With the AHS11 proportional control turned on, the correspondence between actuated controls and triggered working movements is changed.

It is the responsibility of the owner of the machine to authorize an operator to operate the machine with the AHS11 proportional control.

Actuate the mini joystick to X(-) and keep it tilted: The cylinder of the additional equipment is extended and the additional equipment is moved correspondingly.

Actuate the mini joystick to X(+) and keep it tilted: The cylinder of the additional equipment is retracted and the additional equipment is moved correspondingly.

3.4.9

Commutation of control for an additional attachment (option) Danger!

Risk of accident due to an unintentional movement by an uninformed machine operator!

When the commutation of the control is turned on, the correspondence between the controls and the working movements is changed.

When the key is removed from the switch or when the touch is gone out, the machine can be operated only with the usual control system, installed at machine delivery.

It is the responsibility of the owner of the machine to grant an operator authorization to operate the machine with the activated special control system.

Caution!

Check out the functions of the additional controls when starting the machine, especially when a commutation of control is activated.

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Control and operation

Operating manual

Working with the machine

Standard control

Fig. 3-68

Commutation of standard control for an additional attachment

The additional attachment can be operated alternatively with the left double pedal or with the right joystick. The commutation of control can be activated with the key switch S114 on the rear right control desk.

Turn the key switch S114 to select the joystick position.

The additional attachment is now operated with the right joystick (movements to e and f).

The bucket tilt function is now operated with the left double pedal (m-k).

The key is locked in the switch S114.

Turn the key switch S114 to select the foot pedal position.

The additional attachment is now operated with the left double pedal again.

The key can be removed from the switch S114.

Proportional control Mini joystick / Joystick

Fig. 3-69

Commutation of proportional control for an additional attachment

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Control and operation Working with the machine

The additional attachment can be operated alternatively with the right mini joystick or with the right joystick. The commutation of control can be activated with the key switch S195 on the rear right control desk.

Turn the key switch S195 to select the joystick position.

The additional attachment is now proportionally operated with the right joystick (movements to e and f).

The bucket tilt function is operated with the right mini joystick (movements to X- and X+).

The key is locked in the switch S195.

Turn the key switch S195 to select the mini joystick position.

The additional attachment is proportionally operated with the right mini joystick.

The key can be removed from the switch S195.

Mini joystick / Pedals

Fig. 3-70

Commutation of proportional control for an additional attachment

The additional attachment can be operated alternatively with the right mini joystick or with the left pedals. The commutation of control can be activated with the touch on the right control desk.

Press the touch.

LED in the touch illuminates.

The additional attachment is proportionally operated with the right mini joystick.

Press the touch.

LED in the touch goes out.

The additional attachment is proportionally operated with the left pedals.

3.4.10

Special control system of the joysticks At delivery, the control system of the joysticks, i. e. the correspondence between the actuated directions at the joystick levers and the resulting working movements of the excavator always correspond to the standard control according to ISO. You can find the description of this ISO-control-systems in the subchapters "Working attachment control" and "Operating the swing gear" in this manual.

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Control and operation

Operating manual

Working with the machine

"commutation for special control system".

With this option, the commutation from the ISO control system into the special control system is achieved by commuting the switching lever situated on the floor of the cabin, under the right joystick.

Fig. 3-71

Location of the switching lever

Danger!

Risk of accident due to an unintentional movement by an uninformed machine operator!

With switched on special control system, the correspondence between movements of the joystick and the induced working movements is changed.

With the switching lever in PCSA position, the excavator can be operated only according to ISO-control-system.

It is the responsibility of the owner of the machine to authorize an operator to operate the machine with the AHS11 proportional control.

Turn the switching lever to position 1. the special control system is turned on, now the joystick functions correspond to the information on the label pos. A which is sticked on the side window of the cab.

The label A is specific to the special control system installed on the machine and ordered by the customer.

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Control and operation Working with the machine

Fig. 3-72

Instruction plate A and warning plate B

The label B informs that the excavator is fitted with a special control system which can be activated with the switching lever.

Caution!

Make sure that stickers A and B are present on the machine and are well readable!

If necessary they can be reordered at the LIEBHERR Spare Parts Department.

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Control and operation

Operating manual

Working with the machine

3.4.11

Special control (option)

Fig. 3-73

Special control

On request, the machine can be equipped with m and k, and the function "Activating additional equipment" to the operation n and p.

The function "Activating hydraulic hammer" is activated using foot pedale n.

Note Requisite : Option AHS12 must be available, and being adjustate. See corresponding chapter.

Caution!

Additional equipment can have several functions. Always check out its functions on each machine starting Incorrect preselection of the pressure and quantity setting can result in damage to the work tool (eg. hydraulic hammer) or to limited function (eg. boom adjustment cylinder).

3.4.12

Cut-off of attachment movements (option) The movement cut-off restricts the movements of the boom cylinder or the stick cylinder. It enables: orking height, working depth, maximal reach, minimal reach).

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Control and operation Working with the machine

Danger!

The movement cut-off is not a safety device! It is only an assistance to the driver during an attachment movement near a prohibited zone!

Caution!

Danger of rocking motion of the machine and oscillations of the working tool!

Avoid fast attachment movements close to a cut-off point.

Note!

The movement is only cut off to enter into the prohibited zone. The movement to leave it remains possible.

Adjustment of the movement cut-off point At the time of the cut-off, the attachment can enter into the prohibited zone in case of oscillations of the working tool, variations of its dimensions (open/close position) or attachment inertia.

Danger!

The machine driver is responsible for the adjustments precision!

You must keep a safety margin of at least 1.5 m from the prohibited zone.

As soon as the proximity switch detects the reflector, the movement is cut off. The proximity switch or the reflector position is adjustable depending on the configurations.

Fig. 3-74

1 2

Example of a cut-off of the stick movement with an adjustable proximity switch

Reflector Proximity switch nut

3 4

Proximity switch Rail

Bring the attachment into the desired cut-off position.

Loosen the nut 2 of the proximity switch 3 (or reflector).

Move the proximity switch 3 (or reflector) on the rail 4. Place it face to face with the reflector 1 (or proximity switch).

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Control and operation

Operating manual

Working with the machine

If the proximity switch 3 does not detect the reflector 1 when they are face to face, move them closer.

Retighten the nut 2 of the proximity switch 3 (or reflector).

Check the actual cut-off position of the attachement.

If necessary, repeat the adjustment procedure and check the cut-off position again. .

Note!

If the proximity switch and the reflector are difficult to be reached in the cut-off position: Bring the attachment in a stretched and close to the ground position.

Adjust approximately the cut-off point.

Correct it by successive approaches until the desired cut-off position is reached.

Unlocking of movements cut-off Danger!

Danger of personal injury and material damage in case of attachment movements within a prohibited zone by the movement cut-off!

The operator is in any case responsible for the accidents which can occur when the movement cut-off is unlocked.

Fig. 3-75

Unlocking of movement cut-off

Bring the attachment into the cut-off position.

Turn the key switch S54 to position I. Tilt up or down the switch S55 of the left joystick and keep it pressed.

The cut-off of attachement movements is unlocked.

It is possible to move the attachment within the prohibited zone as long as the switch S55 is kept pressed.

Turn the key switch S54 to position 0.

The movement cut-off is actuated again.

If two movement cut-offs are fitted on the machine attachment, turn the key switch S54 to position II to unlock the second cut-off.

Note!

For the machines for the North-American market and fitted with a lifting magnet: Use the switch S5L of the left joystick to unlock the cut-off.

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EP 944C / 10360388

Operating manual

Control and operation Working with the machine

3.4.13

Use of the excavator for lifting loads overhead Under "lifting loads overhead" it is understood the lifting, transporting and unloading of loads requiring a securing method (ropes, chains, or other permitted lifting accessories) and where personnel are required to assist in securing and unloading the load. This includes, for example, the lifting and unloading of pipes, shaft-top supporting rings or containers.

Danger!

An hydraulic excavator may only be operated for lifting loads overhead if all the prescribed safety devices are present and functioning correctly.

In accordance with European standard EN 474-5, and so to guarantee the protections of the persons attaching or removing the loads during lifting operations, the machines used for lifting loads overhead must be equipped with the following safety devices: a load hooking system ensuring the safe attaching and removing of the loads (optional equipment) Safe hooking systems include for example lifting hooks which are mounted in place of the bucket. Safety lifting hooks welded directly to the bucket are also allowed. an overload warning device (optional extra) The overload warning device must alert the machine operator visually or acoustically if the permitted load value has been reached or exceeded, according to the rated lift capacity chart. a boom lowering control device (such as load check valves) to prevent unintentional lowering or dropping of the boom because of the weight of the load, which could happen if a line in this hydraulic circuit suddenly develops a leak (for example, should a hydraulic line break or a hose burst,...).

This boom lowering control device must correspond with the requirements of ISO 8643.

Such a boom lowering device can be installed as an option on all models up to R924C, it is serially installed on all models R934C and above. a rated lift capacity chart (commonly called load chart), attached inside the cab and within the view of the operator..

If the points referred to above are not or are only partially fulfilled, the machine may not be used for lifting loads overhead.

Every LIEBHERR hydraulic excavator can be fitted with all the safety devices required for lifting loads operation.

Danger!

Only employ sling ropes and accessories which are permitted for lifting operation, regularly checked and in good condition.

No person may fasten or unfasten a load without approval of the operator and this person may only approach the load from one side. The operator may only approve this action when the excavator has stopped and the attachment is not moving.

Never lift loads over people.

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Control and operation

Operating manual

Working with the machine

3.4.14

Overload warning system (option) Description The overload warning system indicates to the machine operator when the maximum permitted load capacity is reached or exceeded.

The permitted load capacity depends on the configuration of the machine (undercarriage, working attachment). The maximum load capacity can be found on the load capacity chart in the operator's cab.

The load capacity values achieve a maximum of 75% of the tip load or 87% of the hydraulic lifting power acc. to ISO 10567.

The permissible load capacity is dependent on the following factors:

The overload warning device does not release the machine operator from the responsibility of only lifting loads that are known and within the safe working load of the machine in accordance with the load lift chart.

With the specified load, the machine can be rotated from 360° on even and horizontal ground.

Checking the overload warning system The overload warning system must be checked for correct function every time the machine is started and before load lifting work.

Slowly extend the hoist cylinder up to stop.

Operate the hoist cylinder up to stop.

The overload warning status symbol appears on the display.

An audio warning sounds in the operator's cab.

If a malfunction occurs: Do not lift loads.

Have the overload warning system repaired.

Using the overload warning system Danger!

Tipping over of the machine!

Damages, injuries, death.

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

Follow the accident prevention precautions relative to load hoisting work.

Follow the instructions if the overload warning system is triggered.

Press switch S18.

The overload warning system is activated.

The LED in the switch is lit.

If the overload warning system is triggered: overload warning status symbol appears on the display.

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Operating manual

Control and operation Working with the machine

Reduce the reach. or Lower the load to the ground without increasing the reach.

Deactivating the overload warning system Note Increased pressure in the hydraulic cylinders of the machine during earth-moving operations!

If the overload warning system is activated, it is triggered permanently.

Switch off the overload warning system for earth-moving operations.

Press switch S18.

The overload warning system is deactivated.

The LED in the switch goes out.

3.4.15

Adjustable hydraulic cab (option) Two types of adjustable hydraulic cabs are available:

The hydraulic cab has a stepless height adjustment.

The hydraulic adjustment is controlled with the rotary switch S200 on the right side control panel.

Fig. 3-76

Control of the adjustable hydraulic cab

Make sure that the Diesel engine is started.

Make sure that the safety lever is in the upper position.

Lifting the hydraulic cab Danger!

Tipping over of the machine with lifted cab!

Damages, injuries, death.

Make sure that no obstacle is in the path of the machine.

Operate only on level and firm ground.

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Control and operation

Operating manual

Working with the machine

Make sure that the machine is stationary.

Move and hold the rotary switch S200 to the left position 2.

The cab lifts.

Lowering the hydraulic cab Danger!

Crushing hazard when lowering the hydraulic cab!

Injuries, death.

Make sure that nobody is in the dangerous area.

Keep your arms and legs away from moving parts.

Move and hold the rotary switch S200 to the right position 1.

The cab lowers.

Emergency lowering of the hydraulic cab In case of failure, the hydraulic cab can be lowered:

The emergency shutoff valve in the cab is on the floor below the right control panel.

Fig. 3-77 Danger!

Crushing hazard when lowering the hydraulic cab!

Injuries, death.

Make sure that nobody is in the dangerous area.

Set the emergency shutoff valve in position 2.

The cab lowers.

When the cab is fully lowered: Set the emergency shutoff valve back in position 1.

The cab can be lifted.

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Operating manual

Control and operation Working with the machine

Emergency lowering from the uppercarriage The emergency shutoff valve on the uppercarriage is at the rear of the cab hydraulic lifting system.

Fig. 3-78

Emergency shutoff valve on the uppercarriage

Danger!

Crushing hazard when lowering the hydraulic cab!

Injuries, death.

Make sure that nobody is in the dangerous area.

Keep your arms and legs away from moving parts.

Set the emergency shutoff valve in position 2.

The cab lowers.

When the cab is fully lowered: Set the emergency shutoff valve back in position 1.

The cab can be lifted.

Maintenance and repair Danger!

Crushing hazard from lowering hydraulic cab!

Damages, injuries, death.

Before carrying out any maintenance or repair work on the adjustable hydraulic cab: Lower the cab fully.

If the operation requires that the hydraulic cab be in lifted position: Place appropriate support equipment below the cab.

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Control and operation

Operating manual

Emergency operation

3.5 Emergency operation 3.5.1

Emergency control circuit board E52 for electric motor & servo control The printed circuit board E52 is located at the very rear of the right control console.

The emergency control function enables the operator to manoeuvre and operate the hydraulic excavator to a limited extent in the event of failure of the electronic main control circuit.

Fig. 3-79 E52

Emergency control circuit board E52

Emergency control circuit board

H_b Indicator light / control system 24V in emergency mode H73_bIndicator light / emergency operation of servo pressure circuits

S_b S73

Switch / emergency start of control system 24V Switch / emergency operation of servo pressure circuits

Emergency switching of control system 24V Set the battery main switch S9 to position 1 (ON).

Fig. 3-80

Battery main switch S9 on the heating box

In normal operating mode, the control electronics of the machine release the control system 24V. In the event of a fault in the electronics, the control system can be released manually by tilting the switch S_b to its emergency position.

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Operating manual

Control and operation Emergency operation

Move the safety lever down.

Actuate the rocker switch S_b to set the machine to emergency mode.

The indicator light H_b is on.

The control system is powered on.

Emergency switching of servo pressure circuits In normal operating mode, the control electronics of the machine release the servo pressure to the pilot control units and the slewing gear brake.

In the event of a fault in the electronics, the servo pressure can be released manually by tilting the switch S73 to its emergency position.

Fig. 3-81

Emergency switching of servo circuits - emergency switch and warning symbols on display

Move the safety lever down.

Actuate the rocker switch S73 to set the machine to emergency mode.

The three symbols S73a, S73b and S73c are displayed on the screen.

The indicator light H73_b is on.

The pilot control units are pressurised with servo pressure.

The slewing gear brake is released.

Danger!

The emergency mode must only be used for short times and if it is not possible to release the slewing gear brake and/or if the servo pressure supply to the pilot control units is not reliably ensured through the normal control circuit.

In emergency mode, the slewing gear brake is released as soon as the key is in contact position and the normal control of the brake system is disabled.

Inform all persons involved in the operation and maintenance of the machine of the fact that the machine is in emergency mode and that its control is thus altered.

Have the damage or fault that required you to switch to emergency mode rectified as soon as possible.

Note!

The servo pressure supply to the pilot control units is shut off as the safety lever 1 is tilted up and remains shut off even when the switch S73 in set to its emergency position.

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Control and operation

Operating manual

Emergency operation

3.5.2

Emergency operation of the working pumps In normal operating mode, the volumetric flow of the hydraulic pumps is continuously adjusted by the electronic performance regulator based on the current pressure level in the working circuits.

In the event of a fault or malfunction at the performance regulator or its auxiliary circuits, the pumps are automatically set to minimum flow.

In this case, the machine can still be operated at reduced pump performance.

Fig. 3-82

Setting working pumps to emergency mode

2

Cotter pins

H Horizontal position (emergency position)

3

Lever

V

Y50-1Regulating valve

Vertical position

Y50-2Regulating valve

Switch the lever 3 at the control oil unit at the rear of the hydraulic tank. To do this: from the regulating valves Y50-1 and Y50-2.

2.

3 into a horizontal position (emergency position).

The system is now in emergency mode.

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Operating manual

Control and operation Attaching and dismounting equipment parts

3.6 Attaching and dismounting equipment parts 3.6.1

Removal and installation of a bucket

Fig. 3-83

Removing and installing the bucket

1

Digging bucket

222

Restrictor check valve

2

Stick

232

Restrictor check valve

3-4

Pin

25

Complete pin bearing sealing

5-6

Locking plate

25.1 Sealing ring

7

Connecting link

25.2 O-Ring 25.3 O-Ring

The following is a description of how to attach and dismount buckets. Buckets are, for example, hoe type buckets, ditcher buckets or breaker teeth.

To remove a bucket Position the attachment in such a way that the entire lower part of the bucket is laying on the ground.

Unscrew locking plate 5 and locking plate 6.

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Control and operation

Operating manual

Attaching and dismounting equipment parts

Knock out pin 3 and pin 4 and remove the complete pin bearing sealing 25.

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

To reinstall a new bucket Position the bucket to be attached in such a way that its entire lower part is laying on the ground.

Start the engine and move the equipment until the stick mount and the bearing points A of the bucket are squared.

Engage the pin 4 in its bore and push it in the complete pin bearing sealings 25 between bucket and stick while pressing in the pin. Observe the correct installation direction of the complete pin bearing sealings 25 .

Make the O-rings 25.1 slide to the interior .

Secure the pin 4 with the locking plate 6.

Extend the shovel cylinder slowly until the bore hole in connecting clip 7 is located precisely between the bearing points B. Engage the pin 3 in its bore and push it in the complete pin bearing sealings 25 between bucket and stick while pressing in the pin. Observe the correct installation direction of the complete pin bearing sealings 25 .

Make the O-rings 25.1 slide to the interior .

Secure the pin 3 with the locking plate 5.

Lubricate all greasing points of pins 3 and 4 directly or with the automatic grease system (if mounted) until clean grease comes out of the greasing points.

Note!

After installation of a new digging bucket, the restrictor check valves 222 and 232 for stick, respectively bucket tilt cylinders must be eventually readjusted so to have the correct velocity of the working attachment (due to weight differences of the digging bucket).If necessary, consult a LIEBHERR mechanic.

In particular on machines, which are delivered without digging bucket or grapple, this restrictor check valves must be (if mounted) adjusted after installation of the digging tool, so to avoid uneven or jerky movements of the attachment parts.

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EP 944C / 10360388

Operating manual

Control and operation Attaching and dismounting equipment parts

3.6.2

Attaching and dismounting the bucket with improved sealing

Fig. 3-84

Attaching and dismounting the bucket

1

Digging bucket

7

Connecting link

2 1.1

Stick Bushing

8 9

Protection ring O-ring

2.1 3-4

Bushing Pin

222 232

Restrictor check valve Restrictor check valve

5-6

Cover

The following is a description of how to attach and dismount buckets with improved sealing.

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Control and operation

Operating manual

Attaching and dismounting equipment parts

Dismounting a bucket Position the bucket to be attached in such a way that its entire lower part is laying on the ground.

Remove the covers 5 and 6.

Remove the protection rings 8 of all the bearing points and draw the O-rings 9 up onto the bushing 1.1 on the bucket side.

Drive out the pins 3 and 4.

If necessary, lift the attachment slightly to remove the pin 4.

Take off the O-rings 9 and if necessary replace them.

Attaching a new bucket Position the bucket 1 so that the flat part of the bucket rests on the ground.

Draw the O-rings 9 up onto the bushing 1.1 of the digging bucket, as well on bearings bucket to stick as on bearings bucket to connecting link 7.

Start the engine and move the attachments until the stick and bucket bore holes A align.

Insert pin 4 and reinstall the covers 6 with O-rings.

Slowly extend the stick cylinder until the bore of the connecting link 7 is exactly between bore holes B. Insert pin 3 and reinstall the covers 5 with O-rings.

Slip the O-rings 9 laterally until they are in the grooves between bushings 1.1 and 2.1 (see detail D) and install the two piece protection rings 8.

Lubricate all greasing points of pins 3 and 4 directly or with the automatic grease system (if mounted) until clean grease comes out of the greasing points.

