Liebherr Hydraulic A 904 C-Litronic Operating manual 25567 - PDF DOWNLOAD

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Operating instructions Hydraulic excavator A 904 C-Litronic from serial number 25567

Document identification Id. number:

8720337

Edition:

08 / 2005

Valid for:

A 904 C-Litronic from serial number 25567

Author:

LHB - Technical documentation department

Product identification Manufacturer:

LIEBHERR Hydraulikbagger GmbH

Type:

A 904 C-Litronic

Type no.:

439 / 441

Conformity:

CE

Address Liebherr Hydraulikbagger GmbH Liebherr-Straße 12 88457 Kirchdorf / Iller, Germany

Operating instructions

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

This will also be helpful when ordering spare parts.

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

Year of manufacture: . . . .

Delivery date: . . / . . / . .

MJFCIFSS

A 904 C-Litronic / 8720337

Foreword

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

It contains: regulations.

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

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

Service, including maintenance, inspection and repair work.

Transportationor loading of the machine.

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

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

The operating manual is part of the machine. Place a copy in the document compartment in the cab for easy access.

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

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

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

Operating instructions

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

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

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

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

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

1-2

MJFCIFSS

al business conditions will

A 904 C-Litronic / 8720337

Operating instructions

Table of contents 1

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

1.2 2

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

2.4

2.5 3

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

Symbols in the operating instructions .................................................................................................... 2-1 Use in accordance with the regulations ................................................................................................. 2-2 Safety instructions ................................................................................................................................. 2-2 2.3.1 General Safety instructions ...................................................................................................... 2-2 2.3.2 Crushing and burn prevention .................................................................................................. 2-3 2.3.3 Fire and explosion prevention .................................................................................................. 2-4 Signs on the machine ............................................................................................................................ 2-4 2.4.1 Introduction............................................................................................................................... 2-4 2.4.2 Arrangement of signs ............................................................................................................... 2-5 2.4.3 Explanation of signs ................................................................................................................. 2-6 2.4.4 Arrangement of different signs (American version) ................................................................ 2-10 2.4.5 Explanation of the different signs (American version) ............................................................ 2-11 Identification tags on the machine ....................................................................................................... 2-13

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

3.2

3.3

Operating and control elements............................................................................................................. 3-1 .. 3-1 3.1.2 Arrangement of joysticks .......................................................................................................... 3-3 3.1.3 Keypad ..................................................................................................................................... 3-4 3.1.4 Monitoring screen..................................................................................................................... 3-9 3.1.5 Main screen ............................................................................................................................ 3-12 Operation ............................................................................................................................................. 3-27 3-27 3.2.2 Safety lever ............................................................................................................................ 3-28 ............ 3-29 3.2.4 Adjusting the steering column ................................................................................................ 3-33 3.2.5 Front windshield ..................................................................................................................... 3-34 3.2.6 Sun visor ................................................................................................................................ 3-34 dow ............................................................................................... 3-35 3.2.8 Interior illumination ................................................................................................................. 3-35 3.2.9 Fire extinguisher (option)* ...................................................................................................... 3-36 3.2.10 Windshield wiper .................................................................................................................... 3-36 3.2.11 Lighting................................................................................................................................... 3-38 3.2.12 Heating and Air conditioning system ...................................................................................... 3-39 Operation ............................................................................................................................................. 3-45 3.3.1 Safety instructions .................................................................................................................. 3-45 3.3.2 Starting / shutting down the machine ..................................................................................... 3-47 3.3.3 Starting aids ........................................................................................................................... 3-53 3.3.4 Jump start procedure ............................................................................................................. 3-55 3.3.5 Emergency operations ........................................................................................................... 3-55 3.3.6 Travel operation ..................................................................................................................... 3-58 3.3.7 Travel warning device (option) ............................................................................................... 3-60 3.3.8 Drive deactivation (optional extra).......................................................................................... 3-60 3.3.9 Travelling on public roads ...................................................................................................... 3-61 3.3.10 Towing the machine ............................................................................................................... 3-63 3.3.11 Oscillating axle lock ................................................................................................................ 3-66