Note!

After installation of a new digging bucket, the restrictor check valves 222 and 232 for stick, respectively bucket tilt cylinders must be eventually readjusted so to have the correct velocity of the working attachment (due to weight differences of the digging bucket).If necessary, consult a LIEBHERR mechanic.

In particular on machines, which are delivered without digging bucket or grapple, this restrictor check valves must be (if mounted) adjusted after installation of the digging tool, so to avoid uneven or jerky movements of the attachment parts.

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EP 944C / 10360388

Operating manual

Control and operation Attaching and dismounting equipment parts

3.6.3

Attaching and dismounting the grab on stick

Fig. 3-85

Attaching and dismounting the grab on the stick

1

Grab mounting

11

Hose

4

Pin

12

Hose

6

Locking plate

13

Hose

7 8

Connecting link Carrier bracket

14 15

Hose Valve blocks

9

Reversing lever

25

Pin bearing sealing

10

Cotter pin

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Control and operation

Operating manual

Attaching and dismounting equipment parts

Before attaching a clamshell bucket or grapple, ensure that the required hydraulic lines for operating the grab are built into the stick.

Attaching and dismounting a grab should be carried out by two people.

Danger!

Risk of injury. moving the attachment.

Attaching the grab If necessary, dismount the bucket.

Retract the bucket cylinder as far as the stop.

Fix the connecting link 7 to the right reversing lever 9 with carrier bracket 8.

Secure with cotter pin 10.

Position the grapple with the shells fully opened.

Move the equipment until the lower mount of the stick is between the bearing points of the grab mounting 1.

Guide in the pin 4 in its bore and push in the pin bearing sealings 25 complete with protection ring while pressing in the pin.

Secure the pin 4 with plate 6.

Connect the hydraulic hoses 11 and 12 for the shell cylinder to the hydraulic lines of the bucket cylinder circuit.

For grapple with hydraulic rotator, hoses 13 and 14 must be connected to the hydraulic lines for added functions on the stick.

Operating the grab Two hydraulic lines on the shovel arm are set in for operating either the tilting cylinder or the grab.

The lines are reversible via two valve blocks 15: A - Tilting cylinder operation (for buckets) B - grab operation (for grab, scrap cutter etc.)

Turn the lever of the valve blocks 15 in position B (Position B, Grab operation).

Note!

If the machine is equipped with a hydraulic quick-change adapter and LIKUFIX, there is no need to switch between tilt cylinder operation and grab operation. There is no valve block 15.

Lubricate all greasing points of the pin 4 and of the grab directly or with the automatic grease system (if mounted) until clean grease comes out of the greasing points.

Carry out all work movements several times without a load (open and close the shell or move the grab to the left and to the right) so that any air that may be present in the hydraulic circuits can escape.

Dismounting the grab Set the grab down onto level ground with the shells fully opened.

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Operating manual

Control and operation Attaching and dismounting equipment parts

Turn off the engine and, with the ignition key in the contact position, push the right joystick briefly to the left and then to the right in order to remove the pressure in the hydraulic circuits.

Turn the lever of each valve block 15 in position A (Position A, bucket operation) and push the right joystick briefly to the left and then to the right in order to remove the pressure in the hydraulic circuits.

Push the safety lever up.

Separate hydraulic hose 11, hydraulic hose 12 and, if present, hydraulic hoses 13 and 14 from the pipes on the stick.

Close open lines immediately to prevent any dirt entering.

Support the grab so that it is stable.

Remove the plate 6. Drive out the pin 4 and remove the pin bearing sealings 25.

If necessary, start the engine and lift the attachment slightly to remove the pin 4.

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Control and operation

Operating manual

Attaching and dismounting equipment parts

3.6.4

Attaching and dismounting the grab on the industrial stanchion

Fig. 3-86

Attaching and dismounting the grab on the industrial stanchion

Before attaching a clamshell bucket or grapple, ensure that the required hydraulic lines for operating the grab are attached to the industrial stanchion.

Attaching and dismounting a grab should be carried out by two people.

Danger!

Risk of injury. moving the equipment.

Attaching the grab Position the grab with the shell fully open.

Move the equipment until the lower mount of the industrial stanchion is between the bearing points of the grab mounting 1.

Guide in bolt 4 and secure using disk 6.

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Operating manual

Control and operation Attaching and dismounting equipment parts

Connect hydraulic hose 11 and hydraulic hose 12 for the shell cylinder supply to the pipes for the shovel tilting cylinder.

For a grab with a hydraulic torsional mechanism, also connect hoses 13 and 14 to the pipes for this auxiliary device.

Operating the grab Carry out all work movements several times without a load (open and close the shell or move the grab to the left and to the right) so that any air that may be present in the hydraulic circuits can escape.

Dismounting the grab Set the grab down onto level ground with the shell fully opened.

Turn off the engine and, with the ignition key in the contact position, push the right joystick (for Open and Close grab)briefly to the left and then to the right in order to remove the pressure in the hydraulic circuits.

Separate hydraulic hose 11, hydraulic hose 12 and, if present, hydraulic hoses 13 and 14 from the pipes on the shovel arm.

Close open lines immediately to prevent any dirt entering.

Support the grab so that it is stable.

Unscrew disk 6 and knock bolt 4 carefully out. You may have to start the engine and raise the equipment slightly to do this.

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Control and operation

Operating manual

Attaching and dismounting equipment parts

3.6.5

Attaching and dismounting the stick to the boom

Fig. 3-87

Attaching and dismounting the stick to the boom

7 16

Connecting link Stick cylinder

20 21

Pin Hoses

17 18

Pin Bucket cylinder

222

Restrictor check valve

Dismounting the stick Figure A If necessary, remove the bucket.

Retract the bucket and stick cylinder as far as the stop, position the attachment on the ground.

If necessary, tie the connector bracket 7 to the bucket cylinder so it can not slip out.

Turn the engine off.

Release the pressure in bucket and stick cylinder circuit by turning the ignition key to contact position, tilting the safety lever down, and moving the right joystick to the left and right, the left joystick forward and backward.

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Operating manual

Control and operation Attaching and dismounting equipment parts

Release the pressure in the hydraulic tank.

Attach the lower part of the stick cylinder 16 to the lift with a strap.

Position a wooden block under the stick cylinder, remove the plate of pin 17, lightly lift the the cylinder, drive out the pin 17and position the stick cylinder 16 on wooden blocks.

Figure B Insert the pin 17 in the rear bearing of the stick and secure it with the plate, then attach the pin 17 to the lifting device with a strap.

Attach the head of the bucket cylinder 18 (or to the hook of the bucket, if the stick is removed with the bucket in place), to the lift with a strap.

Disconnect both hoses 21 from the tilt cylinder 18 and close them off to prevent contamination.

Remove the cotter pin and the castle nut on pin 20 and drive the pin out. If necessary, start the engine and slightly lift the attachment to reduce the weight of the boom on pin 20.

Raise the stick (or the stick with the bucket) with a lift, pull the stick from the boom and position it on the ground, supported by wooden blocks and remove the lift.

Attaching the stick (or stick with bucket) Figure B Insert the pin 17 in the rear bearing of the stick and secure it with the plate, then attach the pin 17 to the lifting device with a strap.

Attach the top of the bucket cylinder 18 (or the hook of the bucket, if the stick is removed with the bucket in place), to the lifting device with a strap.

Raise the stick (or the stick with the bucket) with a lift inside the bore holes of the boom so that the pin 20 can be inserted.

Insert pin 20 and fix the castle nut and the cotter pin to the pin 20.

Remove the pin 17.

Reconnect both hoses 21 to the tilt cylinder 18.

Figure A Attach the lower part of the stick cylinder 16 to the lift.

Slightly lift the stick cylinder and if necessary run engine to extend or retract cylinder so that cylinder head fits between the bore holes of the stick.

Insert the pin 17 and secure it with the plate.

If necessary, install the bucket.

Lubricate all greasing points between stick and boom and between bucket and stick directly or with the automatic grease system (if mounted) until clean grease comes out of the greasing points.

Lift the attachment and tilt the bucket out and in several times to release the air from the hydraulic system.

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Control and operation

Operating manual

Attaching and dismounting equipment parts

Note!

After installation of a new stick and digging bucket combination, the restrictor check valve 222 for stick cylinder must be eventually readjusted so to have the correct velocity of the working attachment (due to weight difference of the attachment parts).

If necessary, consult a LIEBHERR mechanic.

3.6.6

Mechanical quick-change adapter (option) Safety instructions attaching and dismounting work tools. Move the work equipment as slowly as possible when attaching and dismounting a work tool.

Get to know the mode of operation of the quick-change adapter before attaching or dismounting work tools. unlocking to avoid creating conditions which may lead to danger. stand on the work tool. locking pin for the quick-change adapter inserts in the bore holes on the work tool which are designed for the purpose and that the work tool raises correctly. A direct visual check must be made to ensure that the work tool is correctly positioned. is only raised to the point where the correct position of, for example, the pin in the pin eye can be tested by tilting in and out. change adapter or the integrated lifting hook can exceed or fall short of the load carrying capacity of the carrier device.

When operating, it should be ensured that the values provided in the load chart and the technical data for the carrier device are adhered to.

Overview

Fig. 3-88

Mechanical quick-change adapter

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Operating manual

Control and operation Attaching and dismounting equipment parts

1 2

Locking pin (removed) 3 Locking screw 4

Crank Sealing plug

5 6

Lifting hook Take-up hook for work tool

Attaching the work tool To move the equipment into position:

Fig. 3-89

Positioning the equipment

The equipment must be standing stable or lay loose on the ground.

Move the stanchion and work tool into position.

Insert the shovel tilting cylinder fully.

To unlock the quick-change adapter: Danger!

Risk of injury.

Ensure that the work equipment 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 using the crank 3 from the locking pin 1 (see Fig. 3-88).

Insert the crank 3 in the locking pin 1 and turn to the left (anti-clockwise), until both locking pins 1 are inserted as far at the stop.

Taking up the work tool:

Fig. 3-90

Taking up the work tool

Move the quick-change adapter into a position that allows the work tool to be picked up using the take-up hook.

Raise the work tool from the ground and extend the shovel tilting cylinder fully until the bearing panel for the work tool is laying on the quick-change adapter stop.

The bore holes of the work tool and the locking pins of the quick-change adapter must form a row.

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Control and operation

Operating manual

Attaching and dismounting equipment parts

To lock the quick-change adapter:

Fig. 3-91

Locking the quick-change adapter

Danger!

Before locking, there is no fixed connection between the work tool and the quickchange adapter. The work tool could under certain circumstances fall out and injure people.

Approach the quick-change adapter with the utmost care.

Push the safety lever up to secure the work equipment against unintentional movement.

No work movements can be carried out when pilot control devices, eg. 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 extended as far as the stop.

The work tool is bolted on when taking up normally.

Screw the locking screw 2 into the locking pin.

Danger!

An incorrectly locked quick-change adapter could open when operating!

Ensure that the locking pins are always locked by the sealing 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 correctly positioned.

Caution!

Hydraulic lines are pressurized!

Remove the pressure using the joystick before connecting the hydraulic lines (switch off the engine, turn the ignition key into the contact position, operate the joystick).

Connect hydraulic lines or electrical lines, if necessary (eg. when attaching a grab).

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Control and operation Attaching and dismounting equipment parts

Detaching a work tool To move the equipment into position: Caution!

Hydraulic lines are pressurized!

Remove the pressure using the joystick before removing the hydraulic lines (switch off the engine, turn the ignition key into the contact position, operate the joystick).

Disconnect hydraulic lines or electrical lines, if necessary (eg. when dismounting a grab).

Extend the shovel tilting cylinder fully.

To unlock the quick-change adapter:

Fig. 3-92

Unlocking the quick-change adapter

Danger!

Risk of injury.

Once unlocked, there is no fixed connection between the adapter and the work tool.

The work tool could work itself out independently.

Ensure that the work equipment cannot be moved by others when this action is being carried out.

Always keep the work tool as close to the ground as possible when unlocking to avoid creating conditions which may lead to danger.

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

Insert the crank 3 in the locking pin 1 and turn to the left (anti-clockwise), until both locking pins 1 are inserted as far at the stop.

To put down the work tool:

Fig. 3-93

Putting down the work tool

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Attaching and dismounting equipment parts

Slowly insert the shovel tilting cylinder and lay the work tool on the ground.

The new work tool can be taken up.

Using the quick-change adapter for hoisting work

Fig. 3-94

Mechanical quick-change adapter

The quick-change adapter has two integrated lifting hooks. The machine may only be used for hoisting work if the safety devices required for the purpose are present and functioning correctly (see chapter "Hoi The maximum load carrying capacity of each individual lifting hook is given on the quick-change adapter. The load carrying capacity of the quick-change adapter or the integrated lifting hook can exceed or fall short of the load carrying capacity of the carrier device.

When operating, it should be ensured that the values for the carrier device / quickchange adapter given in the load chart and the technical data are adhered to.

Load hoisting work can be carried out with attached or dismounted work tools. With dismounted work tools, it is sensible to fully insert the locking pins when carrying out hoisting work. This prevents the load take-up device being turned round too strongly by the locking pins and damaged.

Danger!

Never use the take-up hook 6 to fasten a load because there is no secure hold for the load take-up device, eg. rope or chains, in the take-up hook.

Fasten the load on the lifting hook as

3.6.7

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

Familiarize yourself with the mode of operation of the quick-change adapter without attached work tools if possible. adapter is monitored by a visual and acoustic warning device (buzzer and telltale light). The function of the warning device should be checked daily by operating the quick-change adapter.

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Control and operation Attaching and dismounting equipment parts

tivated without a deliberate locking or unlocking procedure being carried out, stop all work at once. If the buzzer and telltale 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 unmonitored position change of the locking pins due to mechanical or hydraulic damage. A defect may also be present in the electrical system (eg. proximity switch or buzzer).

Only resume working once defective parts have been repaired or replaced. purpose is pressed.

Always keep the work tool as close to the ground as possible when unlocking to avoid creating conditions which may lead to danger. Only activate the quickchange adapter to carry out a deliberate locking or unlocking procedure. locking pins for the quick-change adapter insert in the bore holes on the work tool which are designed for the purpose and that the work tool raises correctly. A direct visual check must be made to ensure that the work tool is correctly positioned. with the work tool ,where the work tool is only raised to the point where the correct position of, for example, the pin in the pin eye can be tested by tilting in and out. hook can exceed or fall short of the load carrying capacity of the carrier device.

When operating, it should be ensured that the values provided in the load chart and the technical data for the carrier device are adhered to.

Overview

Fig. 3-95 1

Hydraulic quick-change adapter

Locking pin (extended)

5

Lifting hook

6

Take-up hook for work tool

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Attaching and dismounting equipment parts

Operating elements

Fig. 3-96

Operating elements for the hydraulic quick-change adapter

Switch S19 Use switch S19 to activate the auxiliary hydraulic device for the grab torsional mechanism and quick-change adapter.

Press switch.

Auxiliary device is activated.

LED in switch illuminates.

Press switch again Auxiliary device is deactivated.

LED in the switch goes out.

Key switch S47: Pressing the button activates the quick-change locking pins.

Pushbuttons L and R Pushbutton L = extend locking pin (lock) Pushbutton R = retract locking pin (unlock) The pushbuttons are located on the left and/or right joystick (depending on the

Fig. 3-97 E

Pushbutton on the joystick

Operation with left joystick (standard)

F

Operation with left and right joystick (optional extras)

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Control and operation Attaching and dismounting equipment parts

Symbol "Quick change adapter" The symbol appears:

Two-hand operation The quick-change adapter is activated using two-hand operation. The locking pins can only be moved at first if button S47 and one of the pushbuttons L or R are pressed.

The control has a hold function which allows both joysticks to be operated simultaneously when attaching and dismounting work tools. If one of the pushbuttons, L or R is continued to be pressed, 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, button S47 and the relevant pushbutton L or R must be pressed.

Caution !

The extension of the locking pins (locking of the coupler) is possible even without depressing S47.

However this must be absolutely avoided since it causes a quick wear of the sealing rings in the LIKUFIX hydraulic coupling system.

Attaching the work tool To move the equipment into position:

Fig. 3-98

Positioning the equipment

The equipment must be standing stable or lay loose on the ground.

Move the stanchion and work tool into position.

Insert the shovel tilting cylinder fully.

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

Quick-change adapter is activated.

LED in switch illuminates.

Press and hold button S47.

Quick-change adapter is activated.

Press and hold pushbutton R until the locking pins are fully inserted.

The buzzer sounds.

The quick-change adapter is unlocked.

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Attaching and dismounting equipment parts

Taking up the work tool:

Fig. 3-99

Taking up the work tool, first step

Move the quick-change adapter into a position that allows the work tool to be picked up using the take-up hook.

Fig. 3-100 Taking up the work tool, secondary step Raise the work tool from the ground and extend the shovel tilting cylinder fully until the bearing panel for the work tool is laying on the quick-change adapter stop.

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

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

Quick-change adapter is activated.

LED in switch illuminates.

Press and hold button S47.

Quick-change adapter is activated.

Press and hold pushbutton L until the locking pins are fully removed.

The buzzer goes off.

The quick-change adapter is locked.

The work tool is bolted on when taking up correctly.

Release button S47.

Press switch S19.

Quick-change adapter is deactivated.

LED in the switch goes out.

Caution!

Hydraulic lines are pressurized!

Remove the pressure using the joystick before connecting the hydraulic lines (switch off the engine, turn the ignition key into the contact position, operate the joystick).

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Control and operation Attaching and dismounting equipment parts

Connect hydraulic lines or electrical lines, if necessary. (eg. when attaching a grab).

A direct visual check must be made to ensure that the work tool is correctly positioned.

This means that the work tool should be raised before use to the point at which the correct positioning of, for example, the pin in the pin eye, can be checked by tilting in and out.

Danger!

The electronic monitoring system for the quick-change adapter displays defective functions. These could be caused by an unmonitored position change of the locking pins or by mechanical or hydraulic damage. A defect may also be present in the electrical system (eg. proximity switch or buzzer).

If the buzzer and telltale light are activated without a deliberate locking or unlocking procedure being carried out, stop all work at once.

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

Only resume working once defective parts have been repaired or replaced.

Performing the working cycle Before starting to use the work tool (eg. grab, ditcher bucket), the special

Detaching a work tool To move the equipment into position: Caution!

Hydraulic lines are pressurized!

Remove the pressure using the joystick before removing the hydraulic lines (switch off the engine, turn the ignition key into the contact position, operate the joystick).

Disconnect hydraulic lines or electrical lines, if necessary (eg. when dismounting a grab).

Extend the shovel tilting cylinder fully.

To unlock the quick-change adapter:

Fig. 3-101 To unlock the quick-change adapter

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Attaching and dismounting equipment parts

Danger!

Risk of injury!

Once unlocked, there is no fixed connection between the adapter and the work tool.

The work tool could work itself out independently.

Always keep the work tool as close to the ground as possible when unlocking to avoid creating conditions which may lead to danger.

Press switch S19.

Quick-change adapter is activated.

LED in switch illuminates.

Press and hold button S47.

Quick-change adapter is activated.

Press and hold pushbutton R until the locking pins are fully inserted.

The buzzer sounds.

The quick-change adapter is unlocked.

To put down the work tool:

Fig. 3-102 Putting down the work tool Slowly insert the shovel tilting cylinder and lay the work tool on the ground.

The new work tool can be taken up.

Using the quick-change adapter for lifting work

Fig. 3-103 Hydraulic quick-change adapter The quick-change adapter has two integrated lifting hooks. The machine may only be used for hoisting work if the safety devices required for the purpose are present The maximum load carrying capacity of each individual lifting hook is given on the quick-change adapter. The load carrying capacity of the quick-change adapter or the

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Control and operation Attaching and dismounting equipment parts

integrated lifting hook can exceed or fall short of the load carrying capacity of the carrier device.

When operating, it should be ensured that the values for the carrier device / quickchange adapter given in the load chart and the technical data are adhered to.

Load hoisting work can be carried out with attached or dismounted work tools. With dismounted work tools, it is sensible to fully insert the locking pins when carrying out hoisting work. This prevents the load take-up device being turned round too strongly by the locking pins and damaged.

Danger!

Never use the take-up hook 6 to fasten a load because there is no secure hold for the load take-up device, eg. rope or chains, in the take-up hook.

Before using for hoisting work, deactivate the quick-change adapter.

LED in switch S19 has gone out.

Release button S47.

To cancel the buzzer (warning tone) e buzzer (warning tone) indicate that the quick-change adapter is not locked or is incorrectly locked.

After putting down the work tool, the buzzer (warning tone) continues to sound if the locking pins are not removed.

When the overload warning device is switched on, the warning tone for the quickchange adapter can be cancelled.

If no new work 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.

Press switch S349.

The buzzer will switch off. een will continue to be displayed.

The acoustic warning device will only activate automatically once the locking pins have been removed again.

To reactivate the warning tone for the quick-change adapter, remove the locking The buzzer (warning tone) for monitoring the quick-change adapter is reactivated.

LIKUFIX enables automatic coupling of hydraulic lines in connection with the hydraulic quick-change adapter. The machine operator does not have to connect or separate hydraulic lines for work tools himself.

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Overview

Fig. 3-104 LIKUFIX 1

Protective cover on quick-change adapter

4

LIKUFIX hydraulic coupling on work tool

2

Protective covering on work tool

5

Alternative hydraulic coupling on work tool

3

LIKUFIX hydraulic coupling on quick-change adapter

Attaching and dismounting work tools

Fig. 3-105 Connecting LIKUFIX Please also note: Before attaching, remove the protective coverings on the quick-change adapter 1 and the work tool 2.

Always keep hydraulic couplings 3 and 4 clean.

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

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Control and operation Attaching and dismounting equipment parts

Connect or separate the hydraulic coupling slowly as with any change of work tool.

When attaching the quick-change adapter, tilt until the coupling disks are connected as a result of the self weight of the work tool.

Remove the locking pins.

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

Oil quantity and pressure must be adapted to suit the work device concerned.

When the work is completed, and particularly before transportation, put the protective coverings 1 and 2 back on.

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

Fig. 3-106 LIKUFIX work tool on quick-change adapter without LIKUFIX 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, ensure that you have the quick-change adapter reworked at the LIEBHERR customer service centre.

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

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

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General working methods

3.7 General working methods 3.7.1

Minimum impact working methods for your machine To increase the service life of the machine and avoid unnecessary damage and the resulting repairs, please note the following points: stopping the equipment on the walls of the ditch. e the equipment is knocked against the material to be removed, in the longitudinal direction too, is not permitted.

Repeatedly hitting the work equipment against rock or other hard material will damage steel parts and machine components. and work tool, the work tool could hit or operator. in rocky material. This will extend the work cycles and could result in damage to the bucket and other machine components. l partner if special teeth are required for heavy or special applications.

If this should occur, slowly lower the machine to the ground. ickly and do not intercept the falling movement using the hydraulics, since this could result in damage to the machine.

3.7.2

Preparatory activities Danger!

Risk of fatal injury and damage to the machine when working. operating instructions.

Fig. 3-107 Position the machine so that the load or grab material can be taken up above the rigid axle or the leading wheel.

For mobile devices, lower the support when possible and lock the full floating axle.

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Control and operation General working methods

Danger!

Insufficient support and machine damage.

Do not use a skimming shield to support the machine.

Fig. 3-108 Safe working Danger!

Risk of fatal injury due to rotating the machine.

Ensure that nobody stands within the danger area r of the machine.

Caution!

Risk of injury when working.

Always wear safety shoes and, particularly when leaving the cab when demolition work is going on, a protective helmet and goggles.

Always wear the seat belt.

Use the horn to give a short warning signal before starting work.

3.7.3

Using a backhoe bucket Danger!

Risk of fatal injury and damage to the machine when moving the backhoe bucket.

Ensure that the backhoe bucket is not slewed too close to the cab. operator.

Ensure that nobody is standing within the danger area of the backhoe bucket.

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General working methods

The machine must be in the working position.

Fig. 3-109 Aligning the stick and backhoe bucket Align the stick in such a way that its underside is at an angle of approx. 45° to the ground.

Align the backhoe backhoebucket in such a way that its ground side can enter the ground at an angle of approx. 90°.

Fig. 3-110 Taking up grab material To lift out the grab material, slowly and evenly slew in the stick and slowly and evenly slew in the backhoe bucket simultaneously.

As soon as the stick is perpendicular to the ground, raise the boom slowly and evenly in addition to slewing in the stick and the backhoe bucket. Stopping suddenly will result in impact loads and vibrations.

Fig. 3-111 Raising grab material When the backhoe bucket is full or the stick can no longer be slewed in, raise the boom and backhoe bucket until the filled surface is parallel to the ground.

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Control and operation General working methods

3.7.4

Loading a transport vehicle Danger!

Risk of fatal injury due to falling grab material.

Do not load the transport vehicle so high that the grab material could drop out over the walls of the vehicle.

Ensure that nobody is standing in the danger area or in the transport vehicle when loading.

Fig. 3-112 Emptying grab material If possible, the machine should stand higher than the transport vehicle to avoid having to lift the grab material unnecessarily.

Stop the transport vehicle in a position that allows it to be loaded from the rear or the side.

Slew the machine's equipment above the loading area of the transport vehicle.

Distribute the grab material evenly over the loading area of the transport vehicle by slewing the backhoe bucket and the stick out, slewing the upper carriage and possibly also moving the boom.

If the backhoe bucket is not sufficiently emptied or there is still grab material in the backhoe bucket, slew the backhoe bucket in and out several times to loosen the grab material.

3.7.5

Skimming Skimming work can either be carried out using the bucket or with a skimming shield (optional extra).

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General working methods

Fig. 3-113 Skimming The machine must be in the working position.

The support should be raised.

Danger!

Serious risk of injury when moving the machine.

Ensure that nobody is standing within the working area of the machine.

Caution!

The machine could be damaged.

Never move the machine while the work equipment is touching the ground.

To skim with a backhoestick bucket, lay this on the ground (see Fig. 3-113) and move the stick slowly forwards and backwards. Move the boom steadily up and down while the stick is moving.

If a skimming shield is present (optional extra), lower it to the ground and move slowly forwards and backwards with the machine.

3.7.6

Using a clamshell bucket (earthmoving attachment) Danger!

Risk of fatal injury and damage to the machine due to a swinging clamshell.

Ensure that the shell type bucket does not swing too close to the cab.

The shell type bucket could damage the cab when swinging and injure the Ensure that the shell type bucket does not swing towards anyone in the working area.

The shell type bucket could injure people standing in the vicinity when swinging.

Move the joystick slowly and evenly to prevent the shell type bucket swinging.

Hold the stick in such a way that the shell type bucket cannot swing towards the machine when driving or braking.

Do not lift a load with the boom and stick extended too far and do not slew a heavy load too far to the left or right.

The stability of the machine could be affected.

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Control and operation General working methods

The machine must be in the working position.

Fig. 3-114 Straightening the stick Open the grab shells fully.

Lower the stick perpendicular to the excavation area.

Fig. 3-115 Closing the grab shells Close the grab shells.

Raise the stick slightly when doing this in order to reduce ground pressure.

Danger!

The device could lift out when closing the shell type bucket.

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General working methods

Fig. 3-116 Raising grab material Close the grab shells fully.

Raise the boom.

Move the machine to the unloading area (eg. transport vehicle).

Fig. 3-117 Emptying grab material Slew the stick out as far as possible to prevent any risk due to the swinging grab.

Open the grab shells, empty the grab material.

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Control and operation General working methods

3.7.7

Using a multiple tine grapple (industrial attachment) The machine must be in the working position.

Fig. 3-118 Taking up the load Take the load up above the supported corners of the machine to attain maximum stability.

The maximum lifting capacity is attained when the load is taken up as close to the chassis as possible.

Fig. 3-119 Transporting a load Transport the load close to the chassis, but with sufficient safety distance to the cab (swinging grab!) and as close to the ground as possible.

Caution!

Particularly when loading wood, it can be necessary when working with a grab to move with the working equipment raised and the load taken up. This will shift the centre of gravity of the machine upwards. The way the machine drives will be negatively affected because of this. these operating instructions.

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General working methods

3.7.8

Using an hydraulic hammer Please also refer to the operating instructions provided by the manufacturer of the hydraulic hammer.

Danger!

The hydraulic hammer must be selected very carefully. Operating requires increased care and attention.

Only use hydraulic hammers approved by LIEBHERR. The use of a hydraulic hammer not approved by LIEBHERR could damage steel parts or other machine components.

Only use the hydraulic hammer to break up rocks, concrete and other breakable objects.

To avoid damaging the machine, do not try to break up rocks or concrete by moving the lever on the work equipment or by the hydraulic hammer.

Do not use the drop power of the hydraulic hammer to break up rocks or other objects. Do not move objects with the hydraulic hammer. Do not lift the machine when using the hydraulic hammer.

This could damage both the hydraulic hammer and the machine.

Do not use the hydraulic hammer to lift objects.

Only use the hydraulic hammer in t Do not operate the hydraulic hammer in the direction of the machine, since exploding rocks or concrete could damage the machine and / or injure the driver.

Close all windows in the cab before working.

Fig. 3-120 Hydraulic hammer The machine must be positioned in the working position on level, solid ground.

The stick may not stand vertically.

No cylinder may be fully taken in or extended.

Do not operate the hydraulic hammer on the same spot continually or for longer than 15 seconds.

Overly continual operation of the hydraulic hammer leads to the hydraulic oil overheating unnecessarily.

Change the position of the machine and resume hammering work.

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Operating manual

Control and operation Installing and removing counter weight

Fig. 3-121 Permissible A and not permissible B work areas of the machine with hydraulic hammer Danger!

The stability of the machine could be affected.

When using a hydraulic hammer, only work with the machine in area A.

3.8 Installing and removing counter weight 3.8.1

Safety instructions for the attachment and removal of the counter weight Danger!

To ensure that the stability of the machine is not impaired when the counter weight is removed, you dismantle a part of the working attachment before removing the counter weight.

As a rule, only the gooseneck boom or the basic boom must remain attached to the machine and propped up on the ground before the counter weight is removed.

Never stand under the counter weight while it is lowered or lifted or if it is not secured with all mounting bolts.

The table below shows the weight of the counter weight that must be taken into account when choosing suitable lifting gear and tackle.

Hydraulic excavator

Weight [kg]

E 934 C

7 500

E 944 C / R 944 C HR

11 000

Caution!

The weight in the table is the maximum weight, so that the respective lifting gear and the lifting screws 10 (DIN 580 M64, Liebherr ID no.: 4902031) has definitely the necessary capacity.

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Installing and removing counter weight

3.8.2

Removing counter weight

Fig. 3-122 Mounting bolts 2 3

Centring bolts Mounting bolts

5 Washers 10 Loading ring

Lift the counter weight with the loading ring 10.

Loosen the mounting bolts 3 of the counter weight and remove them.

Detach the counter weight from the machine and lower it to the ground.

Danger!

Place the counter weight only on firm and level ground. If necessary, use supports to ensure that it is in a horizontal position.

3.8.3

Re-attaching counter weight Lift the counter weight and align it with the centring bolts 2.

Tighten the mounting bolts 3 (M30 - 10.9, Tightening torque 1900 N.m)..

The ballast is re-attached to the machine.

Caution!

It is forbidden to start the excavator before all mounting screws for the counter weight have been properly tightened.

Risk of damage to the steel construction!

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Control and operation Installing and removing elastic bearing in electric excavator

3.9 Installing and removing elastic bearing in electric excavator 3.9.1

Safety instructions for the installation and removal of the elastic bearing Danger! secured with wheel blocks. ys use suitable lifting gear in good conditions and with appropriate load-bearing capacity. When handling cables, always wear working gloves. s with cables and chains to prevent them from becoming dislodged. . Avoid wearing rings, watches, ties, scarves, open jackets or loose clothing. There is a risk of injury from such objects becoming caught in the machine. For certain work, workers must wear personal protective equipment (protective goggles, hard hats, safety footwear, protective gloves, luminous jacket, hearing protection, etc.).

weight must be replaced with new once every time the parts are dismantled. cal safety regulations and rules. operator. The guide must position himself within view of the operator or be in voice contact with him. trained electrician or specialist technician under the supervision of an electrician and in accordance with the relevant electro-technical regulations and guidelines. to the emergency-stop or main switch to shut down the system in the event of an emergency. Cordon off the work area, using a red and white chain and a suitable warning sign. Always use suitable insulated tools.

-voltage assemblies, first disconnect them from the power supply, and then short-circuit the supply line and the assemblies (e.g. capacitors) using an earthing rod. they are fully de-energized, and then ground and short-circuit them. Insulate adjacent powered parts. machine from the power mains. This must be done by a qualified electrician. The main isolator (outside the machine) must be open. machine, attach a warning sign "Do not start" to the ignition. For a diesel excavator, remove the start key.

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Control and operation

Operating manual

Installing and removing elastic bearing in electric excavator

3.9.2

Installing elastic bearing

Fig. 3-123 Mounting screws 1

Lid

10

Hex nut

2

Roll pin Ø8

11

Washer

3 4

Roll pin Ø5 Hex head screws

12 14

Hex nut holder Axle

5 6

Mounting screws Washers

15 16

Upper rubber block Lower rubber block

7

Crown nut

100

Rotary connection

8

Washer

400

Elastic bearing

9

Support Prepare the machine to be supported by wheel blocks.

Secure the uppercarriage by thightening the transport lifting gear (see chapter 3 "Loading machine with a crane").

Commission an electrician to disconnect the rotary connection power cable connecting the machine to the on-site power source by pulling it from the plug housing.

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Control and operation Installing and removing elastic bearing in electric excavator

Commission an electrician with pulling the power cables from the switch cabinet and removing the gland seal to remove the cable tips from the switch cabinet.

Remove all cable fixtures from the uppercarriage.

Loosen and remove the mounting bolts 5 and the washers 6 of the elastic bearing.

Lift the uppercarriage. Keep an eye on the rotary connection power cable (for the weight of the uppercarriage, see chapter 3 "Transport").

Lower the uppercarriage onto the timber beams placed in suitable positions on the ground.

Lower the rotary connection to facilitate transportation. Keep an eye on the pluged rotary connection power cable.

Secure the elastic bearing by thightening the transport lifting gear (see table below).

Remove the roll pins 2 and 3 and then the crown nut 7 with the washer 8.

Remove the screws 4 and the lid 1.

Remove the axles 14 with the hex nuts 10, the washers 11 and the hex nut holders 12.

If possible, mount the crown nut 7 with the washer 8 and the roll pins 2 and 3 without delay on the axle 14.

Lift the elastic bearing 400 and lower it on the timber beams placed in suitable positions on the ground.

Danger!

Lower the machine and the elastic bearing only onto firm and level ground. If necessary, use supports to ensure that the parts are in a horizontal and safe position.

The table below shows the weight of the elastic bearing that must be taken into account when choosing suitable lifting gear and tackle.

Hydraulic excavator

Weight [kg]

EP 934 C

5 050

EP 944 C

6 500

EP 954 C

7 550

Caution!

The weight in the table is the maximum weight, so that lifting gear and tackle chosen based on this value is definitively suitable for the task.

3.9.3

Reinstalling elastic bearing Lift the support 9 of the elastic bearing, position it correctly (see figure below) and weld the support in the correct position (fillet weld dimensions and quality of the weld must be specified by pontoon manufacturer by means of a load diagram).

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Control and operation

Operating manual

Installing and removing elastic bearing in electric excavator

Install the lower rubber block 16.

Lift the elastic bearing, align it correctly and place it on the attached support (see figure below).

Install the upper rubber block 15.

A Weld of support 9

C Weld of lower plate

B Weld of upper plate

L

Longitudinal direction of pontoon

Caution!

For the positioning of the support and/or elastic bearing, observe the longitudinal direction of the pontoon.

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EP 944C / 10360388

Operating manual

Control and operation Installing and removing elastic bearing in electric excavator

Fixture of elastic baring on support Screw the crown nuts 7 with the washers 8 to the axles 14 until the roll pins 2 and 3 can be inserted.

First adjust roll pin 2 and then align roll pin 3 inside the first one.

Align the axle with the crown nut 7 and the washer 8 to the hole in the support 9.

Mount the special tool ID no.: 10378487 on the axle 14 (on the side of the crown nut 7).

Adjust parts 10 and 11, secure the hex head screw 10 (tightening torque: 2700 Nm / 1990 ft.lbs) and then turn the entire assembly so that the hex nut holder 12 can be attached.

Note!

If the elastic element is properly installed, the distance between the upper edge of the support and the upper surface of the elastic element without lid 1 must be 691 mm.

The correct settings were applied: The devices have been properly secured.

The correct settings were not applied: Check the tightening torque of the mounting bolts 10.

If a check of the tightening torque reveals that the correct settings were not adhered to, contact Liebherr customer service department.

Remove the special tool.

Adjust the lid 1 with the screws 4.

Follow these instructions for all elastic elements Mounting rotary connection on elastic bearing Position the rotary connection. Keep an eye on the rotary connection power cable fed through the slewing ring.

Tighten the mounting screw with the prescribed torque (see "Electrical rotary connection", item 27).

Mounting uppercarriage on elastic bearing Lift the uppercarriage (see chapter 13 "Loading machine with a crane") align it (holes on holes) and place it on the already fixed elastic bearing. Keep an eye on the rotary connection power cable fed through the slewing ring.

Adjust the parts 5 and 6 and tighten the mounting screws 5 with the prescribed torque (see table below).

The elastic bearing is fully installed.

Caution!

It is forbidden to start the excavator, unless all mounting screws of the elastic bearing are in place and properly tightened.

Risk of damage to the steel construction.

Commission an electrician to connect the power cable to the switch cabinet.

Commission an electrician to connect the rotary connection power cable to the plug housing.

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3 - 127

Control and operation

Operating manual

Transport

Tightening torques of mounting bolts Tightening torque of the mounting screws 5 for the elastic bearing: Machine

Tightening torque Size

Quality [Nm]

[ft.lbs]

EP 934 C

M24

10.9

960

708

EP 944 C

M27

10.9

1400

1030

EP 954 C

M27

10.9

1400

1030

3.10 Transport Investigate the travel route.

Danger!

Drive with increased caution under obstacles, particularly electrical lines.

Respect the safety instructions and local circulation legislation.

If required, adapt the machine, its vehicle, the lifting gears and lashing materials to the restrictions about the load, the height, the length and the width of the convoy.

Make sure that the whole machine can be transported by checking the maximal authorized load of the vehicle.

When restarting the machine, proceed according to the operating manual instructions.

3.10.1

Lifting the machine with a crane Danger!

The machine could slip or fall!

Employ only experienced personnel with the attachment of the load and the guiding of the crane operator.

Use only suitably dimensioned lifting gear or the special lifting gear available from LIEBHERR. Ensure that the crane tackle is sufficiently long.

Always wear work gloves when working with cables.

Have another person guide and signal the operator during the operations.

Never stand under the lifted machine!

Switch off the engine (or motor). Turn the ignition key to the contact position (and in case of an electric machine, switch the machine on).

Relieve pressure lines by moving carefully the joystick several times in all directions.

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EP 944C / 10360388

Operating manual

Control and operation Transport

Remove the ignition key (and in case of an electric machine, switch the machine off). Push the safety lever up.

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

Preparatory removals Remove the whole machine attachment (see «Attaching and removing attachment parts» in this chapter).

Remove the counterweight (see «Installing and removing the counterweight»).

Danger!

All work on the electrical system of the machine must be carried out by a trained electrician or specialist technician under the supervision of an electrician and in accordance with the electro-technical regulations.

In case of an electrical machine and if required, remove the slip ring.

If required, remove the catwalks.

Lifting gear

1

Nut

4

Shackle

2 3

Washer Rear lifting gear

5 6

Screw Front lifting gear

Attach the front lifting gear 6 with the attachment pins on the uppercarriage.

Thread the lifting cables through the shackle 4. Connect the shackle to the front lifting gear 6.

Secure the rear lifting gear 3 on the upprcarriage with the screws 5, the washers 2 and the nuts 1 (M30 - 10.9, tightening torque 1900 N.m).

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3 - 129

Control and operation

Operating manual

Transport

Thread the lifting cables through the shackle 4. Connect the shackle to the rear lifting gear 3.

Lifting the machine The table below shows the forces that must be considered when choosing lifting gear: Model

F1 [daN]

F2 [daN]

EP 934 C

13 200

5 500

EP 944 C

13 200

8 700

ER 934 C High Rise

13 200

5 500

ER / R 944 C High Rise

13 200

8 700

for a standard machine with elastic suspension, without attachment nor counterweight for a standard machine without attachment nor counterweight

Fig. 3-124 Lifting gear Model

L1 [m]

L2 [m]

1 [°C]

2 [°C]

FT [daN]

EP 934 C

9,7

10

84

79

16 000

EP 944 C

9,4

10

83

78

20 000

ER 934 C High Rise *

9,7

10

84

79

16 000

ER / R 944 C High Rise *

9,4

10

83

78

20 000

* Those values are only viable for lifting the standard uppercarriage alone.