A 904 C-Litronic / 8720337

MJFCIFSS

Operating instructions

3.4

3.5

3.6

3.7

4

3.3.12 Support ................................................................................................................................... 3-67 Working with the machine.................................................................................................................... 3-69 3.4.1 Working with the machine safely ............................................................................................ 3-69 3.4.2 Sensor controlled low idle automatic ...................................................................................... 3-73 3.4.3 Operating the swing gear ....................................................................................................... 3-74 3.4.4 Locking the uppercarriage ...................................................................................................... 3-76 3.4.5 Working position ..................................................................................................................... 3-76 3.4.6 Operating the working attachment.......................................................................................... 3-77 3.4.7 Lowering the attachment when the engine is not running ...................................................... 3-80 3.4.8 Operate the adjustable boom cylinder .................................................................................... 3-80 3.4.9 Adjusting the boom to side (option) ........................................................................................ 3-81 3.4.10 Operate the attachment.......................................................................................................... 3-82 3.4.11 Change over of controls (option) ............................................................................................ 3-84 3.4.12 Turning, rotating, locking and unlocking the attachments ...................................................... 3-85 3.4.13 Magnet system (option) ......................................................................................................... 3-86 Installation and removal of attachment parts ....................................................................................... 3-87 3.5.1 Safe installation and removal of attachment parts.................................................................. 3-87 3.5.2 Safe removal and installation of attachment pins ................................................................... 3-87 3.5.3 Installation and removal of digging tool .................................................................................. 3-88 3.5.4 Installation and removal of grapple on stick ........................................................................... 3-90 3.5.5 Mechanical quick change adapter (option) ............................................................................. 3-92 3.5.6 Hydraulic quick change adapter (option) ................................................................................ 3-97 3.5.7 LIKUFIX Hydraulic coupling system (option) ....................................................................... 3-103 General working methods .................................................................................................................. 3-105 3.6.1 Guidelines for minimum impact working methods ................................................................ 3-105 3.6.2 Preparatory activities ............................................................................................................ 3-106 3.6.3 Working with the backhoe bucket ......................................................................................... 3-107 3.6.4 Loading the transport vehicle ............................................................................................... 3-108 3.6.5 Working with the hydraulic hammer...................................................................................... 3-108 3.6.6 Grading ................................................................................................................................. 3-110 3.6.7 Working with the grab ........................................................................................................... 3-111 3.6.8 Load lifting work.................................................................................................................... 3-113 3.6.9 Overload warning device ...................................................................................................... 3-114 Transport............................................................................................................................................ 3-115 3.7.1 Transporting the machine safely .......................................................................................... 3-115 3.7.2 Transporting the machine on a flatbed trailer ....................................................................... 3-116 3.7.3 Loading the machine with a crane ........................................................................................ 3-119

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

4.2

4.3

Error code charts ................................................................................................................................... 4-1 4.1.1 Sensors .................................................................................................................................... 4-2 4.1.2 Regulating circuit ...................................................................................................................... 4-2 4.1.3 Stick cylinder shut off (only with industrial or special equipment)............................................. 4-3 4.1.4 Keypad ..................................................................................................................................... 4-3 4.1.5 Display ...................................................................................................................................... 4-4 4.1.6 Coding error.............................................................................................................................. 4-4 4.1.7 Other errors .............................................................................................................................. 4-4 4.1.8 Error due to warning symbols in SY field.................................................................................. 4-5 Problems and remedies ......................................................................................................................... 4-5 4.2.1 Diesel engine and fuel system.................................................................................................. 4-5 4.2.2 Hydraulic system ...................................................................................................................... 4-6 4.2.3 Travel gear ............................................................................................................................... 4-7 4.2.4 Steering .................................................................................................................................... 4-8 4.2.5 Brakes ...................................................................................................................................... 4-8 4.2.6 Electrical system....................................................................................................................... 4-8 4.2.7 Heating and Air conditioning system ........................................................................................ 4-9 4.2.8 Work attachment ...................................................................................................................... 4-9 Fuses and relays.................................................................................................................................. 4-10

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

4.3.1 4.3.2 5

Fuse box E50 ......................................................................................................................... 4-10 ESP02 board .......................................................................................................................... 4-10