Note!

The lengths L1 and L2 (or the angles 1 and 2) are the lengths (or angles) at which the machine is lifted into an horizontal position.

The force FT corresponds to the whole weight to be lifted.

Carefully lift the machine with the crane to pretension the slings.

Lift the machine on the trailer.

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Operating manual

Control and operation Transport

3.10.2

Secure the machine Danger!

If the machine is badly secured, it could slip or fall.

Before the transport, secure the machine and each separately transported components on the trailer.

Avoid contact metal on metal.

Fig. 3-125 To secure a machine with an elastic suspension

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Control and operation

Operating manual

Transport

Fig. 3-126 To secure a machine without an elastic suspension A C

Rubber strip B Protection Welded support (specific part for each machine) Place rubber strips A on the trailer.

Weld the support C to the trailer (see section "Welding on the machine" in chapter 5).

Place protections B. Attach the chains to the provided lashing points on the machine. They are given on the undercarriage by the opposite sign.

Place the chains crosswise to avoid slidings. Respect the lashing angles.

Attach the chains to he provided lashing points on the trailer.

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4 Troubleshooting Warning messages and fault messages:

Identifying and rectifying faults and errors: incorrect operating or maintenance of the machine.

For each fault, therefore, read the relevant chapter in the operating instructions carefully once more.

if you contact LIEBHERR customer service.

Precise information makes it possible to find and rectify the cause of the fault quickly. Additionally, therefore, precise information on the type and serial number of the machine is also required.

Fig. 4-1

LIEBHERR service

If the cause of the fault cannot be recognised or rectified using the error codes and fault charts, please consult LIEBHERR customer service.

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4-1

Troubleshooting

Operating manual

Error code list

4.1 Error code list Danger!

When switching over to emergency operation, the speed can no longer be changed using the arrow keys on the monitoring screen. The servo control, parking brake and slewing gear brake can no longer be activated. in this regard.

These error codes will not be displayed in th can only be read off the S-Exxx menu list. See chapter 3 "Main screen".

Error code

Effect

Cause

Measure / remedy

E 010

Hydraulic oil level not being monitored.

Short circuit to earth Short circuit + 24 V

Check hydraulic oil level, consult LIEBHERR customer service.

E 011 E 012 E 013 E 014

Cable break Hydraulic oil temperature not being monitored.

E 015 E 016 E 017

Short circuit to earth Short circuit + 24 V Cable break

Splitterbox oil temperature not being monitored. (depends on

E 018

Short circuit to earth Short circuit + 24 V

Check that the radiator is not dirty, consult LIEBHERR customer service.

Check oil level, consult LIEBHERR customer service.

Cable break

E 027

Faulty hydraulic power

LR cable error at output stage for hydraulic power regulation

Switch to emergency control speed adjustment S_b and emergency operation work pumps Y50, consult LIEBHERR customer service.

E 030

Faulty hydraulic power

EV 4 (LR2) cable error at output stage for hydraulic power regulation

Consult LIEBHERR customer service.

E 033

Maximum fan speed

EV 5 cable error at output stage of electric valve for hydraulic fan control

Consult LIEBHERR customer service.

E 036

Flow reduction for hydraulic equipment not being carried out.

EV 1 cable error at the output stage for flow regulation of hydraulic pump

Do not operate flow reduced equipment, consult LIEBHERR customer service.

E 039

Flow reduction for hydraulic equipment not being carried out (from R934, optional extra).

EV 2 cable error at the output stage for flow regulation of second hydraulic pump

Do not operate flow reduced equipment, consult LIEBHERR customer service.

E 045

Pressure reduction for hydraulic equipment not being carried out.

EV6 cable error at the output stage for pressure regulation of the hydraulic circuit.

Do not operate pressure reduced equipment, consult LIEBHERR customer service.

E 150

The control pressure for the stick movements is not being monitored. The stick movements may be jerkily.

Short circuit to earth or circuit break of sensor B159.

Check the state of the fuse F4, the sensor B159, the connexions and the cabling.

E 151

Short circuit + 24 V for sensor B159.

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Operating manual

Troubleshooting Error code list

Error code

Effect

Cause

Measure / remedy

E 153

The control pressure for the boom movements is not being monitored. The boom movements may be jerkily.

Short circuit to earth or circuit break of sensor B160.

Check the state of the fuse F4, the sensor B160, the connexions and the cabling.

The control pressure for the left swing movements is not being monitored. The left swing movements may be jerkily.

Short circuit to earth or circuit break of sensor B167.

The control pressure for the translation movements is not being monitored. The translation movements may be jerkily.

Short circuit to earth or circuit break of sensor B162.

The control pressure for the bucket movements is not being monitored. The bucket movements may be jerkily.

Short circuit to earth or circuit break of sensor B163.

The control pressure for the right swing movements is not being monitored. The right swing movements may be jerkily

Short circuit to earth or circuit break of sensor B168.

The control pressure for the dozer blade movements is not being monitored. The dozer blade movements may be jerkily

Short circuit to earth or circuit break of sensor B85.

The power regulation for the pump 1 is defective (B186)

Short circuit to earth

Short circuit to earth

E 183

The power regulation for the pump 2 is defective (B188)

E 302

No entry possible using keypad

No coding plug

Consult LIEBHERR customer service.

E 305

Malfunctions, e g. swing gear brake, servo control

No CAN bus connection between keypad and ESP01 board (message also appears if ESP01 not operating).

Switch to emergency switching of servo pressure circuits S73, consult LIEBHERR customer service.

E 308

No display or incorrect display on screen

No connection keypad / screen or keypad not operating

Consult LIEBHERR customer service.

E 154 E 156 E 157 E 159 E 160

E 162 E 163 E 165 E 166 E 168 E 169 E 179 E 180

E 182

Short circuit + 24 V for sensor B160.

Short circuit + 24 V for sensor B167.

Short circuit + 24 V for sensor B162.

Short circuit + 24 V for sensor B163.

Short circuit + 24 V for sensor B168.

Short circuit + 24 V for sensor B85.

Short circuit + 24 V

Short circuit + 24 V

Check the state of the fuse F4, the sensor B167, the connexions and the cabling.

Check the state of the fuse F4, the sensor B162, the connexions and the cabling.

Check the state of the fuse F4, the sensor B163, the connexions and the cabling.

Check the state of the fuse F4, the sensor B168, the connexions and the cabling.

Check the state of the fuse F4, the sensor B85, the connexions and the cabling.

Fix or replace the connectors, repair the short circuit, change the fuse F4 or the pressure transmitter.

Fix or replace the connectors, repair the short circuit, change the fuse F4 or the pressure transmitter.

E 309

No Software compatibility between screen and keypad

E 310

For boring excavators, Hardware coding and software coding are not in concordance.

Consult LIEBHERR customer service.

B144 pressostat wiring default.

Courant < 3mA ou > 21 mA

Consult LIEBHERR customer service.

E 447

No more monitoring of the translation motor regulation pressure.

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4-3

Troubleshooting

Operating manual

Troubleshooting

Error code

Effect

Cause

Measure / remedy

E 450

The pressure for pressureless boom down movement not being monitored.

B154 pressostat wiring default.

Current < 3mA or > 21 mA

Consult LIEBHERR customer service.

E 454

The hydraulic power of the swing is no more controlled.

Possible slappings in the valves

Short circuit + 24 V

Consult LIEBHERR customer service.

E 455 E 460

Short circuit to earth or cable break

The main engine and the 24V electrical circuit are switched off. The main disconnecting switch remains switched on.

E 601

Client power supply: overvoltage / undervoltage / phase rotation order

Consult LIEBHERR customer service.

Connection default for plate ESP01

Consult LIEBHERR customer service.

4.2 Troubleshooting 4.2.1

Hydraulic system

Error / fault

Cause

Remedy

Unusual noises / noise from hydraulic pumps Note!

Immediately shut down motor.

Stop valve on hydraulic tank closed

Open stop valve

Hydraulic pumps take in air

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

Hydraulic oil temperature too high

Radiator dirty

Clean radiator

Fan or fan control defective

Eliminate fault / consult customer service department

Hydraulic oil level too low

Oil loss

Repair leak, replace hoses, add oil through the return filter

Travel function not available

Move the safety lever up

Move safety lever down

No direction of travel selected

Select direction of travel using the travel selection switch in the right joystick

Pressure switch of parking brake defective

Consult LIEBHERR customer service

Parking brake not released

Release parking brake using the switch

Parking brake cannot be released with the switch

Servo pressure OK: actuate emergency function Y6 No servo pressure: consult LIEBHERR customer service

Operating brake applied

Release operating brake

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Operating manual

Troubleshooting Troubleshooting

Error / fault

Cause

Slewing gear failure

Remedy

Servo control not working

Move safety lever down Switch on servo control

Slewing gear brake activated

Move safety lever down Release slewing gear brake

No working movement

Servo control not working

Move safety lever down Switch on servo control

4.2.2

No servo pressure

Consult LIEBHERR customer service

No pump high pressure

Consult LIEBHERR customer service

Travel gearbox

Error / fault

Cause

Remedy

Oil escaping at running rollers, support rollers or idler

Seal defective

Replace seal

Chain guide at idler defective

Excessive play of idler guide system at the running roller frame

Adjust play of idler guide system

Chain jumps from guides

Insufficient chain tension / chain wheel worn

Adjust chain tension

Correctly tightened chain becomes loose after short operation

Chain tensioning cylinder defective

Check chain tensioning cylinder; replace or reseal, if necessary (to be done by authorised specialist technician)

Running or support roller stiff

Drive extremely dirty

Clean drive

4.2.3

Electrical system

Error / fault Batteries not sufficiently charged

Cause

Remedy

Batteries defective

Replace batteries

Battery connections dirty / oxidised

Clean battery connections

Cable loose or defective

Reconnect or replace cable

Failure of indicator light or indicating instrument

Incandescent lamp burnt out; indicating instrument defective

Replace defective part

Failure of one or more instrument panel functions

Adapters disconnected or defective; earth connector disconnected; short circuit - fuse blown

Plug in or change adapter; eliminate cause of short circuit; replace fuse or reset automatic cut-out

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4-5

Troubleshooting

Operating manual

Troubleshooting

Error / fault

Cause

Servo control cannot be activated with switch

Remedy

Fault in electrical system of excavator

Parking brake cannot be released with switch Slewing gear brake cannot be released with switch

4.2.4

Switching of emergency function with switch S73 in right control console Caution: the servo and brake circuit can now only be switched off with the safety lever; keyboard is disabled Consult LIEBHERR customer service

Working attachment

Error / fault

Cause

Remedy

Cylinder responds to load

Piston seal in cylinder defective

Service cylinder

Excessive bearing play in attachment

Bearings worn

Replace bearing components

Grapple / bucket cannot be moved

Valve block at tilt cylinder connected incorrectly

Change connections to valve block

Attachment cannot be rotated / swivelled / operated

Auxiliary function not activated

Release auxiliary function with switch S19

Lines not connected

Connect lines

4.2.5

Heating and air-conditioning system

Error / fault

Cause

No warm air from heating system

Heating blower not working

Low air circulation rate in operator's cab

Remedy

Set switch S206a to position 0 (off) or switch S206b to position 0 (0 kW)

Set switch to correct position

Heater fluid is missing

Fill the expantion tank (see § "Heater and air conditioner")

No power

Check fuse and cable; replace if required

Blower motor defective

Replace blower motor

Ambient air filter / recirculated air filter dirty

Clean air intake openings; replace ambient air filter

Air outlet closed

Open air outlet

The error codes shown on the display of the control panel facilitate troubleshooting of the heating and air-conditioning system.

The error codes listed below indicate faults or errors at specific components in the control and operating circuit of the heating and air-conditioning system.

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Operating manual

Troubleshooting Troubleshooting

Error code "F0": fault at room temperature sensor: The control system has detected a fault at the room temperature sensor, and regulation is disabled.

Cause of fault: Short circuit, sensor cable break, loose connection at sensor or control unit, temperature sensor defective.

Eliminate the fault. The sensor is again ready for operation, and the error code disappears.

After a fault, the regulator is operated with the settings as entered before the fault.

Error code "F1": fault at blow-out temperature sensor: The control system has detected a fault at the blow-out temperature sensor, and regulation is disabled.

Cause of sensor fault: Short circuit, sensor cable break, loose connection at sensor or control unit, temperature sensor defective.

Eliminate the fault. The sensor is again ready for operation, and the error code disappears.

After a sensor fault, the regulator is operated with the settings as entered before the fault.

Error code "F2": fault at reserve temperature sensor: The control system has detected a fault at the reserve temperature sensor, and regulation is disabled.

Cause of fault: Short circuit, sensor cable break, loose connection at sensor or control unit, temperature sensor defective.

Eliminate the fault. The sensor is again ready for operation, and the error code disappears.

After a sensor fault, the regulator is operated with the settings as entered before the fault.

Error code "F3": fault at legroom/windscreen ventilation flap: The control system has detected a fault at the legroom/windscreen ventilation flap. Regulation remains operational.

Cause of fault: Short circuit, cable break, loose connection at the ventilation flap motor or control unit, flap motor defective.

Eliminate the fault. The error code disappears.

In the event of a flap fault, the regulator continues working as normal, although the centre position of the air flap cannot be used.

Error code "F4": pressure fault / fault at magnetic clutch: The control unit has detected a fault at the pressure switch or the magnetic clutch.

Cause of fault: Short circuit, cable break to magnetic clutch, loose connection at the clutch or control unit, overpressure or underpressure (insufficient refrigerant) in cooling circuit of the a/c system.

Eliminate the fault. The error code disappears.

The regulator is not affected by a pressure fault / magnetic clutch fault, and only the magnetic clutch output is interrupted.

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MJFCIFSS

4-7

Troubleshooting

Operating manual

Troubleshooting

Error code "F5": data transmission fault between control panel and control unit: The data transfer from the control panel to the control unit interrupted.

Cause of fault: Short circuit or cable break in the data line to the control unit, loose connection at the control panel or control unit.

The control panel repeatedly attempts to establish a data connection to the control unit. Eliminate the error. The error code "F5" disappears.

If data communication cannot be re-established, switch off the ignition and switch it on again to reset the system.

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Operating manual

Troubleshooting Fuses and relays

4.3 Fuses and relays 4.3.1

Power switch cabinet with main fuses E50

Fig. 4-2

Fuses and relays in power switch cabinet E50

Fuses in electric cabinet E50 F19

100 A

Terminal 30 Automatic cut-out / Centrifugal pump (power circuit of heating system - booster pump).

F20

50 A

Terminal 30 Automatic cut-out / Circuit terminals 30 + 15.

F22* F31*

15 A 7.5 A

Terminal 30 Fuse / Reserve.

Terminal 15 Fuse / Control unit air-conditioning system.

F33* F34

7.5 A 15 A

Terminal 15 Fuse / Reserve.

Terminal 30 Fuse / Reserve..

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4-9

Troubleshooting

Operating manual

Fuses and relays

F35

15 A

F36*

20 A

Terminal 30 Fuse / Headlight (E12) on counter weight (power circuit).

Terminal 30 Fuse / Reserve.

F36-2* 15 A F37 20 A F109

50 A

Terminal 15 Fuse / Stick cylinder shut-down*.

Terminal 30 Fuse / Conrol unit air-conditioning system and ventiation.

Terminal 30 Automatic cut-out / Circuit terminal 30)

F110 F115

50 A 7.5 A

Terminal 30 Automatic cut-out / Reserve.

Terminal 15 Fuse / (terminals 127 + 128).

F116

7.5 A

F117

7.5 A

Terminal 30 Fuse / Centrifugal pump (power circuit of heating system - booster pump).

Terminal 15 Fuse / Reserve.

F122

7.5 A

Terminal 30 Fuse / Centrifugal pump (power circuit of heating system - booster pump).

F133* F253

7.5 A 15 A

Terminal 30 Fuse / Reserve.

Terminal 30 Fuse / Work headlight on attachment (E1) (power circuit).

Relays in electric cabinet E50 K10-1

20 A

K56

20 A

Relay / Auxiliary headlight on counter weight.

(E12) Relay / Reserve.

K66-1* 5/10 A

K127

5/10 A

Relay / Installation kit shut-down of attachment movement.

Relay / Installation kit shut-down of attachment movement.

Relay / Reserve.

K128 K288

5/10 A 75 A

Relay / Reserve.

Main relay / Terminal 15.

K302 K359

75 A 2x10 A

Relay / Heating system - booster pump.

Relay / Reserve.

K415

20 A

Relay / work headlight on attachment (E1).

K66-2* 5/10 A

* Special equipment Terminal 15: +24V contact.

Terminal 30: +24V permanent.

4.3.2

A1010 printed circuit board All other fuses are located in the left control console of the operator's cab.

Danger Incorrect or bridged fuses do not provide the protection required for the safety of the machine operator and the electrical equipment.

Use only original fuses.

Never bridge fuses.

If necessary, order replacement fuses from LIEBHERR.

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EP 944C / 10360388

Operating manual

Troubleshooting Fuses and relays

Fig. 4-3

Fuses and relays on printed circuit board A1010

Fuses on terminal 15 F1 F2

15 A 15 A

Central lubrication system, screen wiper on cab roof*.

Autoradio (transformer 12V).

F3 F4

15 A 15 A

F5

7.5 A

Reserve.

Windscreen washer system (M3), windscreen wiper control circuit (M4), 24 V stabiliser for sensors and transducers (B19R, B19L, B21, B33-2, B40, B41, B53, B143, B145, B177, B178, B179 and B188), Qmin circuit (Y78), pressure-free lowering (Y139), beacon* (E9), rotating grapple* (Y22 and Y23).

Windscreen wiper motor (power circuit).

F6

7.5 A

Reserve.

F7

7.5 A

Keyboard and display.

F8

15 A

Safety lever, solenoid valve for pilot control pressure (Y7), slewing gear brake (Y3), fast travel (Y24), additional pressure level (Y160).

F9

15 A

Power supply of BST.

Fuses on terminal 30 F10

25 A

Work headlight on attachment* (E1), revolving deck (E2) and cab (E5), travel light (E3 and E4).

F11

15 A

Reserve.

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4 - 11

Troubleshooting

Operating manual

Fuses and relays

F12

15 A

Reserve.

F13

7.5 A

Reserve.

F14

15 A

F15

15 A

Internal lighting (E7), roof-mounted light, cigarette lighter (E8), horn (H9).

Reserve (solenoid valve for flow allocation Y149).

Relay on printed circuit board A1010 K5

Reserve.

K6

Horn (H9).

K7

Auxiliary headlight on cab roof* (E5) and on counter weight (E12).

K8

Reserve.

* Special equipment

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EP 944C / 10360388

5 Maintenance 5.1 Access doors for maintenance 5.1.1

Overview of access doors

Fig. 5-1

Access doors at the machine

10

Motor hood

120

Left doors

11

Motor hood

140

Right door

60 80

Motor hood Right hood

220 220

Front left hood Front left side door

Access door

Locking mechanism

10 or 60

Motor hood

Gas pressure spring, with mechanical holding device

80

Right hood

Gas pressure spring and screwed part

120

Left side doors

Mechanical holding device

140

Right side door

Mechanical holding device

Access to:

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5-1

Maintenance

Operating manual

Cleaning machine

230

Access door

Locking mechanism

Front left side door

Mechanical holding device

Access to:

The machine has 8 access doors for maintenance. For safety reasons, the locks integrated in the handles 4 must be unlocked before starting to work with the machine.

The right hood 80 is a screwed part which opening is not necessary in the limits of usual maintenance works.

5.1.2

Door retaining rods Caution!

Access doors can close accidentally and trap the operator or maintenance personnel.

After you have opened the access doors, latch them using the retaining rods..

Fig. 5-2

Door retaining rod

To stop the access doors from moving unintentionally (eg. due to wind), open them fully and allow the door lock (see arrow) to latch in.

5.2 Cleaning machine The machine should be cleaned before carrying out any maintenance or repair work.

In particular, the connections and screws should be cleaned of oil, fuel and residue of cleaning agents.

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Operating manual

Maintenance Care for rubber components

Note!

High-pressure water jet cleaners (steam cleaners) can damage the coating.

Do not use high-pressure water jet cleaners during the first two months after commissioning (or after recoating).

Observe the prescribed safety distances.

Before cleaning the machine: Before cleaning the machine with water or with a steam cleaner (high-pressure water jet cleaner), carry out the following tasks to protect the equipment against penetrating water.

Lubricate all bearing points, bolt connections and the slewing ring; if necessary, use the central lubrication system to do this.

Cover or seal all openings that must be protected against penetrating water for safety reasons (particularly at risk of damage are electric motors, electric components, switch cabinets, plug connections, measuring sensors and air filters).

Cleaning: Use flint-free cleaning cloths.

Do not use aggressive detergents or flammable liquids.

When cleaning the engine compartment, ensure that the temperature sensor of the fire alarm and extinguishing systems (if installed) are not accidentally brought into contact with the hot cleaning solution, After cleaning: Remove all seals and covers.

Check all fuel, engine oil and hydraulic lines for leakage, loose connections, chaffing and damage.

Repair any defects without delay.

Lubricate all bearing points, pin connections and the slewing ring to remove any water that might have been penetrated.

If required, renew the preservation layer (anti-corrosion protection) on components and surfaces.

5.3 Care for rubber components The service life of rubber seals can be prolonged by treating them with a rubber care product.

Clean and regularly treat the rubber seals on doors and panelling elements with a care product. This helps prevent premature wear and protects the rubber seals during the cold season.

Recommended care products: Silicone, talcum powder, deer tallow

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5-3

Maintenance

Operating manual

Lubricants and fluids

5.4 Lubricants and fluids 5.4.1

General information Observe the instructions for lubricants and fluids. Lubricate the machine and change the oils at the prescribed intervals. For more information, see lubrication chart and inspection and maintenance schedule.

Keep workplaces for these activities clean. This enhances the service life and reliability of the machine.

All work on the machine must be carried out while it is standing on firm and level ground.

Switch off the electrical engine and turn off the main isolating switch, outside of the machine at the customer power supply connection.

Clean lubricating nipples before adding grease.

Clean all filling points and the area around them before opening the caps and screws.

The oil should be changed while it is at operating temperature.

After each oil change or refilling, check the fill level in the respective unit (the specified fill levels are guide values).

Collect old lubricants and fluids in suitable containers and dispose of them according to the applicable statutory regulations.

5.4.2

Filling volume and lubricant chart Recommended lubricants

Designation

Recommended lubricants

Symbol

Electric motor

See electric motor type plate

See electric motor type plate

Hydraulic system (System capacity / Oil change quantity)

Liebherr Hydraulic Basic 68 Liebherr Hydraulic Basic 100 Liebherr Hydraulic HVI Liebherr Hydraulic Plus Liebherr Hydraulic Plus Arctic

625 / 497

Slewing gear mechanism

Liebherr Gear Basic 90 LS

12

Pump distributor gear

Liebherr Gear Basic 90 LS

11.3

Tracks and corresponding gearing of swing ring, equipment mounting

Liebherr Universalfett 9900

-

Hinges, joints, locks

Engine oil

-

Quantity [Litres]*

-

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Operating manual

Maintenance Lubricants and fluids * = Guide values

Recommended fuels and process chemicals Designation

Recommended fuels and process chemicals

Heating system fluid

Liebherr Antifreeze Mix Liebherr Antifreeze Concentrate

Windscreen washing system

Standard windscreen cleaning agent or denatured alcohol

Symbol

Quantity [Litres]* 20

-

5

* = Guide values

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5-5

Maintenance

Operating manual

Lubricants and fluids

Lubrication chart

Fig. 5-3

Lubrication chart

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Operating manual

Maintenance Lubricants and fluids specification

Symbol

Designation For the oil change interval, observe the instructions of the operating manual.

Filling point

Slewing gear transmission

Splitterbox

Check gear oil level

Check hydraulic oil level

Lubrication point

Carry out a manual lubrication Carry out a semi-automatic lubrication

Tab. 5-1

Lubricant chart legend

5.5 Lubricants and fluids specification 5.5.1

Lubricant for motor bearing See type plates at the electric motor.

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Maintenance

Operating manual

Lubricants and fluids specification

Fig. 5-4

Type plates at the electric motor.

G1

Recommended lubricant type

G2

Lubricant quantity (cm3)

G3

Lubricant change intervals (hours) at ambient temperature (at 50 / 60 Hz)

Caution The standard grease is ESSO UNIREX N3. We recommend using the same product for subsequent lubrication at the prescribed intervals.

Never mix different lubricants.

5.5.2

Heating fluid system General recommendations The heating system works only properly when pressurised. It is therefore imperative that it is kept clean and sealed at all times and that the required heating fluid level is maintained.

Corrosion inhibitors/antifreeze agents approved by LIEBHERR ensure proper protection against frost, corrosion and cavitation without causing damage to seals and hoses and without foaming.

Heating fluids that contain unsuitable corrosion inhibitors or antifreeze agents or that have been prepared incorrectly might cause failure of assemblies and component parts in the heating circuit due to cavitation or corrosion. Heat-insulating deposits on components that conduct heat might result in overheating and consequently failure of the motor.

Water (fresh water) Clear and clean water free of particles that meets the following chemical requirements is suitable for use as a heating fluid.

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

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Operating manual

Maintenance Lubricants and fluids specification

Designation

Value / unit

Total alkaline earth metals (water hardness)

0.6 to 3.6 mmol/l (4 to 25 °e)

pH at 20 °C

6.5 to 8.5

Chloride ion concentration

max. 80 mg/l

Sulphate ion concentration

max. 100 mg/l

Tab. 5-2

Fresh water quality

Designation

Value / unit

Total alkaline earth metals (water hardness)

0.6 to 2.7 mmol/l (4 to 19 °e)

pH at 20 °C

6.5 to 8.0

Chloride ion concentration

max. 80 mg/l

Sulphate ion concentration

max. 80 mg/l

Tab. 5-3

Fresh water quality with use of DCA 4*

* = Diesel Coolant Additives

Water analysis results are available from the local authorities.

Mixing ratio for heating fluid The heating fluid must contain min. 50% corrosion inhibitor and antifreeze agent at all times of the year.

Mixing ratio Outdoor temperature to Water %

Corrosion inhibitor/antifreeze agent %

-37 °C

50 %

50 %

-50 °C

40 %

60 %

Tab. 5-4

Permissible mixing ratio (for all seasons)

Fig. 5-5

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

A Ambient temperature B Corrosion inhibitor/antifreeze agent concentration in heating fluid

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Maintenance

Operating manual

Lubricants and fluids specification

Permissible corrosion inhibitors/antifreeze agent Note!

Improper mixing of different products might negatively affect the properties of the heating fluid and cause damage to the heating system.

Use only approved products. Do not mix different products.

Never mix products containing silicone with silicone-free products.

If the recommended LIEBHERR product is not available locally.

Concentrate Product name

Manufacturer

Liebherr Antifreeze Concentrate

Liebherr

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

Manufacturer

Liebherr Antifreeze Mix

Liebherr

Premix = ready-mixed product (50 % water and 50 % corrosion inhibitor/antifreeze agent)

Approved corrosion inhibitors without antifreeze agent Note!

Improper mixing of different products might negatively affect the properties of the heating fluid and cause damage to the heating system.

Use only approved products. Do not mix different products.

Never mix products containing silicone with silicone-free products.

If the recommended LIEBHERR product is not available locally: In exceptional circumstances and at ambient temperatures that are always above the freezing point, e.g. during use in tropical regions where there are no corrosion inhibitors/antifreeze agents available, the following inhibitors must be added to the heating fluid: voline / Total product In this case, the heating fluid must be changed annually.

As part of routine maintenance work, check the concentration and correct it, if necessary.

Product name

Manufacturer

DCA 4 Diesel Coolant Additives

Fleetguard / Cummins Filtration

Caltex CL Corrosion Inhibitor Concentrate

Chevron Texaco

Chevron Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free (ELC)

Chevron Texaco

Havoline Extended Life Corrosion Inhibitor (XLI)

Chevron Texaco

Total WT Supra

Total, Paris

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Operating manual

Maintenance Lubricants and fluids specification

5.5.3

Checking heating fluid, adjusting mixing ratio Heating fluid with corrosion inhibitor/antifreeze agent The mixing ratio must at all times conform to a frost protection of -37 °C. Take an heating fluid sample and analyse it with a suitable method for the frost protection temperature.

Adjust mixing ratio, if the frost protection is not sufficient.

Fig. 5-6

Determining refill volume - example for -15 °C:

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Maintenance

Operating manual

Lubricants and fluids specification

1

Corrosion inhibitor/antifreeze agent (concentrate), refill volume in litres

3

Max. frost protection temperature of the heating system -°C

2

Auxiliary line

4

Heating fluid volume in system in litres

Determining refill volume - example for -15 °C / 50 litres of heating fluid: Based on the measured frost protection temperature (-15 °C) follow the auxiliary line 2 from the left bottom corner to the vertical line 4 and from there horizontally to the left scale. The refill volume 1 is 14.8 litres.

This corresponds to the refill volume of corrosion inhibitor/antifreeze agent (concentrate) to be added in order to again achieve a frost protection temperature of -37 °C. Correcting mixing ratio The necessary refill volume is known.

To correct the mixing ratio, at least the (previously determined) volume must be drained from the heating system.

Add the determined volume of corrosion inhibitor/antifreeze agent (concentrate).

To achieve the required heating fluid level, add some of the previously drained heating fluid.

Heating fluid with corrosion inhibitor (without antifreeze agent) When using DCA 4: Take an heating fluid sample and analyse the concentration using a Fleetguard CC 2602 M testing kit.

If the concentration is incorrect, correct the mixing ratio (according to the values indicated by the test kit).

When using Caltex / Chevron / Havoline / Total: The mixing ratio must always show a Brix value of 2.8-0.9+0.9 % . This corresponds to 5 to 10 % of corrosion inhibitor and 90 to 95 % of water.

Take an heating fluid sample and analyse with a Gefo refractometer.

Fig. 5-7

Gefo refractometer 2710

Refractometer:

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Operating manual

Maintenance Lubricants and fluids specification

Measuring procedure: Carefully clean the lid and prism.

Apply 1 to 2 drops of sample liquid onto the prism.

Close the lid.

The liquid is distributed.

Hold the device against a light-coloured background and look through the eyepiece.

Adjust focus on scale and read the value at the blue separating line.

Fig. 5-8 1 2

Determining refill volume - example for 1 % Brix.

Corrosion inhibitor, refill volume in litres Auxiliary line

3

Refractometer value in % Brix

4

Heating fluid volume in system in litres

Determining refill volume - example for 1 % Brix / 50 litres of heating fluid: Based on the measured value (1 % Brix), follow the auxiliary line 2 from the left bottom corner to the vertical line 4 horizontally to the left scale. The refill volume 1 is 2.4 litres.

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Maintenance

Operating manual

Lubricants and fluids specification

This corresponds to the refill volume of corrosion inhibitor (concentrate) to be added in order to again achieve a value of 2.8 % Brix.

Correcting mixing ratio The necessary refill volume is known.

To correct the mixing ratio, at least the (previously determined) volume must be drained from the heating system.

Add the determined volume of corrosion inhibitor.

To achieve the required heating fluid level, add some of the previously drained heating fluid.

5.5.4

Hydraulic oil Hydraulic oils must meet the requirements given below.

Maximum water content of hydraulic oil: < 0.1 %

Liebherr hydraulic oil Liebherr recommends using the following hydraulic oils in its machines (depending on temperature range):

Fig. 5-9

Liebherr hydraulic oil, viscosity grade selection based on temperature

A Ambient temperature B Cold-start range with warm-up instruction C Operating range Liebherr Hydraulic Plus and Liebherr Hydraulic Plus Arctic are applicable for both long-term use and use in environmentally sensitive areas.

If Liebherr oils are not available locally, use one of the engine oils listed in section "Engine oils for use as hydraulic oils". Before choosing an oil, contact the Liebherr customer service.

Warm-up instructions The black bar B indicates ambient temperatures that are up to 20 °C below the operating range C.

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Operating manual

Maintenance Lubricants and fluids specification

For cold starting at an ambient temperature below range B, the following warm-up instructions for the hydraulic oil apply: 1. Start the electric engine and set it to medium speed (not exceeding 50% of maximum speed).

2. Carefully activate the working hydraulics. Operate the hydraulic cylinders and move them briefly to the stop.

3. After approximately 5 minutes, start the travel hydraulics. The total warm-up time is approximately 10 minutes.

For cold starting at lower ambient temperatures: Before starting the engine, warm up the hydraulic oil tank. Then follow warm-up instructions 1 to 3.

Biodegradable hydraulic oil Caution!

Do not mix hydraulic oil products!

When mixing different ester-based biodegradable hydraulic oils or mixing such products with mineral oils, aggressive chemical reactions might occur, causing damage to the hydraulic system.

Do not mix biodegradable hydraulic oils from different producers. Do not mix biodegradable hydraulic oils with mineral oils.

Depending on the temperature range, Liebherr recommends the following hydraulic oils for the machine: Liebherr Hydraulic Plus or Liebherr Hydraulic Plus Arctic These products are polyalphaolefins (HEPR) conforming to CEC-L-103-12 that are biodegradable by more than 80% (within 21 days).

When using these hydraulic oils, bypass filtration is not mandatory.

If these oils are not available locally, use fully saturated hydraulic environmental ester synthetic (HEES) fluids. Before choosing an oil, contact the Liebherr customer service.

Caution!

The use of synthetic ester-based oils without a bypass filter causes damage to the hydraulic system!

If synthetic ester-based oils are used, bypass filtration is mandatory, in order to maintain the water content in the oil below 1000 ppm (0.1%).

Use a bypass filter (optional equipment).

When using such fluids, we recommend replacing the hydraulic hoses every 4000 operating hours or at least every 4 years.

Do not use vegetable oils, as they do not possess the necessary thermal stability.

Under certain circumstances, the use of polyglycols is permitted, although they can cause damage to seals or the paintwork. Do not use oils containing polyglycols without first consulting the Liebherr customer service.

When using third-party products, request a certificate from the oil manufacturer, confirming that the product meets the above specifications.

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Maintenance

Operating manual

Lubricants and fluids specification

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

Liebherr recommends carrying out regular oil analyses.

See "Oil analysis".

Oil change Not for use in environmentally sensitive areas without oil analysis

with oil analysis* (optional)

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

LIEBHERR mineral oil Liebherr Hydraulic HVI Liebherr Hydraulic Basic 68 Liebherr Hydraulic Basic 100

every 3000 h

every 6000 h

- ***

Liebherr-PAO** Liebherr Hydraulic Plus Liebherr Hydraulic Plus Arctic

every 4000 h

every 8000 h

every 8000 h

Third-party product - mineral oil

every 2000 h

every 2000 h

- ***

Third-party product - fully saturated synthetic ester

- ***

- ***

every 2000 h

Oil type

Tab. 5-5

Oil change intervals

*

If the result of the oil analysis is satisfactory, you may continue using the oil for a longer period.

If the result of the oil analysis is negative, immediately change the oil. ** PAO = polyalphaolefin *** not permissible

Use in environmentally sensitive areas: machines operated in such areas must be filled with biodegradable hydraulic oil.

If the machine is operated for less than 1000 hours per year, an oil sample must be taken at least once a year. If a hydraulic oil remains in the machine for a prolonged period of time, it must be changed at least every 4 years (mineral oils and fully saturated synthetic esters) or every 6 years (Liebherr-Plus oils).

If the machine is not in use for a period of more than 6 months, carry out an oil analysis before restarting it.

Oil analysis For regular oil analyses, LIEBHERR recommends contracting the specialist company OELCHECK and changing the oil when indicated by the test results in the lab report.

See also customer service and product information.

Reasons for regular oil analyses:

medium

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Operating manual

Maintenance Lubricants and fluids specification

Oil sampling / operating conditions Oil sampling in machines operated under normal operating conditions

Oil sampling in machines operated under extremely dusty conditions

The oil sampling interval is determined by the actual operating conditions (for more information, see chapter "Dust-intensive applications, reduction of oil contamination").

Tab. 5-6

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)

LIEBHERR mineral oil Liebherr Hydraulic HVI Liebherr Hydraulic Basic 68 Liebherr Hydraulic Basic 100

every 1000 h

every 250 h

- **

- **

Liebherr-PAO* Liebherr Hydraulic Plus Liebherr Hydraulic Plus Arctic

every 1000 h

every 250 h

first at 0 h, then every 1000 h

first at 0 h, then every 250 h

Third-party product - mineral oil

first at 1000 h, then every 500 h

every 250 h

- **

- **

Third-party product - fully saturated synthetic ester

- **

- **

first at 0 h, then every 500 h

first at 0 h, then every 250 h

Oil type

Tab. 5-7

Oil sampling depending on operating conditions

* PAO = polyalphaolefin ** not permissible

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Maintenance

Operating manual

Lubricants and fluids specification

Filter change Filter change / operating conditions Filter change in machines operated under normal operating conditions

Filter change in machines operated under extremely dusty conditions

The filter change interval is determined by the actual operating conditions (for more information, see chapter "Dust-intensive applications, reduction of oil contamination").

Tab. 5-8

Symbols: Filter change depending on operating conditions

Change of return filter (use only LIEBHERR filters)

every 1000 h

Tab. 5-9

every 500 h

Filter change depending on operating conditions

Change of bypass oil filter LIEBHERR filter

Filters from other manufacturers

every 2000 h or as indicated

every 500 h

every 250 h

Tab. 5-10 Filter change depending on operating conditions

Dust-intensive applications, reduction of oil contamination If the machine is regularly operated with a hydraulic hammer or under similar conditions (very dusty environment), the hydraulic oil can become more contaminated than under normal working conditions.

To prevent premature wear of the hydraulic components, the oil change and sampling intervals must be shortened.

Observe the following: hours and after every hydraulic oil change. placed every 500 operating hours and after every hydraulic oil change.

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Operating manual

Maintenance Lubricants and fluids specification

Machines delivered with a hydraulic hammer attachment and retrofitted hydraulic hammer kits are already equipped with 10-µm filter cartridges in the return filter.

Please take this into account when ordering spare parts.

5.5.5

Lubricants for gearboxes Quality Recommended lubricant

Specification

Liebherr Gear Basic 90 LS

API: GL-5 MIL-L: 2105 D ZF: TE-ML 05C, 12C, 16E, 21C

Liebherr Gear Plus 20W-40

API: Niveau von GL4 ZF: TE-ML 05F, 06K, 17E

Liebherr Gear Hypoid 90 EP

API: GL 5 MIL-L: 2105 B, C, D ZF: TE-ML 05A, 12A, 16C, 17B, 19B

Liebherr Hypoid 85W-140 EP

API: GL-5 MIL-L: 2105 D, PRF-2105 E ZF: TE-ML 05A, 07A, 16D, 21A

Liebherr Hydraulic-Gear ATF

GM: Dexron II D ZF: TE-ML 03D, 04D, 11A, 14A, 17C

Liebherr Syntogear Plus 75W-90

API: GL-4, GL-5, MT-1 MIL-L: 2105 D, PRF-2105 E ZF: TE-ML 02B, 05B, 07A, 12B, 16F, 17B, 19C, 21B

Tab. 5-11 Lubricating oil specifications If LIEBHERR oils are not available locally, use an oil that conforms to the specifications (before choosing an oil, contact our customer service department).

Viscosity

Fig. 5-10

Temperature-based selection of the SAE class

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Maintenance

Operating manual

Lubricants and fluids specification

A Ambient temperature 1 Use in gearboxes 2 3

Use in automatic transmissions Use in pump distributor gear systems

*

If the pump distributor gear is equipped with an oil cooler, the oil is not suitable for the marked temperature range (shaded area).

The choice of the lubricating oil viscosity is based on the SAE classification (Society of Automotive Engineers). The SAE classification does not provide any indication as regards the quality of a lubricating oil. The relevant factor for the correct choice of SAE class is the ambient temperature. Incorrect viscosity can impair the operation of axles and gearboxes.

The temperature ranges shown in the diagram are approximate ranges that might temporarily be exceeded.

5.5.6

Grease Quality Recommended lubricant

Specification

Liebherr Universalfett 9900

Soap-base grease (lithium complex) KPF 2 N - 25 (DIN 51502) NLGI grade: 2 (DIN 51818) VKA welding force: > 6000 N (DIN 51350 / 4)

- Liebherr Universalfett Arctic (for lowtemperature operation)

Soap-base grease (lithium complex) KPFHC 1 N - 60 (DIN 51502) NLGI grade: 1 (DIN 51818) VKA welding force: > 5500 N (DIN 51350 / 4)

The grease is used for both automatic and manual machine lubrication. it is supplied by the central lubrication system or through lubrication nipples to the respective lube points.

Examples:

Operating temperature

Fig. 5-11

Operating temperature for Liebherr greases

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Operating manual

Maintenance Electric motor

A Grease temperature * The grease is not suitable for the temperature range (shaded), if used in a central lubrication system. ** The grease may only be within the temperature range (shaded) for short periods of time. Peak temperatures of max. 200 °C (392 °F) are possible.