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

Maintaining the machine safely ............................................................................................................. 5-1 5.1.1 General Safety instructions ...................................................................................................... 5-1 5.1.2 Cleaning ................................................................................................................................... 5-1 5.1.3 Crack inspection ....................................................................................................................... 5-2 5.1.4 Welding .................................................................................................................................... 5-3 5.1.5 Operating and service fluids ..................................................................................................... 5-3 5.1.6 Repair ....................................................................................................................................... 5-3 5.1.7 Electrical system ...................................................................................................................... 5-4 5.1.8 Pressure accumulator .............................................................................................................. 5-4 5.1.9 Hydraulic hoses and lines ........................................................................................................ 5-5 5.2 Maintenance access doors .................................................................................................................... 5-6 5.2.1 Overview of access doors ........................................................................................................ 5-6 5.2.2 Door lock .................................................................................................................................. 5-7 5.2.3 Engine hood lock ...................................................................................................................... 5-8 5.3 Tires....................................................................................................................................................... 5-8 5.3.1 Checking the tire pressure ....................................................................................................... 5-9 5.3.2 Filling with foam...................................................................................................................... 5-10 5.4 Lubricants and operating fluids............................................................................................................ 5-10 5.4.1 General information to change lubricants and operating fluids .............................................. 5-10 5.4.2 Lubrication chart ..................................................................................................................... 5-12 5.4.3 Lubrication chart ..................................................................................................................... 5-14 5.4.4 Operating fluid chart ............................................................................................................... 5-15 5.5 Lubricant and operating fluid specifications......................................................................................... 5-15 5.5.1 Lube oil for the Diesel engine ................................................................................................. 5-15 5.5.2 Fuel ........................................................................................................................................ 5-17 5.5.3 Hydraulic oil ............................................................................................................................ 5-18 5.5.4 Gear oil................................................................................................................................... 5-21 5.5.5 Lubricating grease and other lubricants ................................................................................. 5-21 5.5.6 Coolant ................................................................................................................................... 5-22 5.6 Diesel engine ....................................................................................................................................... 5-26 5.6.1 Checking the oil level in the Diesel engine............................................................................. 5-26 5.6.2 Changing the Diesel engine oil............................................................................................... 5-26 5.6.3 V-belt for A/C compressor and alternator installation ............................................................. 5-27 5.6.4 Oil separator ........................................................................................................................... 5-28 5.7 Cooling system .................................................................................................................................... 5-29 5.7.1 Checking and cleaning the cooling system ............................................................................ 5-29 5.7.2 Checking the coolant level ..................................................................................................... 5-30 5.7.3 Coolant antifreeze and anti-corrosion fluid ............................................................................. 5-30 5.7.4 Changing water filters............................................................................................................. 5-31 5.7.5 Changing the coolant ............................................................................................................. 5-31 5.8 Fuel system ......................................................................................................................................... 5-34 5.8.1 Refuelling ............................................................................................................................... 5-34 5.8.2 Draining the water from the fuel tank ..................................................................................... 5-35 5.8.3 Emptying and cleaning the fuel tank ...................................................................................... 5-36 5.8.4 Draining and changing fuel filter cartridges ............................................................................ 5-36 5.8.5 Bleeding the fuel system ........................................................................................................ 5-37 5.9 Dry air filter .......................................................................................................................................... 5-38 5.9.1 Changing the main element ................................................................................................... 5-39 5.9.2 Changing the safety element.................................................................................................. 5-40 5.9.3 Checking the filtered air line ................................................................................................... 5-40 5.10 Hydraulic system ................................................................................................................................. 5-40 5.10.1 Preparatory activities .............................................................................................................. 5-41 5.10.2 Checking the oil level in the hydraulic tank ............................................................................ 5-41 5.10.3 Relieving the pressure in the hydraulic system ...................................................................... 5-42

A 904 C-Litronic / 8720337

MJFCIFSS

Operating instructions

5.11

5.13

5.14

5.15

5.16

5.17 5.18

5.19

5.10.4 Emptying and refilling the hydraulic tank ................................................................................ 5-43 5.10.5 Return filter ............................................................................................................................. 5-44 5.10.6 Servo oil filter .......................................................................................................................... 5-45 5.10.7 Servo circuit ............................................................................................................................ 5-46 5.10.8 Bleeding the hydraulic pump .................................................................................................. 5-46 5.10.9 Servicing the hydraulic cylinder .............................................................................................. 5-47 5.10.10 Replacing hydraulic hoses...................................................................................................... 5-48 Changing the oil on components ......................................................................................................... 5-49 5.11.1 General notes ......................................................................................................................... 5-49 5.11.2 Swin gear - oil change ............................................................................................................ 5-49 ...... 5-50 5.11.4 Steering and rigid axle - oil change ........................................................................................ 5-51 ............................................................................. 5-51 ........... 5-52 Electrical system .................................................................................................................................. 5-52 5.13.1 Notes for electrical system ..................................................................................................... 5-52 5.13.2 Battery master switch ............................................................................................................. 5-53 5.13.3 Battery care ............................................................................................................................ 5-53 5.13.4 Slip ring assembly (option) ..................................................................................................... 5-54 Heating and Air conditioning system.................................................................................................... 5-55 5.14.1 Recirculated and fresh air filter ............................................................................................... 5-55 5.14.2 Heating system ....................................................................................................................... 5-56 5.14.3 Air conditioning system........................................................................................................... 5-57 Lubricating the machine....................................................................................................................... 5-59 5.15.1 Semi-automatic central greasing system................................................................................ 5-59 5.15.2 Fully automatic central greasing system (optional extra)........................................................ 5-61 5.15.3 Lubricate king pin bearing, oscillating pin ............................................................................... 5-63 5.15.4 Central lubrication of undercarriage (option) .......................................................................... 5-63 5.15.5 Lubricating the digging tool / bucket tilt device ....................................................................... 5-63 5.15.6 Lubricating the grapple (option) .............................................................................................. 5-64 Quick change systems......................................................................................................................... 5-65 5.16.1 Lubricate the mechanical quick change adapter (option) ....................................................... 5-65 5.16.2 Hydraulic quick change adapter (option) ................................................................................ 5-65 5.16.3 LIKUFIX (option) ..................................................................................................................... 5-66 Parking and swing gear brake ............................................................................................................. 5-68 General Maintenance points ................................................................................................................ 5-69 5.18.1 Replacing wear parts .............................................................................................................. 5-69 5.18.2 Replacing the teeth on the digging tool .................................................................................. 5-69 5.18.3 Welding work on the machine ................................................................................................ 5-70 Inspection and maintenance schedule................................................................................................. 5-70

MJFCIFSS

A 904 C-Litronic / 8720337

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

1.1.1

Machine and construction equipment

Fig. 1-1

Machine and construction equipment

100 200

Uppercarriage Undercarriage

320 330

Adjusting cylinder Boom

300

Hoist cylinder

340

Stick cylinder

310

Basic boom

350

Stick

360 370

Tilt cylinder Digging tool

Product description

Operating instructions

Assembly - Overview

1.1.2

Uppercarriage

Fig. 1-2

1-2

Uppercarriage

500

Diesel engine

6220 Control panel, left

530 560

Dry air filter Radiator

6230 Control panel, right 7100 Hydraulic and fuel tank

700 Swing gear 1000 Rotary connection

7300 Hydraulic pump 7600 Control valve block

6000

8700 Operator's cab

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Product description Technical data

1.1.3

Undercarriage

Fig. 1-3 600

Undercarriage

Transmission

1000 Rotary connection 1500 Outrigger support

4000 Steering axle 4100 Rigid axle 9680 Step with toolbox

1700 Dozer blade

1.2 Technical data Please refer to the accompanying technical description.

A 904 C-Litronic / 8720337

MJFCIFSS

1-3

Product description

Operating instructions

Technical data

1-4

MJFCIFSS

A 904 C-Litronic / 8720337

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

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

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

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

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

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

Caution!

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

Note!

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

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

Safety information, signs

Operating instructions

Use in accordance with the regulations

This symbol identifies an action.

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

This symbol means "Carry out an activity".