5.5.7

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

Product (manufacturer)

Contact spray for slip rings

Cramolin

Lubricant for pistons, piston nuts and for the mounting of piston rod bearings at hydraulic cylinders

Gleitmo 800

Special corrosion inhibitor for mounting recesses of sealing elements at hydraulic cylinders

Rostilo Tarp CFX

5.6 Electric motor 5.6.1

Type plate

Fig. 5-12

Example of type plate of an electric motor

V

Mains voltage

P2

Protection class

Hz

Mains frequency

IC

Insulation material class F

min-1 revolutions per minute

M1

Three-phase motor

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Maintenance

Operating manual

Electric motor

kW

5.6.2

Rated power

N

Serial number of motor

cos j Power factor

T

A DE

Rated current Bearing side A (shaft)

Preset ambient temperature at operation

M2

Series

NDE Bearing side B (fan) G1 Recommended lubricant type

M3 M4

Size Housing index

G2

Lubricant quantity

M5

Impregnation index

G3

Lubricant change intervals

P1

Weight

Routine maintenance Note Regular and preventive maintenance are describe in the attached user manual of the electric motor.

Caution Before operating on the motor, ensure that : sconnected from the main power.

Carefully establish the failure causes (blockage of rotor, mains phase failure, shut-down by thermal protection, lack of lubricant, etc.).

Inspection after commissioning After approx. 50 operating hours and every 1000 operating hours, check the mounting bolts of the motor and the coupling element for proper tightening.

Fig. 5-13

Mounting bolts of the electric motor and the coupling element

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Operating manual

Maintenance Electric motor

Mounting bolts

Tightening torques

Dimension

Class

[ Nm ]

[ ft.lbs ]

M10

10,9

68

50

M16

10,9

280

206

M18

10,9

390

288

M20

10,9

560

413

M24

10,9

960

708

Tab. 5-12 Tightening torques of mounting bolts

Lubricating motor bearings Note quality of the grease are indicated on the type plates. contamination by dust, water or other substances).

Caution years, even if it is a storage period or an extended stop. of grease can cause overheating of the bearing and can damage it.

Fig. 5-14

Lube points of the electric motor

The electric motor is switched on.

Connect the hand lubricating pump to the lube point.

Every 30 seconds, release a little grease until the specified quantity is applied.

Remove the hand lubricating pump Repeat the procedure at the second lube point.

Inspection of bearings Check the bearing for damage, in the event of: despite of correct lubrication.

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Maintenance

Operating manual

Electric motor

Damaged bearings must be replaced without delay in order to prevent more serious damage to the motor and the driven elements.

Cleaning Before cleaning, ensure that the motor is completely tight (terminal box, condensate bores, etc.).

Note cleaning. ensure that dust and other particles do not enter the shaft seal rings.

Ensure that the motor is free of dust and foreign objects who might block the fan hood or the cooling fins of the housing.

Check that the extractor hood and the hoses are free of foreign objects and dust.

Their presence in the motor aeration circuit lead to an overheating of the motor and reduce considerably its lifecycle.

5.6.3

Reversible fan (option) General The option "reversible fan" allows an easy cleaning of the cooler cores by inverting the way of rotation of the fan.

Fig. 5-15

Push button and control light for option reversible fan

Cleaning the cooler Danger !

Before checking the condition of the cooler, you must absolute shut off the engine and wait until the fan does not turn any more.

With running engine, depress the push button S160 and keep it depressed.

The fan stops progressively (approx. 15 seconds), then the control light H90 lights up and the fan starts rotating in the opposite way.

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Maintenance Hydraulic system

In case of a diesel engine, bring it to high idle while keeping the push button S160 depressed.

Let the engine run at high idle for approx. 1 minute (max. 3 minutes).

Release the push button S160.

The control light H90 goes out, the fan stops progressively (approx. 15 seconds), then the fan rotates in the normal way again.

Shut off the engine.

Wait until the fan does not turn any more.

Check the condition of the cooler.

If necessary, repeat the cleaning procedure.

5.7 Hydraulic system Maintenance work on the hydraulic system is generally limited to the hydraulic tank.

All other components of the system do not require any special maintenance or servicing.

The network of pipes and hoses must however be inspected regularly for leaks.

Note!

Cleanliness is of particular importance for the proper working of the hydraulic system.

For this reason, the prescribed intervals for

5.7.1

Depressurising the hydraulic system Before carrying out any work on the hydraulic system, you must fully depressurise it.

Danger!

Do not use your bare hands to check the system for leaks.

Fine jets of fluid escaping under high pressure can penetrate the skin and result in serious injury.

Observe the following: Park the machine on level firm ground and place the attachment on the ground.

Depressurise the high-pressure circuits.

Shut down the motor.

Operate the pilot control units (joystick and pedals) in all directions (while the start key is in contact position and the safety lever is folded down).

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Maintenance

Operating manual

Hydraulic system

Depressurise the pilot control circuits.

Operate the pilot control units (joystick and pedals) several times in all directions (while the start key is in contact position and the safety lever is folded down).

Fig. 5-16

Depressurising the hydraulic system

Depressurising hydraulic tank Turn out the breather filter 1 by maximum one full turn.

The hydraulic system is gradually being depressurised.

The breather filter 1 can be rotated by hand when the safety pin 2 is inserted. If necessary, use an open end spanner to turn the filter.

Note!

The safety pin 2 (or anti-vandalism key) should always be removed from the breather filter and attached to the machine start key.

Danger!

When at operating temperature, the hydraulic oil is hot and might be under pressure.

Avoid skin contact with hot oil or components containing hot oil.

5.7.2

Checking oil level in hydraulic tank; emptying and refilling tank Excavator position

Fig. 5-17

Machine position for the oil level check of the hydraulic system

Before checking the oil level or adding oil:

cylinders are fully extended (i.e. bucket and stick fully tilted in),

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EP 944C / 10360388

Operating manual

Maintenance Hydraulic system

Checking oil level in hydraulic tank

Fig. 5-18

Oil level in hydraulic tank

When the machine is in inspection position, the level may not drop below the centre mark in the sight glass.

If required, add oil through the return filter until the level reaches the centre mark.

The upper mark MAXI indicates the maximum oil level when all cylinders are fully retracted.

The lower mark MINI indicates the minimum oil level when all cylinders are fully extended.

If the oil level drops below the lower mark MINI, the minimum level is reached and the respective warning symbol is shown on the display.

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Maintenance

Operating manual

Hydraulic system

Emptying and refilling hydraulic tank

Fig. 5-19

Draining and adding hydraulic oil

1 3

Breather filter Drain hose

2 4

Return filter Screw plug on return chamber

5

Drain valve on hydraulic tank

6

Drain valve of return chamber

7

Centring tube

R Return chamber

If possible, empty and refill the hydraulic system using a filler unit.

Draining oil: The hydraulic system is depressurised.

Turn out the breather filter 1 by maximum one full turn.

The hydraulic system is gradually being depressurised.

Remove the lid from the return filter 2.

Connect the drain hose to the drain valves 5 and 6 at the bottom of the hydraulic tank and at the bottom of the collecting pipe.

Let the oil flow into a suitable container.

Adding hydraulic oil: Turn out the breather filter 1 by maximum one full turn.

The hydraulic system is gradually being depressurised.

Remove the lid from the return filter 2.

Add oil through the filter cartridge 2 or through the screw plug 4 at the return chamber until the level reaches the centre mark in the sight glass (see Fig. 5-18).

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Operating manual

Maintenance Hydraulic system

Tighten the breather filter 1.

Fill the tank to the upper edge. When adding oil through the filter lid, ensure that the return chamber R around the centring tube 7 is also completely filled.

Replace the lid of the return filter 2 or tighten the screw 4 respectively.

Caution!

Bleed the hydraulic pumps after each hydraulic oil change.

Draining condensate: Drain the condensate from the hydraulic tank at the intervals prescribed in the maintenance schedule.

Place a suitable container under the machine.

Connect the drain hose to the drain valves 5 and 6 (see Fig. 5-19) until the oil flowing into the container does not contain any water.

Interval: see maintenance schedule Note!

When using biodegradable hydraulic fluids, we recommend draining of condensate each time the machine is started after a prolonged period of standstill (longer than 24 hours).

5.7.3

Checking and cleaning oil cooling system

Fig. 5-20

Oil cooler

11 Hydraulic oil cooler

15 Transmission oil cooler

16 Condenser in a/c system The hydraulic oil cooler is integrated into the combined cooler unit.

A clean oil cooler is a prerequisite for optimum oil cooling.

Regularly check the fan and the cooler for damage and clean it, if necessary.

If required, clean the cooling fins with compressed air or steam jet (from the inside out, see arrow). If necessary, the combined cooler might be in a tilted position (see Fig. 5-21).

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Maintenance

Operating manual

Hydraulic system

Caution!

Risk of injury from crushing between the combined cooler and the catwalk.

Fig. 5-21

5.7.4

Combined cooler in tilted position

Return filter This return filter is located at the top of the hydraulic tank.

Fig. 5-22 1

Return filter

Lid

4

Magnetic rod

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Operating manual

Maintenance Hydraulic system

2

Screw

5

3

Flat gasket

Filter cartridge

The magnetic rod 4 of the return filter must be cleaned and the fibre glass filter cartridge 5 must be replaced at prescribed intervals (see maintenance schedule).

Note!

In areas with excessive dust, observe the special instructions for the filter change.

Cleaning the magnetic rod and/or replacing filter cartridge: The hydraulic system is depressurised.

Loosen the screws at the filter lid and lift off the lid 1 together with the magnetic rod 4.

Carefully clean the magnetic rod removing any persistent dirt.

Remove the spent filter cartridge 5 holding it by the bracket.

Insert the new filter cartridge vertically into the tank, holding it by the bracket, and push it slightly down. Place the bracket along the side of the tank ring.

Caution!

Ensure that the filter cartridge is aligned vertically in the tank and that the flat gasket 8 is not damaged.

Centre and place the lid 4 carefully on the filter cartridge 5. Ensure that the flat gasket 3 is not damaged and positioned correctly.

5.7.5

Leak oil filter

Fig. 5-23

Leak oil filter

The return filter 2 for leak oil of the hydraulic pumps and motors, which is attached to the rear of the hydraulic tank must also be regularly inspected and serviced.

For intervals, see maintenance schedule.

When servicing the filter, replace the filter insert or clean it with cleaner's solvent or engine oil.

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Maintenance

Operating manual

Hydraulic system

Note!

The filter insert can be cleaned maximum three times before it needs to be replaced.

Cleaning filter Open the filter pot.

Remove the filter cartridge.

Clean the filter cartridge and the filter pot.

Inserting new or cleaned cartridge Apply a little oil to the threads and sealing faces on the filter pot and the filter head and to the O-rings.

Carefully slide the filter cartridge onto the mounting stud.

Screw the filter pot by hand to the stop and then tighten it with a spanner attached to the hexagon section at the base of the filter pot (tightening torque: 40+10 Nm).

5.7.6

Control oil filter The pressure filter 11 is an integral part of the control oil unit 1 located at the rear of the hydraulic tank.

Fig. 5-24

Control oil unit

1 2

Control oil unit Mounting stud

12 13

Filter cartridge Filter cartridge sealing ring

10

Accumulator

14

Filter pot

11

Pressure filter

15

Filter pot sealing ring

Note!

Cleaning and re-using the filter cartridge is prohibited!

Replace the cartridge each time you open the filter pot.

Replacing filter cartridge: The hydraulic system is depressurised.

Screw off the filter pot 14 of the pressure filter 11 and pull out the filter cartridge 12.

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EP 944C / 10360388

Operating manual

Maintenance Hydraulic system

Clean the filter pot 14.

Apply a little hydraulic oil to the threads and sealing faces of the filter pot 14 and the control oil unit 1 as well as to the sealing rings 13 and 15.

Carefully place the new filter cartridge 12 onto the mounting stud 2.

Screw in the filter pot 14 to the stop and then turn it back by hand by 1/4 revolution (90°).

5.7.7

Feed line filter of the slewing gear circuit The filter is attached to the slewing gear pump.

Fig. 5-25

Feed line filter of the slewing gear circuit

2

Filter pot

7

Spring

3

Filter cartridge

10

O-ring

Unscrew the filter pot 2 of the filter and pull out the filter cartridge 3 and the O-ring 10.

Clean the filter pot 2.

Apply a little oil to the threads and sealing faces of the filter pot 2 and the filter head.

Carefully mount the new filter cartridge 3, the new O-ring 10 and the spring 7 on the mounting stud.

Screw in the filter pot 2 of the filter.

5.7.8

Control circuit The control circuit does not need to be serviced.

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Maintenance

Operating manual

Hydraulic system

Regularly inspect the pipelines and the connections of all units (accumulators, pressure-relief valve, pressure filter, etc.) for leakage.

Danger!

The pressure accumulator 10 (see Fig. 5-24) ensures that the control circuit remains pressurised after the motor is shut down so that a number of movements remain possible.

Prior to interfering with the control pressure circuit, it must be depressurised: To do this, place the working attachment on the ground.

Shut down the motor.

Repeatedly actuate the two joysticks (while the start key is in contact position and the safety lever is folded down).

5.7.9

Bleeding the hydraulic pumps Caution!

The hydraulic pump and the pump regulator must be carefully bled before the first start up of the machine, after replacement of the pump or after any reparation works in the hydraulic circuit of the pump (suction line, leakage oil line, ...) and after replacement of the hydraulic oil.

The pump must also be bled after each repair work making necessary to depressurize the hydraulic tank with a vacuum pump, and especially if the fan driving pump is mounted higher or at the same height as the oil level in the hydraulic tank.

To bleed the pump efficiently, we recommend to pressurize the tank before bleeding (0.3 to 0.5 bar air pressure). The pressurization of the tank is essential if the pump is higher or at the same height as the oil level in the hydraulic tank.

When starting the pump for the first time, and after a repair or a pump change, the oil housing must be filled with hydraulic oil. This is done through the above bleeder plugs and fittings.

Bleeding the working and slewing gear pumps Note!

To bleed the pumps, we recommend using a special tool (ID no. 7408148) to pressurise the hydraulic tank.

If the pumps are bled without a special tool and tank pressurisation, you must switch on the motor for the duration of the bleeding process.

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Operating manual

Maintenance Hydraulic system

Fig. 5-26

Hydraulic pumps

1

Fitting / bleeding of working pump

2

Screw plug / bleeding of slewing gear pump

3 5

Working pump Screw plug / bleeding of fan drive pump

4 6

Slewing gear pump Fan drive pump

To bleed a working pump 3, loosen the fitting 1 and allow the air to escape.

Tighten the fitting 1 as soon as the oil escaping at the opening is free of air bubbles.

To bleed the slewing gear pump 4, loosen the screw plug 2 and allow the air to escape. Tighten the screw plug 2 as soon as the oil escaping at the opening is free of air bubbles.

Bleeding the fan drive pump E944C and E954C To bleed the fan drive pump 6, loosen the screw plug 5 and allow the air to escape. Tighten the screw plug 5 as soon as the oil escaping at the opening is free of air bubbles (see picture before).

E934C

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Maintenance

Operating manual

Hydraulic system

Preferably unscrew a fitting on the hose on high pressure port of the pump if this port is situated near the top of the pump.

Let oil escape until it contains no more air bubbles and retighten the fitting.

Otherwise loosen (without removing) the topmost plug 28 on the pump housing, let. oil escape until it contains no more air bubbles and retighten the plug 28.

Bleeding the pump regulator The extremity of the solenoid valve Y347 is fitted with a bleeding plug 30 allowing to deaerate the pump regulator.

Insert a (2 mm) Allen wrench in the hexagon bore of the plug and unscrew of about 1/4th a turn.

Let oil escape until it contains no more air bubbles.

Retighten the plug 30 (torque to 1 Nm).

Caution!

If no hydraulic tank pressurization system is available, the bleeding of the pump while turning the motor (with injection solenoid valve disconnected) is allowed only if the pump is sufficiently filled with oil. If necessary, previously fill the pump housing with oil before bleeding.

Thoroughly check the suction and leak oil lines of the pump for correct fastening and sealing, so to make sure no air entry in the hydraulic system is possible.

Start the motor. Check that the fan drive motor starts (at low RPM in the cold condition of the machine).

Let the motor run for few minutes to let escape the air possibly remaining in the pump or in the hydraulic circuit.

5.7.10

Bleeding the hydraulic cylinders The cylinders must be bled after each cylinder replacement and after work carried out on the cylinders (replacement of seals, etc.) or the hydraulic circuits (replacement of hose, etc.).

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Operating manual

Maintenance Hydraulic system

Fig. 5-27 2

Hydraulic cylinder

Seal plug for bleeding

3

Measuring neck

Hydraulic cylinders equipped with bleeder plugs 2 must be bled according to bleeding procedure 1. Hydraulic cylinders without bleeder plug must be bled according to bleeding procedure 2.

Bleeding procedure 1 Remove the seal plugs 2 on both sides.

Screw in two measuring necks 3 to replace the plugs and equip them with a measuring hose each.

Start the electric motor and let it run for the duration of the procedure.

If possible, move the attachment in such a way that the side to be bled (supplied side) of the cylinder is in the upper position.

The cylinder movements must be slow and carefully controlled. We recommend first bleeding one side of the cylinder without making any movements (e.g. if cylinder is already retracted, first initiate the cylinder retraction and then bleed the rod side).

The procedure is completed when the oil flowing through the measuring hose is free of air bubbles.

Actuate and bleed the other side of the cylinder.

Switch off the motor, disconnect the measuring hoses and replace the measuring necks with the seal plugs 2.

Complete bleeding procedure 2.

Bleeding procedure 2 Start the motor and let it run for the duration of the procedure.

If possible, move the attachment in such a way that the side to be bled (notsupplied side) of the cylinder is in the upper position.

Slowly extend the cylinder to the stop and then slowly retract it again to the stop.

Ensure that all movements are slow and even. Repeat this process five times.

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Maintenance

Operating manual

Hydraulic system

Danger!

If the cylinder is not properly bled, gas bubbles might form in the system (mixture of air and hydrocarbon). At high operating pressures in the cylinder, these gases might explode (Diesel effect).

5.7.11

Disconnecting suction hose of pump For maintenance work on the pump suction side (replacement of sight glass, removal of working pump, etc.), you can close the suction hose of the working pump by means of a stopcock so that it is disconnected from the hydraulic tank.

Fig. 5-28

Stopcock at hydraulic tank

The suction hose stopcock on the hydraulic tank can be set to two positions: a open b closed Depressurise the hydraulic system.

Close the stopcock at the hydraulic tank (position b).

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Operating manual

Maintenance Hydraulic system

Fig. 5-29

Draining oil from the working pumps

Loosen the screw plug 1 at the suction hose neck on the pump side.

Drain the hydraulic oil from the pump and suction hose.

After completion of the repair, turn the stopcock to its initial position a and engage it.

Tighten the breather filter on the hydraulic tank.

5.7.12

Breather filter on hydraulic tank

Fig. 5-30

Breather filter of hydraulic tank

The hydraulic system is depressurised.

Replace the filter 1 together with the safety pin 2 (see inspection and maintenance schedule).

Note! n areas with excessive dust, observe the special instructions for the filter change.

The safety pin 2 (or anti-vandalism key) should always be removed from the breather filter and attached to the machine start key.

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Maintenance

Operating manual

Hydraulic system

5.7.13

Bypass oil filter for hydraulic system (option) The purpose of the bypass oil filter is to eliminate the smallest impurities and the water contained in the hydraulic system.

The bypass oil filter is mounted to the front of the hydraulic tank, resp. in the hydraulic pumps compartment.

On machine model R964 C and above, two bypass oil filters are mounted in parallel due to the oil flow to be filtered.

Note!

LIEBHERR insistently recommends to fit with a bypass oil filter the excavators which are operated with environmentally friendly hydraulic fluids.

Fig. 5-31 1 3

Bypass oil filter for hydraulic system

Pressure gauge Filter housing

2 4

Tightening clamp Filter element

The more the oil is contaminated, the higher the pressure in the filter housing.

Depending on the machine applications and the dirt/water collection in the filter, the filter cartridge might need to be replaced before the standard change interval (2000 operating hours) is reached.

If the pressure gauge 1 indicates a value of more than 2.5 bar during operation, the filter element is too much contaminated to ensure sufficient filtering of the hydraulic oil.

Checking filter contamination The contamination grade of the bypass oil filter must be checked at the regular intervall indicated in the maintenance chart When checking, the hydraulic oil must be at a temperature of at least 50 °C (operating temperature) and the engine must be running.

Read the indication of the pressure gauge.