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

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

Additional points that should be observed are:

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

quires special equipment and may also require special safety devices. These attachments (e.g. log grapple, demolition hammer, concrete cutter etc.) may only be attached and used with approval and in accordance with the basic machine manufacturer. intended use. The manufacturer is not liable for damage resulting from this action. The risk must be assumed solely by the user. and the inspection / maintenance instructions is also deemed to be appropriate and destined use in accordance with regulations.

2.3 Safety instructions 2.3.1

General Safety instructions ating instructions before starting the machine. tions relating to special accessories for the machine. perate, maintain or repair the machine.

The legal minimum age must be observed.

2-2

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Safety information, signs Safety instructions

Clearly define who is responsible for the operation or set up, maintenance and repair. Allow personnel to refuse unsafe instructions given by a third person. This also applies to traffic regulations. should only operate or work on the machine under the constant supervision and guidance of an experienced person. ically if they observe safety instructions and guidelines given in the Operating manual. wearing rings, watches, ties, scarves, open jackets or loose clothing. There is a danger of injury, as these items could get caught or be pulled in. s, safety boots, work gloves, reflective vests, ear protection etc. are required. r special safety instructions and regulations.

el or the joysticks as handholds. Inadvertent movements, which could cause accidents, should be touched off. vided to climb off or on the machine. h the emergency exit through the front window.

ground,

h the ignition key in contact position, move all servo controls (joysticks and pedals) in all directions to relieve the servo pressure and the remaining pressures in the working circuits. Then relieve the pressure in the tank, as described in this operating manual. walk around inspection. Check if all warning signs are on the machine and if they are all legible. difications on the machine, which could affect the safety, without obtaining explicit approval from the manufacturer. This also applies to the installation and adjustment of safety devices and safety valves as well as to any welding on load carrying parts.

2.3.2

Crushing and burn prevention long as it is not safely resting on the ground or properly supported.

a suitable alignment tool. fans will swirl and throw out objects, which can damage the fan.

A 904 C-Litronic / 8720337

MJFCIFSS

2-3

Safety information, signs

Operating instructions

Signs on the machine

pressure. Avoid contact with any components containing coolant. Danger of severe burns. diator cap on the expansion tank is cool enough to touch. Turn the cap carefully to relieve the pressure. ine and the hydraulic oil are hot. Do not allow your skin to come into contact with hot oil or components containing hot oil. sparks and open flames.

cured with the appropriate supports to prevent them from closing inadvertently. raised with the attachment, without being properly supported from below with hardwood beams.

2.3.3

Fire and explosion prevention

aged wires or cables must be repaired immediately by an electrician or especially trained personnel. ine except in appropriate storage tanks.

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

2.4 Signs on the machine 2.4.1

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

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

2-4

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Safety information, signs Signs on the machine

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

Danger!

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

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

Replace missing or illegible safety and information plates immediately.

2.4.2

Arrangement of signs

Fig. 2-1

Arrangement of signs on the machine

4

Identification tag

50

Warning sign Danger zone

15

Lubrication chart

52

Warning sign Engine shut-down

20

Prohibition sign

60

22

Sign Operating symbols

65

Load chart

30

Lubrication chart, engine

66

Warning sign Accident prevention, safety lever, attachments

32

Speed sign*

67

Warning sign Operating brake, parking brake

output level Lwa

A 904 C-Litronic / 8720337

MJFCIFSS

2-5

Safety information, signs

Operating instructions

Signs on the machine

35

Information sign Loading and anchoring points Information sign Latch points

80

Information sign Safety belt

90

Warning sign Operating brake*

45

Information sign Tackle - lifting point

250

Information sign Emergency exit rear window

47

Warning sign Jump starting

40

*

2.4.3

Only applicable for Germany

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

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

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

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

2-6

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Safety information, signs Signs on the machine

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

Sign 32: Speed sign (only applicable for Germany) Displays the construction-dependent top speed of the machine.

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

Sign 40: Latch point

Sign 45: Tackle lifting point

A 904 C-Litronic / 8720337

MJFCIFSS

2-7

Safety information, signs

Operating instructions

Signs on the machine

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

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

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

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

Sign 65: Load chart Shows the permissible load carrying capacities depending on the working radius.

2-8

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Safety information, signs Signs on the machine

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

Sign 66, Part 2: Safety lever

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

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

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

A 904 C-Litronic / 8720337

MJFCIFSS

2-9

Safety information, signs

Operating instructions

Signs on the machine

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

Sign 90: Operating brake (only applicable for Germany) The operating brake may only be applied when the machine is operating. The operating brake may not be used as a parking brake when leaving the machine.

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

2.4.4

Arrangement of different signs (American version) Signs for the American version differs somewhat from the standard version:

Fig. 2-2

2 - 10

Arrangemet of different signs on the machine (American version)

105 119

Identification tag Warning sign Attachment

152 154

Warning sign Engine shut-down Warning sign Accident prevention note

121 122

Warning sign Safety lever Sign Operating symbols

170 171

Warning sign Steering Warning sign Operating brake

147

Warning sign Jump starting

172

Warning sign Parking brake

150

Warning sign Danger zone

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Safety information, signs Signs on the machine

2.4.5

Explanation of the different signs (American version) Sign 105: Machine identification tag The identification tag displays the following information:

Sign 119: Attachment The attachment can reach the operator's cab! Caution when attachment is retracted.

Sign 121: Safety lever

Sign 122: Operating symbols Describes the functions of the operating devices which are not labelled.

Sign 147: Jump starting The information in the operating instructions must be carefully observed when jump starting the machine.

Sign 150: Danger zone It is prohibited for anyone to remain in the danger zone.

Sign 152: Engine shut-down The engine hood may only be opened when the engine is shut off.

A 904 C-Litronic / 8720337

MJFCIFSS

2 - 11

Safety information, signs

Operating instructions

Signs on the machine

Sign 154: Accident prevention The accident prevention regulations given in the operating instructions must be strictly observed when operating the machine.

Sign 170: Steering The steering can only be operated when the engine is running.

Sign 171: Operating brake The operating brake may only be applied when the machine is operating. The operating brake may not be used as a parking brake when leaving the machine.

Sign 172: Parking brake It is not permitted to apply the operating and parking brakes simultaneously when the machine is operating.

2 - 12

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Safety information, signs Identification tags on the machine

2.5 Identification tags on the machine

Fig. 2-3

A 904 C-Litronic / 8720337

Important identification tags on the machine

1

Hydraulic pump

4

Heating /air condition- 7 ing unit

2 3

Diesel engine Control valve block

5 6

Swing gear Transmission

MJFCIFSS

Axles

2 - 13

Safety information, signs

Operating instructions

Identification tags on the machine

2 - 14

MJFCIFSS

A 904 C-Litronic / 8720337

3 Control, operation 3.1 Operating and control elements 3.1.1

Overview of the

Fig. 3-1 1

Safety lever servo control

A3

Radio (option)

6

Operating brake

P5

Hour meter

7 8

Traveling pedal Air vent, heater

S1 S4

Ignition switch Horn

9

Attachment control (option)

S30

Traveling direction switch

10

Positioning swing brake (option)

S71

Switch automatic / manual throttle control

12

Fuse box

S72

Switch engine RPM + / -

13

Heating and air conditioning system

S73

Emergency operation switch

Control, operation

Operating instructions

Operating and control elements

Fig. 3-2

3-2

2 3

Adjustable steering column Joystick, right

S2 S5

Keypad Push buttons grapple rotation

4

Joystick, left

S32

Blinker lever

5

Outrigger control

S44

E8

Cigarette lighter

S75

Switch - emergency blinker system Switch - oscillating axle automatic

H1

Monitoring screen

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operating and control elements

3.1.2

Arrangement of joysticks

Fig. 3-3

Joystick, right ( 3) and left (4)

Caution!

The machine is delivered in series with standard control.

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

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

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

A 904 C-Litronic / 8720337

MJFCIFSS

3-3

Control, operation

Operating instructions

Operating and control elements

3.1.3

Keypad

Fig. 3-4

3-4

Excavator keypad

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operating and control elements

S10

Work headlight

Press switch.

Work headlight is turned on.

LED 1 in the switch lights up.

Press switch again.

Work headlight is turned off.

LED 1 in switch turns off.