If the pressure exceeds 2.5 bar, change or get changed the filter element at once.

Replacing filter element Switch off the engine.

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Operating manual

Maintenance Hydraulic system

Release the pressure in the hydraulic tank.

Open and remove the tightening clamp 2.

Remove the old filter element 4 and collect the oil leaking from the filter in a suitable container.

Check the inlet and outlet sections of the bypass oil filter and if necessary clean the inner side of the filter head.

Insert a new filter element 4.

Replace the filter housing 3, replace and tighten the clamp 2.

Start the machine and check the bypass oil filter for leakage.

5.7.14

Return oil filter for hydraulic hammer (option) In case of use of an hydraulic hammer or a demolition work, it is strongly advised to install an extra return oil filter.

Thanks to this filter, the effectiveness of the hydraulic system filtration is increased.

The return oil filter for hydrailic hammer is close to the fuel tank.

Fig. 5-32 1 2

Return oil filter for hydraulic hammer

Nuts complete cover

3 4

Seal kit Filter cartridge

5 6

Contamination indicator Filter housing

The return oil filter for hydraulic hammer is mounted on the fuel tank. The intervall of maintenance depends on the indication given by the contamination indicator 5.

If the indicator is green, the filter works correctly.

If the indicator is red, the filter is clogged and the filter unit has to be replaced.

Replacement of the filter cartridge The hydraulic system must be depressurized.

Unscrew the four nuts 1 on the filter cover and lift out cover 2.

Remove the used filter cartridge 4.

Check the seal 3 and replace it if necessary.

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Maintenance

Operating manual

Hydraulic system

Carefully clean off any dirt sticking to the magnetic plug.

Insert a new filter cartridge 4.

Put the seal 3 and the cover 2.

Coat the stud bolts of the filter housing 6 with anti-corrosion grease and tighten the nuts 1.

5.7.15

Servicing the hydraulic cylinder Checking the condition of the piston rod mount

Fig. 5-33

Piston rod mount

Note When a leak appears on the piston rod mount of a hydraulic cylinder (see arrow), the sealing kit must be replaced by a LIEBHERR fitter.

Protecting the piston rods

Fig. 5-34

Machine with piston rods drawn in

When the machine is out of service for more than 4 weeks and particularly for transportation by sea, the following measures must be taken: Position or transport the machine in such a way that the piston rods are fully drawn into the cylinders.

Cover any loose piston rods with a thick layer of non-corrosive anti-corrosion fluid.

For sea transportation, check the condition of the piston rods once more after loading.

Additionally, cover piston rods with anti-corrosion fluid if a cylinder only has a low stroke for certain work, meaning that the piston rod is not regularly moistened with hydraulic oil (eg. cylinder on slewing arm when working over ground).

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Operating manual

Maintenance Hydraulic system

Check the condition of hydraulic cylinders which are not moved a great deal regularly.

5.7.16

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 hoses in such a way that torsion loading is avoided.

Ensure that the hydraulic hose is not twisted when mounting.

Installed high pressure hoses with SAE connections have a nominal diameter of 16, 20, 25, 32 or 40 (5/8", 3/4", 1", 1"1/4, or 1"1/2).

You must tighten the mounting screws of the SAE fittings with the following tightening torques.: Size of screw 4

Torque value in Nm - Quality 10.9 Half flanges 5a

Flat flange 5b

Conical flange 5c

M8

31

/

/

M10

62

45

65

M12

108

70

110

M14

172

120

180

M16

264

170

250

M20

350

250

450

Tab. 5-13 Tightening torques for SAE fittings - Quality 10.9

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Maintenance

Operating manual

Oil changes on components

Size of screw 4

Torque value in Nm - Quality 8.8 Half flanges 5a

M8

22

M10

44

M12

76

M14

122

M16

187

Tab. 5-14 Tightening torques for SAE fittings - Quality 8.8

5.8 Oil changes on components 5.8.1

General information The machine must be standing level.

Switch off the engine.

Wait briefly until the oil has collected in the oil sump.

Drain off the oil (preferably when oil is at operating temperature) Oil quality and quantity: see lubricant chart.

Change intervals: see lubrication and maintenance chart.

5.8.2

Swing gear - Oil level check and oil change

Fig. 5-36

Checking oil level and changing oil in swing gear

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Operating manual

Maintenance Oil changes on components

1 2

Oil reservoir Cover

3 4

Drain valve Drain hose

To check the oil level: When the gear oil is cold, the level in the expansion reservoir 1 should not be below the marking Min. Otherwise add oil until the level reaches the marking Max. To drain the oil: Remove the cover 2.

Unscrew the cover of the drain valve 3 via the opening on the upperdeck.

Screw the drain hose provided 4 to the drain valve 3 and let the oil flow out into a suitable container.

Remove the hose 4.

Screw the cover of the drain valve 3 back on.

To add the oil: Add the oil in the reservoir until the level reaches the Max. marking.

Screw the cover 2 back on.

5.8.3

Pump distributor gear - oil change

Fig. 5-37 4

Oil change in the pump distributor gear

Lid

5

Oil level gauge

7

Drain valve

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Maintenance

Operating manual

Oil changes on components

Checking the oil level: Let the engine run for a few minutes and then shut it down.

Unscrew the dip stick 5 and clean it with a clean, lint-free cloth.

Insert the dip stick 5 and screw it in to the stop , unscrew it again and remove it from the oil tank.

Check the oil level (distance to mark).

If required, add oil and repeat the above oil check.

Screw in the dip stick 5.

Draining oil: Remove the lid 4.

Connect the supplied drain hose to the drain valve 7 and let the oil drain into a suitable container.

Disconnect the drain hose.

Replace the lid of the drain valve 7.

Adding oil: Add oil through the filler neck 4 until the oil level reaches the "Max" mark on the dip stick 5.

Replace the lid 4.

Let the engine run for a few minutes, shut it down and wait until the oil has collected in the tray. then check the oil level again.

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Operating manual

Maintenance Electrical installation

5.9 Electrical installation 5.9.1

Electrical rotary connection

Every 500 operating hours, check the mounting bolts of the rotary connection and of the driver for proper fixture.

Fig. 5-38

Mounting bolts of the slip ring

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Maintenance

Operating manual

Electrical installation

Mounting bolts

Tightening torques

Item

Dimension

Class

[Nm]

[ft.lbs]

27

M20

10.9

560

413

32

M12

10.9

117

86

Tab. 5-15 Tightening torques of mounting bolts The bearing is lubricated for life, so that relubrication is not required.

Servicing is thus generally limited to cleaning the rotary connection. Maintenance interval: 1000 operating hours Clean the outside of dirt.

On the inside, clean the ring slip faces, the brushes and the insulators of dust to prevent leakage current between the individual slip rings.

Remove any condensate from the inside surfaces.

Check the surfaces of the ring slip faces for damage.

Remove any slugs and oxidation.

The carbon brushes have a relatively long service life, due to the low speed and the hardness of the carbon.

Every 1000 operating hours, carry out a visual inspection of the carbon brushes.

The carbon brushes must be replaced on time to prevent that the metal parts of the brush holder or the mounting bolts of the carbon brushes come into contact with the slip rings.

Caution Before carrying out any work on the rotary connection, open the main switch at the power supply unit and lock it.

All work on the electrical system must be carried out by qualified persons who are aware of the risk posed by electric power.

5.9.2

24 V electrical system Regularly inspect the electrical system of the excavator for defects.

Notes regarding the electrical system Regularly inspect the electrical system of the machine for defects.

Identify the cause of blown fuses and broken incandescent lamps, eliminate it and replace the fuse or the lamp.

Caution Use only fuses.

Never bypass, bridge or repair electrical fuses.

Defects such as loose connections, chaffed cables or poorly fixed clamps must be repaired without delay.

Before washing the machine, cover the electrical devices (in particular the alternator, cabling, electrical components and measurement transducers) so that they are protected against splashing water.

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Operating manual

Maintenance Electrical installation

5.9.3

Battery care (option) Danger!

Risk of injury from sparks.

When charging batteries or carrying out other work on batteries, keep away from sparks and naked flames.

Disconnect the negative pole (-) first and reconnect it last.

Always wear goggles and protective gloves.

Note!

The battery might discharge itself during prolonged standstills.

Prior to prolonged standstills, set the battery main switch to position 0 (off).

To ensure that the batteries work properly at all times, keep them clean.

Regularly clean the pole heads and cable terminals A and protect them with a thick layer of acid-proof grease, (see Fig. 5-39).

Danger Kinked rubber hoses of the central gas release system lead to a higher risk of explosion!

The hydrogen produced in the battery may not collect in the battery box and must be released from the enclosure through the rubber hoses. When installing the hoses of the central gas release system, ensure that they are not kinked.

Regularly check the hoses B for damage, especially after installation of the battery, (see Fig. 5-39).

The liquid level in the cells must be about 10 to 15 mm above the upper edge of the plate. If topping up is necessary, add only distilled water.

Fig. 5-39

Battery care

From time to time, check the acid density using a battery tester C. If the battery is fully charged, the density is 1.28 kg/l (31.5° Bé).

If the battery tester shows a lower value, the battery is discharged to some degree and might need to be recharged.

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Maintenance

Operating manual

Electrical installation

5.9.4

Slip ring body (option)

Fig. 5-40

Slip ring body

Slip ring bodies are easily damaged by humidity, as oxide layers might form on the conducting surfaces, impairing electrical conductivity. As a consequence, the electrical consumers in the undercarriage are not sufficiently powered, which can result in malfunctions.

To prevent this, we recommend carrying out the following tasks every 500 operating hours: Unscrew the lock nuts 1.

Remove the slip ring housing 2.

Remove any oxidation from the slip ring body (use cleaning spray, if necessary).

Replace damaged (corroded) fork terminals.

Apply Cramolin contact spray to all slip ring elements.

Replace the housing 1.

Secure the housing 1 with the lock nuts 2 and tighten them all with the same torque.

5.9.5

Cabinet air pressuring system (option) Excavators operating in heavy dust conditions should be equipped with a cabinet air pressuring system. This system create an over pressure in the cabinet, so no dust can penetrate inside.

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Operating manual

Maintenance Heating and air-conditioning system

Filter maintenance Follows the instructions indicated on cover 4.

Filter removing Motor stopped.

Remove the cover 4.

Remove the main element 2 with caution.

Remove the safety element 3 with caution.

Filter assembling Insert with caution the safety element 3.

Insert with caution the main element 2.

Reinstall the cover 4.

5.10 Heating and air-conditioning system The machine is equipped with a combined heating and a/c system as standard.

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Maintenance

Operating manual

Heating and air-conditioning system

5.10.1

Recirculated and ambient air filters

Fig. 5-41

Recirculated air filter

Fig. 5-42

Ambient air filter

If the filters are dirty, the air supply to the heating and a/c system is obstructed, which can result in more frequent icing and shutdown of the system. d ambient air filters 1 and 3 of the heating and a/c system must be removed and cleaned every 500 operating hours. shortened. exchanger 6 could otherwise be quickly blocked (see Fig. 5-43).

Cleaning or replacing recirculated and ambient air filters: To remove the ambient air filter 1, tilt the backrest of the operator seat forward.

Open the quick fasteners 2 by turning them by 90 degrees and remove the recirculated air filter 1.

To remove the recirculated air filter 3, remove the deflector 4.

Remove the ambient air filter 3.

Note!

Never clean the filter cartridges with hot water or steam!

If the filter cartridges are damaged or in poor state, replace them.

To clean the filter cartridges 1 and 3, blow them out with compressed air or wash them in cold or lukewarm water.

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Operating manual

Maintenance Heating and air-conditioning system

5.10.2

Heating system Every year at the start of the heating period, perform the following maintenance routine. ant circuit, the hose connections at the heat exchanger, the seals of the stop valves and the hose clamps. and air-conditioning system" in chapter 3).

Fig. 5-43

Heating unit and solenoid valve

Bleeding heating system: Through the heating unit: To bleed the system, unscrew the red cap of the bleeder valve at opening A. Press in the valve to let the air escape.

Through the air vent 21:

Air bubbles must be released manually through the bleeder valve 23, using the bleeder key 22.

Screw in the bleeder valve 23.

Draining the heater fluid: Unscrew the heater fluid plug 55 with adjustable pliers.

Screw again the heater fluid plug befor refill the circuit.

Cleaning solenoid valve 5: Every year, at the start of the heating period, dismantle and clean the solenoid valve 5 (Y46) of the hot water supply.

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Maintenance

Operating manual

Heating and air-conditioning system

If the heating output is poor, also clean the solenoid valve.

Rinse the solenoid valve diaphragm with water.

Ensure that the compensation hole of the diaphragm is not blocked by dirt.

Inspecting heat exchanger: Every 12 months, inspect the fins of the heat exchanger 6 for damage.

If they are dirty, clean them with compressed air.

If necessary, realign the fins.

5.10.3

Air-conditioning system Switch on the a/c system every 2 to 3 weeks for about 10 minutes, irrespective of the season.

During the operating period of the a/c system, the following maintenance tasks must be completed every 500 operating hours: Inspecting condenser:

Fig. 5-44 2 3

A/c condenser

Condenser Mounting bolts

6 7

Mounting bolts Clamp

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Operating manual

Maintenance Heating and air-conditioning system

4

Washer

8

Sleeve

5

Hex nut

10

Compressor

Inspect the condenser 2 for dirt.

If necessary, fold the condenser 2 down and clean it from the inside (blower side), using compressed air.

Ensure that the condenser fins are clean.

Dirt on the condenser might lead to excessive pressure in the coolant circuit, so that the air-conditioning system is automatically switched off.

Inspecting a/c compressor:

Fig. 5-45

A/c compressor

10

A/c compressor

12

Hex nut

11

Washer

15

Metal-rubber buffer

Tighten the hex nut 12 of the a/c compressor (24 Nm / 17 ft.lbs).

Maintenance of a/c compressor: Regularly inspect the unit according to the applicable regulations and standards: Check the following:

Check coolant circuit (assembly) and its parts for leakage. following: Oil level 1/4 to 3/4 of sight glass height S (see Fig. 5-45) (repeat check several times during the first few operating hours). erating manual KB-100-5 of Bitzer.

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Maintenance

Operating manual

Heating and air-conditioning system

Inspecting dryer-collector unit:

Fig. 5-46

Dryer-collector unit

While the motor is running, switch on the air-conditioning system and inspect the level of refrigerant in the sight glass 10 of the dryer-collector unit 9.

Note!

If there is insufficient refrigerant in the system, the white floating ball 11 is visible at the bottom of the sight glass.

In the event of insufficient cooling output, have the system refilled by a refrigeration technician.

Determine the water content of the desiccant in the dryer-collector unit 9.

Observe the colour of the indicator bead 12 in the sight glass.

If the bead is orange, the water content in the circuit is within the permitted range. A transparent bead indicates that the dryer-collector unit is saturated with water.

Immediately replace the dryer-collector unit 9.

Visually inspect the dryer-collector unit 9.

If the dryer-collector unit 9 shows signs of corrosion or damage (e.g. at the console fixtures, hose connection), replace the dryer-collector unit 9 (pressure vessel).

In the event of rust or damage, have the dryer-collector unit 9 replaced and filled with fresh refrigerant by a technician trained in the field of refrigeration.

For this purpose, the cooling circuit must be emptied, checked for leakage and refilled. Inspect the hose lines for chafe marks and replace any damaged hoses.

Retighten the hose connections.

Additional maintenance tasks:

Fig. 5-47

Blower motor of the heating and air-conditioning unit

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Operating manual

Maintenance Greasing the machine

The following maintenance tasks must be carried out at least once every 12 months by a technician who is trained in refrigeration technology: Functional test of the blower motor 13 (M13) Functional test of the air flaps in the heating and air-conditioning system Inspection of the electrical connections for proper contact Inspection of the electrical lines for chafe marks Inspection of the defrost thermostat 14 (B43) in the evaporator (functional test, proper fit and damage) Functional test of the pressure switch B44 at the dryer-collector unit 9, (see Fig. 5-46)

5.11 Greasing the machine 5.11.1

The centralized lubrication system With this system all or nearly all of the lube points of the machine which require at least daily lubrication are lubricated via an electrical driven grease pump which is turned on during machine operation.

This grease pump is mounted in the area behind the driver's cab.

Construction and operation of the centralized lubrication system .

The grease delivered by the pump U4 is distributed to the different lubrication points LP in metered quantities, first via the main distributor 2 and further via the secondary distributors 3, 4, 5, ... mounted to the front of the upper carriage and to the working attachment.

The lubrication unit complete U4 mainly consists of a transparent grease container 13, and an electric motor 14 driving a lube pump 15.

Fig. 5-48 2 4

Centralized lubrication system

Main distributor Sercondary distributor

3 13

Sercondary distributor Grease container

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Maintenance

Operating manual

Greasing the machine

14

Electric motor

15

Grease pump

U4

Lubrication pump complete

LP

Lubrication points

During a lubricating procedure, all of the lube points LP connected to the system are lubricated one after the other in a predetermined sequence (progressive system).

The flow sequence and amount of lubricant for each lubrication point depend on the combination of the distributors and lubrication lines and on the piston sizes of the different distribution elements.

Lube points connected to the central lubrication system:

reserves for the swing ring teeth lubrication, ints of standard working attachments.

Lube points which are not connected to the central lubrication system: Caution!

When operating a machine and especially if it is fitted with a special working attachment, make sure to lubricate daily all the lubrication points which may be installed separately, i. e. which are not connected to the central lubrication system.

in the area of the connector bracket and shifting lever for the digging tool. k, hydraulic offset boom, ...) some bearing points at the attachment or at the working tool are possibly not connected to the central lubrication system.

This bearing points have to be lubricated daily via separately mounted, red marked lubricating nipples and using a grease gun or a manual grease pump.

Note!

The standard undercarriages of crawler excavators do not require daily lubrication.

On undercarriages with special design necessitating regular lubrication (undercarriages with adjustable track width, ...) the lubrication points are not connected to the centralized lubrication. For description of the corresponding lubrication works, see the subgroups related to the special maintenance for these undercarriages.

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Operating manual

Maintenance Greasing the machine

5.11.2

Semi automatic and full automatic systems

Fig. 5-49

Semi automatic system

Full automatic system 16

The serially installed lubrication pump must be turned on and off via a switch in the cab by the operator (half automatic system) The lube pump is without control unit.

5.11.3

Integrated control unit

The electric motor of the optional mounted full automatic system comprises an electronic control unit 16, which triggers the lubrication cycles on and off during the operation of the machine.

Operation of the semi automatic system pump is controlled by the push button S84 on the rear control desk of the driver's cab.

With the engine running, Depress the button S84.

The control light in the button lights up.

The lubrication procedure is started.

Fig. 5-50

Centralized lubrication

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Maintenance

Operating manual

Greasing the machine

Keep the lube pump running until clean grease runs out of the bearing points boom cylinders to upper carriage, then depress the button S84 again.

The control light in the button turns off and the lubrication procedure is stopped Note!

The time necessary for the lubrication is dependent on the grease viscosity and temperature and on the design and number of connected components. At very low temperatures up to 30 minutes may be necessary for sufficient lubrication.

During lubrication, the delivery of grease can be checked visually while observing, through the transparent cap 27.2 of the stroke controller 27 mounted to the top of the main distributor 2, that the indicator stem 27.1 moves alternately in and out.

Lubrication intervals. daily.

If the machine is used under hard conditions (working under water, in very abrasive t service, it is necessary to lubricate more often (up to once a working shift or every 4 hours).

5.11.4

Operation of the full automatic system Function of the lubrication system After turning on the excavator the control light inside the touch S84 and the green LED 17 of the integrated control unit 16 light up for approx. 1,5 sec. to show that the electric pump is operative. .A lubrication procedure will begin automatically after a "cycle time" is over and stop after all points have been lubricated, this without any action by the operator.

During a lubricating procedure, all lube points are lubricated one after the other in a certain sequence (progressive system).

After completion of a lubrication procedure, the pump is turned off by a proximity switch B51 mounted to a distribution element of the main distributor 2.

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Operating manual

Maintenance Greasing the machine

Fig. 5-51

Full automatic lubrication system

2 13

Main distributor Grease container

14

Electric motor

15 17

Grease pump LED green - in operation

16 18

Electronic control unit LED red - failure

19 B51

Touch - additional lubrication Proximity switch

26

Pressure relief valve

S84

Push button - additional lubrication

U4

Lubrication pump complete

At each stroke of a piston in this element, the switch B51 gives a pulse signal to the control unit 16, which stops the lubricating procedure as soon as the preadjusted number of strokes has been reached.