Roof headlight is turned on. (Option) LED 2 in switch lights up.

Press switch again.

Work headlight and roof headlight are turned on.

LEDs 1 and 2 in the switch light up.

Press switch again.

Work headlight and roof headlight are turned off.

LEDs 1 and 2 in the switch turn off.

S11

Windshield washer system

Press and hold button down.

Water will be sprayed onto the front windshield through nozzles.

The windshield wiper runs in continuous operation.

Release the button.

The water flow stops.

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

S14

Windshield wiper

Press switch.

Intermittent function is activated.

LED I in the switch lights up.

Press switch again.

Continuous operation is activated.

LED C in the switch lights up.

LED I in the switch turns off.

Press switch again.

Windshield wiper is turned off.

LED C in the switch turns off.

S16

Parking brake

Press switch.

The parking brake is applied.

LED in the switch lights up.

Press switch again.

The parking brake is released.

LED in the switch turns off.

S17

Swing gear brake

Press switch.

The swing gear brake is applied.

The uppercarriage is locked.

LED in the switch lights up.

Press switch again.

The swing gear brake is released.

LED in the switch turns off.

A 904 C-Litronic / 8720337

MJFCIFSS

3-5

Control, operation

Operating instructions

Operating and control elements

S18

Overload warning device (option)

Press switch.

The overload warning device is activated.

LED in the switch lights up.

Press switch again.

The overload warning device is deactivated.

LED in the switch turns off.

No overload warning device is installed.

Press switch.

The symbol for "No overload warning device is present" appears on the monitoring screen.

LED in the switch lights up.

Press switch again.

The symbol for "No overload warning device is present" turns off.

LED in the button turns off.

S19

Additional function release

Press switch.

Additional function (such as the rotating grapple) is activated.

LED in the switch lights up.

Press switch again.

Additional function is deactivated.

LED in the switch turns off.

S20

Sensor controlled low idle automatic

Press switch.

Sensor controlled low idle automatic is activated.

LED in the switch lights up.

Press switch again.

Sensor controlled low idle automatic is deactivated.

LED in the switch turns off.

S21

Creeper gear

Press switch.

Creeper gear is activated.

LED 1 in the switch lights up.

Press switch again.

Creeper gear is deactivated.

LED 1 in switch turns off.

3-6

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operating and control elements

S22

Head light

Press switch.

The parking light and tail light are turned on.

Left LED in the switch lights up.

Press switch again.

Low beam headlight and tail light are turned on.

Right LED in the switch lights up.

Left LED in the switch turns off.

Press switch again.

Low beam headlight and tail light are turned off.

Right LED in the switch turns off.

S35

Servo control

Press switch.

Left and right joysticks are operational.

LED in the switch lights up.

Press switch again.

Left and right joysticks are not operational.

LED in the switch turns off.

S36

Special function 1 (option)

Configuration and activation depending on kit.

S37

Special function 2 (option)

Configuration and activation depending on kit.

S38

Special function 3 (option)

Configuration and activation depending on kit.

S39

Special function 4 (option)

Configuration and activation depending on kit.

S41

Rotating beacon (option)

Press switch.

Rotating beacon is turned on.

LED in the switch lights up.

Press switch again.

Rotating beacon is turned off.

LED in the switch turns off.

S42

Gear shift, 1st gear

Press switch.

1. gear is selected.

Left LED in the switch lights up.

Press switch again.

2. gear is engaged.

Left LED in the switch turns off.

A 904 C-Litronic / 8720337

MJFCIFSS

3-7

Control, operation

Operating instructions

Operating and control elements

S56 No function

S85

No function

S86 Mode selection, throttle control Four different modes can be selected by pressing the switch. The currently active mode will be displayed by the LED under the letter.

L: LIFT mode (RPM level 5) F: FINE mode (RPM level 10) E: ECO mode (RPM level 8) P: POWER mode (RPM level 10) P4 Engine RPM display The Diesel engine RPM range is displayed in 10 levels.

S228

Increase RPM

Press switch.

RPM will be increased by one level.

A second LED to the right lights up in display P4.

S229

Decrease RPM

Press switch.

RPM will be decreased by one level.