Starting an additional lubrication procedure If the lubrication system is in working order, an additional lubricating procedure of the lube unit can be started any time by depressing either the push button S84 on the rear control desk or the touch 19 on the motor housing.

Monitoring of the automatic lubrication system During a lubrication procedure of the lubrication unit 2, the control light inside the push button S84 and the green LED 17 are on continuously.

In case of a failure in the lube circuit (no stroke signal delivered by the proximity switch B51 about 20 minutes after begin of a lubrication procedure) both LEDs 17 and 18 and the control light inside S84 will start blinking simultaneously.

The possible causes are: n this case the grease will flow out of the relief valve 26), B51 or of its connecting wire, at very low temperatures,

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Maintenance

Operating manual

Greasing the machine

13, ical circuit for the motor 14.

Immediately locate and remedy the cause of the trouble.

5.11.5

Emergency lubrication with defective lubrication system In case the lubrication pump 15 does not work, all lubrication points connected to the centralized system may be lubricated via the lube fitting 25 using a lubrication gun.

In this case, press daily or per working shift approx. 200 cm3 grease into the fitting 25.

Fig. 5-52 15

5.11.6

Emergency lubrication

Grease pump

25

Emergency lube fitting

To refill a grease container The grease level in the container 13 of the pump must be checked weekly, and if necessary, the container refilled.

See the lubricant chart for grease specification.

The refilling of the grease container should only be done via the special fitting 21.

Note!

Avoid refilling the container 13 via the upper cover 23, since it could create an air pocket in the container and cause the pump 15 to run dry.

Insert a grease cartridge in the special filling pump 31 (Id. No. 10009239). connect the pump to the fitting 21. push the whole content of the cartridge into the container 13.

For indication of ordering number of grease cartridges, refer to subgroup "lubricants specifications".

If the special filling pump 31 or the grease cartridges are not available, refill the container 13 through the grease fitting 22, using a grease gun.

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Operating manual

Maintenance Greasing the machine

Fig. 5-53

5.11.7

Refilling the grease container

13 21

Grease container Fitting for filling pump

15 22

Grease pump Grease fitting

23

Cover

31

Filling pump

Changes in the lubrication circuit Before you make any changes to the lubrication system (for example when changing the attachment configuration), always check with a LIEBHERR mechanic first.

Never remove a line and close off an outlet, which is not being used, or the whole lubrication system would be blocked.

Only plug an outlet after the line has been removed from the distributor and the necessary changes have been achieved at the corresponding distribution elements.

This applies as well for main distributor 4 as for secondary distributors 5.

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Maintenance

Operating manual

Greasing the machine

Fig. 5-54

5.11.8

Main and secondary distributor

Greasing the grab (optional extra) The grab is not lubricated via the central greasing system. It must be regularly greased manually. The relevant oiling points are marked in red.

Fig. 5-55

Greasing the grab

In normal use, each oiling point must be greased daily or per shift until clean grease flows out at the relevant bearing point.

When the machine is working hard, the greasing interval should be shortened accordingly.

Grease quality: see lubrication chart

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Operating manual

Maintenance Quick-change systems

5.12 Quick-change systems 5.12.1

Greasing the mechanical quick-change adapter (option) The mechanical quick-change adapter is not lubricated via the central greasing system. The bearing points must be greased using the grease gun.

Fig. 5-56

Greasing the mechanical quick-change adapter

Grease the bearing points via the lubricating nipple using a grease gun.

Note!

If the mechanical quick-change adapter is greased when the pin is drawn out, the hollow area between the locking pins fills with grease and the pins can no longer be reinserted.

Ensure that the locking pins are inserted when greasing.

5.12.2

Hydraulic quick-change adapter (option) Greasing the quick-change adapter The hydraulic quick-change adapter is not lubricated via the central greasing system.

The bearing points must be greased using the grease gun.

Fig. 5-57

Greasing the quick-change adapter

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Maintenance

Operating manual

Quick-change systems

Grease the locking pins 1 via the lubricating nipple using a grease gun.

Note!

The hydraulic quick-change adapter cannot be sufficiently greased if the locking pins are drawn out.

Ensure that the locking pins are inserted when greasing.

Cleaning the sieve filter

Fig. 5-58

Cleaning the sieve filter

The filter disc 12 in the bolt connections between the connecting hoses and the hydraulic cylinder must be checked for blockages and, if necessary, cleaned every 2000 operating hours.

Remove the cover 20 and the screws 21 from the quick-change adapter.

Remove bolt connections and hydraulic hoses from the hydraulic cylinder 10.

Screw out the outer mounting assembly 13 using a suitable tool (e g. a scribe).

Remove the filter disc 12, check and if necessary clean or replace it.

Place the filter disc 12 on the inner mounting assembly 11 and mount the outer mounting assembly 13.

Connect bolt connections and hydraulic hoses to hydraulic cylinder 10.

Fasten the cover 20 with the screws 21 on the quick-change adapter.

5.12.3

LIKUFIX (option) Cleaning LIKUFIX The LIKUFIX hydraulic coupling system is mostly maintenance-free.

It is recommended that the system is cleaned at regular intervals and sprayed with lubricating varnish (see Workshop manual). This will prevent dirt adhering and icing up.

If the system is kept properly clean, the seals are very durable.

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Operating manual

Maintenance Check mounting bolts for tightness

Replacing the sealing ring

Fig. 5-59

Replacing the sealing ring

If leaks occur at the coupler plugs (A , see arrows), the sealing rings should be replaced.

Use a screwdriver to push down the sealing washer and lever out the defective sealing ring using a pointed object (B).

Press the new sealing ring together and place it on the sealing washer with the open side down (C).

Press down the washer as far as the groove, place the screwdriver in the middle of the sealing ring and move your hand away (D).

Allow the sealing ring to jump into the groove (E).

Remove the screwdriver (F).

The sealing washer must move upwards. If necessary, press the sealingring again until the sealing washer is flexible.

5.13 Check mounting bolts for tightness The mounting bolts listed below must be regularly checked and retighten if necessary. See maintenance chart for the checks intervals.

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Maintenance

Operating manual

Check mounting bolts for tightness

Caution!

The mounting bolts for all the main components (especially those listed below), and for the hydraulic hoses and pipes must be replaced after every removal.

Notice : when installing bolts of size bigger than M40 the thread of the screw must be slightly coated with a MoS2 based grease. For these bolt sizes also grease the supporting surface of the bolt head, unless hereafter otherwise specified.

5.13.1

Mounting bolts of the counterweight

Fig. 5-60

Counterweight mounting bolts

The mounting bolts 1 (M30 - 10.9) must be torqued to 1900 Nm (1400 ft.lbs).

5.13.2

Mounting screws of the swing ring

Fig. 5-61

Swing ring mounting bolts

The mounting screws 3 (M27 - 10.9) swing ring to undercarriage must be torqued to 1400 Nm (1030 ft.lbs.).

The mounting screws 4 (M27 - 10.9) swing ring to uppercarriage must be torqued to 1400 Nm (1030 ft.lbs.).

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Operating manual

Maintenance Check mounting bolts for tightness

5.13.3

Mounting screws of the hydraulic oil and fuel tank

Fig. 5-62

Hydraulic oil tank and fuel tank mounting bolts

The mounting screws 5 (M20 - 10.9) must be torqued to 560 Nm (410 ft.lbs.)

5.13.4

Mounting screws of the swing gear and motor

Fig. 5-63

Swing gear and swing motor mounting bolts

The mounting bolts 6 (M20 - 10.9) of the swing gear must be torqued to 560 Nm (410 ft.lbs).

Torque mounting bolts 7 (M20 - 10.9) of the swing motor to 560 Nm (410 ft.lbs).

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Maintenance

Operating manual

Drive unit brakes and swing gear brakes

5.13.5

Fixing bolts of catwalks around the upperstructure Every week visually check, and if necessary retighten the mounting bolts of the railer and also the ladder and suspended platform fixed around the upperstructure.

Perform a general check of the tightening torque of these bolts every 1000 working hours. The bolts must be torqued to the following value: Mounting bolts

Tightening torques

Dimension

Class

[ Nm ]

[ ft.lbs ]

M5

10,9

8,1

6

M6

10,9

14

10

M8

10,9

34

25

M10

10,9

68

50

M12

10,9

117

86

M16

10,9

280

206

M20

10,9

560

412

Tab. 5-16 Tightening torques of catwalks mounting bolts

5.14 Drive unit brakes and swing gear brakes Both the drive unit brakes and the swing gear brakes are spring-applied, pressurereleased multi-plate brakes. They are ventilated hydraulically and are fully sealed and integrated in the travel gear or swing gear transmission.

Their usage purely as parking brakes makes them wear-free and therefore maintenance free.

5.15 General maintenance points 5.15.1

Replacing working parts In addition to the normal maintenance and repair work that is to be carried out at the given intervals, the machine operator and maintenance personnel can also carry out the repairs referred to below: ling material on the pipe and hose system and on the hydraulic unit connections (not, however, on pressure relief valves which are lead sealed at the works). hydraulic system can be replaced.

It should be noted that only original LIEBHERR replacement parts are to be used.

This is particularly relevant for hoses and hydraulic lines, which must be preassembled at the works. For all other repairs, particularly when dismounting the ballast weight, works and dealership fitters are to be consulted.

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Operating manual

Maintenance General maintenance points

5.15.2

Checking or replacing the teeth on the bucket Note!

Do not work with the machine if teeth on the bucket are missing or are heavily worn.

With heavily worn teeth, considerably greater force will be required when using the bucket to penetrate the material to be excavated.

Determine the degree of wear of the teeth visually and at regular intervals (For intervall, refer to the maintenance chart).

Make the necessary to have heavily worn teeth replaced in good time, in any case early enough to prevent any damage occurring to the tooth fitting piece.

To attach and dismount the teeth: Liebherr teeth system with flat locking wedge:

Fig. 5-64

Replacing the teeth

Use a hammer and ejector drift 1 to knock out the wedge 2 (A ).

Remove the old tooth.

Place a new rubber wedge holder 3 onto the tooth holder (B).

Push the new tooth onto the fitting piece.

Use the hammer to knock in the wedge 2 (C).

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Maintenance

Operating manual

General maintenance points

(New) Liebherr teeth system with tooth locking bolt round: To remove an old tooth

1 3

Tooth fitting Tooth locking bolt

2 4

Tooth Latch

5

Expanded foam plug

10

Bolt blocking wrench

Take away the expanded foam plug 5 or the ground out of the square hole in the middle of the locking bolt 3.

Set the bolt blocking wrench 10 (special tool Id. Nb. 10451202) onto the bolt 3 and turn counterclockwise to the stop (movement A - turn by approx. 30°).

Knock out the bolt 3 from the opposite side.

Take the tooth 2 off from the fitting 1 and remove the latching piece 4.

To install a new tooth

Note!

Check the tooth locking bolt 3 and the latch 4 for good condition before reuse when installing a new tooth. Should this parts be distorted or strongly corroded, so they must be replaced by new ones.

Set the latch 4 in the hollow part of the tooth fitting 1 so that the flat side of the latch pushes against the fitting and slide the new tooth 2 over the tooth fitting 1.

Push the tooth locking bolt 3 all the way in.

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Operating manual

Maintenance Inspection and maintenance schedule

Engage the bolt blocking wrench 10 into the square hollow in the middle of the bolt 3 and lock the bolt by turning the wrench clockwise by approx. 30° (when turning, the nose 3a of the bolt is enforced over the protrusion 4a of the latch).

Take the blocking wrench away and press a new expanded foam plug 5 into the middle of the locking bolt 3.

5.15.3

Welding work on the machine Welding work on all main components or structural parts serving the power transmission (such as the undercarriage, uppercarriage, attachment parts etc.) may only be carried out by the manufacturer or by an authorized workshop.

Open the main isolator (outside the machine) before starting any electric arc welding work on the machine.

Switch off the main battery switch (option) and disconnect the batteries. Always disconnect the negative terminal (-) first and reconnect it last.

Caution!

If high currents flow through the bearings or sealing elements, these could be damaged.

Move the earthing cable of the welding tool as close as possible to the welding surface so that the welding current cannot flow over parts like the swing ring, articulations, bearings, bushings, rubber elements or seals.

5.16 Inspection and maintenance schedule Caution!

Careful maintenance is only possible, if the machine is clean. Especially visual inspections, e.g. for cracks, can only be carried out properly on a clean machine.

Therefore clean the machine thoroughly before starting any maintenance work (see also chapter "Safe maintenance of machine", subchapters "Cleaning" and "Crack inspection").

Note The daily maintenance tasks of the machine operator include a functional test of the brakes and the electrical and hydraulic system.

Also to be carried out is a daily visual inspection of the motor, hydraulic system, gearboxes and drive system.

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Maintenance

Operating manual

Inspection and maintenance schedule

Maintenance/ inspection at operating hours

WORK TO BE CARRIED OUT EP 944C by maintenance personnel (machine owner)

by authorised specialist technician

Initial and single interval Repeat interval Special interval: every 250 hours

Note

Initial and single interval Repeat interval

ELECTRIC MOTOR AND PUMP DISTRIBUTOR GEAR Check the terminal box cleanliness.

Inspect and clean the fan hood and the cooling fins of the electric motor.

Lubricate the motor bearings (the lubrication interval and the quantity and quality of the lubricating grease are specified on the type plates, approx. 5400 operating hours / 2 years) (to be carried out by authorised specialist technician).

Check the oil level in the pump distributor gear.

Inspect and clean the radiator and fan.

Replace the oil in the pump distributor gear.

Check the sensor devices and cable connections.

Check the motor brackets and the pump distributor gear for proper attachment.

HYDRAULIC SYSTEM Check the oil level in the hydraulic tank.

Clean the magnetic rod in the return filter (daily during first 300 operating hours).

Replace the filter cartridge in the control oil unit.

Replace the feed oil filter on the slewing gear pump.

Check the components and units for proper fixture.

Inspect and clean the hydraulic oil cooler and the fan.

1)

Dewater the hydraulic tank (max. permissible water content for environmentally friendly fluids: 0.1 %; use bypass filter, take oil sample).

If installed, check the hammer return filter for contamination and replace it.

1)

Replace the return filter cartridge (first time after 500 operating hours).

Replace the leak oil filter cartridge (first time after 500 operating hours).

Replace the cartridge latest after 3 cleaning processes.

1)

Check the degree of contamination of the bypass oil filter (optional equipment); if required, change the filter cartridge.

Check the hydraulic system for leakage; complete a functional test.

Check / readjust the servo, primary and secondary pressures.

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Operating manual

Maintenance Inspection and maintenance schedule

Maintenance/ inspection at operating hours

WORK TO BE CARRIED OUT EP 944C by maintenance personnel (machine owner)

by authorised specialist technician

Initial and single interval Repeat interval Special interval: every 250 hours

Note

Initial and single interval Repeat interval

If required, change the oil in the hydraulic system (to be carried out by specialist technical personnel; add oil through filter). For oil grades and change intervals, see fuels and lubricants, "Hydraulic oil".

Bleed the hydraulic pumps (after hydraulic oil change).

Replace the breather filter on the hydraulic tank.

1)

ELECTRICAL SYSTEM Check the indicator lights and the indicating devices upon start-up.

Check the lighting system.

Check the clogging of the air filter from the electrical cabinet (option).

Empty the dust extraction valve of the air filter from the electrical cabinet (shorten or extend the interval, if necessary) (option).

Replace the main element of the air filter from the electrical cabinet (according to maintenance indicator, at least 1x per year) (option).

Replace the safety element of the air filter from the electrical cabinet (at every 3rd change of the main element / at least 1x per year) (option).

Do not clean it!

Check the cleanness of the motor air line (during maintenance of the filter).

Check the acid density and level in the battery cells (option).

Check and clean the wire terminals and pole heads of the batteries (option).

Check the central vent tubes of the batteries for proper installation and damage (option).

Check the mounting bolts of the rotary connection and the driver for proper fixture.

Clean the rotary connection.

Carry out a visual inspection of the carbon brushes for wear.

Remove the condensate from the inside surfaces.

Check the ring sliding faces for surface damage.

Carry out functional tests of the entire system and all components.

Inspect the electrical box hinges, lubricate or replace them.

Carry out functional tests of the automatic cut-outs.

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Maintenance

Operating manual

Inspection and maintenance schedule

Maintenance/ inspection at operating hours

WORK TO BE CARRIED OUT EP 944C by maintenance personnel (machine owner)

by authorised specialist technician

Initial and single interval Repeat interval Special interval: every 250 hours

Note

Initial and single interval Repeat interval

SLEWING GEAR TRANSMISSION Check oil level and tightness Replace oil (first time at 500 operating hours) Check function and operation of slewing gear brake Check swing gear transmission and hydraulic motor mounts SLEWING RING Check the mounting bolts for proper fixture.

Check the engagement of the slewing gear pinion.

TRAVEL GEAR Check oil level and tightness Check travel gear transmission and hydraulic motor mounts Replace oil (at least every 2 years). Replace oil every 1000 op. hours with dust intensive application or a travelling proportion greater than 20%.

TRACKS Visual check on track tension, retension if necessary Clean track (when work is finished) Check mounts on track pads and sprockets Clean and grease sliding surfaces of tensioning device Check for leaks on idlers, carrier rollers and track rollers OPERATOR'S CAB Check / add detergent solution to the windscreen washer system tank.

Check the door hinges, window hinges and locks.

HEATING SYSTEM Carry out a functional test of the heating system (before start of winter season).

Check the heating system for leakage.

Check / add the heater fluid level.

Check the corrosion inhibitor and antifreeze agent concentration in the heater fluid and adjust it, if necessary.

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EP 944C / 10360388

Operating manual

Maintenance Inspection and maintenance schedule

Maintenance/ inspection at operating hours

WORK TO BE CARRIED OUT EP 944C by maintenance personnel (machine owner)

by authorised specialist technician

Initial and single interval Repeat interval Special interval: every 250 hours

Note

Initial and single interval Repeat interval

Change the corrosion inhibitor and antifreeze agent (every 3000 operating hours or latest every 2 years) (to be carried out by an authorised specialist technician).

Check the water inlet valve for dirt, and clean it, if necessary; carry out a functional test of the valve.

Bleed the Flamco vent.

Change the water of the heating system AIR-CONDITIONING SYSTEM Regularly switch on the air-conditioning system (at least 1 x every 14 days).

Check the condenser for dirt; blow it clean, if necessary.

Clean the recirculated air / fresh air filter; replace it, if necessary; shorten the interval, if there is excessive generation of dust.

Check the mounting bolts of the compressor for proper fixture.

Check the dryer-collector unit (humidity, fill level, damage); replace it, if necessary.

Check the evaporator unit; clean it, if necessary.

Check the electrical lines for chafe marks; check the plug connections for proper fixture.

Perform a functional test of the overpressure switch.

Check the cooling performance after opening/repair, or if required.

Replace the dryer-collector unit every 12 months; also check the cooling circuit for leakage and change the heaterfluid and refrigeration oil.

Every 12 months, contract a refrigeration technician to carry out a functional test of the air flaps, the pressure switches and the defrost thermostat.

UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENT Lubricate the bearing points (undercarriage and attachments) through the lubrication system or directly at the bearing points (for points that are not integrated into the lubrication system).

Inspect the teeth visually for wear.

Check the parts for cracks.

Check the counterweight and the tank for proper fixture.

Check the lines and fittings for proper fixture.

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MJFCIFSS

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Maintenance

Operating manual

Inspection and maintenance schedule

Maintenance/ inspection at operating hours

WORK TO BE CARRIED OUT EP 944C by maintenance personnel (machine owner)

by authorised specialist technician

Initial and single interval Repeat interval Special interval: every 250 hours

Note

Initial and single interval Repeat interval

Inspect the panelling hinges, quick fasteners and gas pressure springs of the hoods; if necessary, lubricate or replace them.

Check the lowering speed of the attachment.

~ 4 sec.

Instruct the operators in the proper use of the machine.

Instruct the operator on how the machine must be lubricated according to the lubricating chart and make him aware of potential operator errors.

HYDRAULIC QUICK CHANGE ADAPTER Perform a functional check of the visual and acoustic warning systems.

Carry out a visual inspection of the extended lock bolts.

Check the hydraulic hoses and the wire harness for damage.

Lubricate the lock bolts.

Clean the mesh filters inside the fittings of the hydraulic hoses.

MECHANICAL QUICK CHANGE ADAPTER Carry out a visual inspection of the extended lock bolts.

Lubricate the lock bolts.

1) The maintenance intervals might have to be shortened, depending on the actual operating conditions (e.g. generation of dust, barrel fuelling).

Tab. 5-17 Maintenance chart

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MJFCIFSS

EP 944C / 10360388