A second LED from the right turns off in display P4.

S354

Super Finish (flow reduction)

Press switch.

The flow reduction selected via LED 1 in the switch lights up.

The symbol ® appears in the TI field, if flow reduction <= 99% Press switch again.

The flow reduction is deactivated.

LED 1 in switch turns off.

If the symbol turns black = 100%

3-8

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operating and control elements

3.1.4

Monitoring screen

Fig. 3-5

A 904 C-Litronic / 8720337

Monitoring screen

A B

Analog value display Indicating instruments

H24 P2

C

Main screen

D

Screen, menu control

P2.1 Coolant temperature display - red area P3 Fuel quantity display

H2

Indicator light, engine oil pressure P3.1 Fuel quantity display, red area

H12

Indicator light, battery

S349 Back button

H19

Indicator light, turn signal

S350 Down button

H20 H23

Indicator light, parking brake Indicator light, accumulator pressure - operating brake

S351 Up button S352 Menu button

MJFCIFSS

Indicator light, steering Coolant temperature display

3-9

Control, operation

Operating instructions

Operating and control elements

3.1.4.1

Area A: Monitoring the Diesel engine P2 Diesel engine coolant temperature display During operation, the display must be in the green area.

In the event of overheating (over 98 ºC), the red LEDs P2.1 at the end of indicator P2 will blink.

At the same time, the buzzer in the cab will sound.

Stop working as soon as possible.

Let the engine continue to run in idle high.

The warning alarm last longer than 60 seconds.

Bring the engine to low idle immediately.

Let the engine run in low idle for another 3 to 5 minutes.

Shut down the engine.

Find the cause and rectify the problem.

P3

Fuel quantity display

The illuminated LEDs in the display indicate the amount of fuel remaining in the tank.

When the red LEDs P3.1 light up, a reserve quantity of 50 liter of fuel remains in the tank.

H2 Indicator light, low engine oil pressure The indicator light lights up if the engine oil pressure drops below a given value during operation.

At the same time, the buzzer in the cab will sound.

When this indicator light lights up, the error will be saved under error code E501.

Bring the engine to low idle immediately.

Shut down the engine.

H12 Indicator light, battery charge The indicator light lights up if the ignition key is moved to contact position.

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

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

Bring the engine to low idle immediately.

Let the engine continue to idle for approx. 5 seconds.

Shut down the engine.

Remedy the error.

H19

Indicator light, turn signal

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

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

3 - 10

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operating and control elements

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

When this indicator light lights up, the error will be saved under error code E510.

Bring the machine to a standstill.

Bring the engine to low idle immediately.

Fold the safety lever up.

Check the brake system.

H24 Indicator light, steering flow through The indicator light lights up if the oil flow rate to the steering servostat is insufficient.

When this indicator light lights up, the error will be saved under error code E509.

Bring the engine to low idle immediately.

Continue to let the engine run in low idle for 2 to 3 minutes.

Shut down the engine.

Check the steering pump and the steering system.

Danger!

The steering can now be operated only with increased effort.

3.1.4.2

Area B: Screen menu control

Fig. 3-6

Screen menu control

The screen can be operated using the following 4 buttons: S349: Back button S350: Down button S351: Up button S352: Menu* button * = Change from main to submenus

move from page to page.

3.1.4.3

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

The set value will be saved.

To change the brightness of the main screen:

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 11

Control, operation

Operating instructions

Operating and control elements

Press button Back and arrow button Up (brighter) or Down (darker) simultaneously.

The set value will be saved.

Note!

A light sensor built into the top left side of the monitoring screen controls the illumination in the main screen, depending upon the brightness of the environment.

Tracking is based on the basic settings, done through the buttons. Illumination will be automatically reduced in low ambient light conditions.

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

Press and hold down the Up and Down buttons simultaneously.

Turn the ignition on again.

Release the buttons once the self-check is completed.

3.1.5

Main screen The main screen appears after the machine has been turned on and remains on display until the screen is changed via to the menu selection screen using the Menu button.

Fig. 3-7

3.1.5.1

Main screen

EC

Wire error display

SY

Symbols / Time

INF

Information

TI

Total operating hours, day counter, current work tool (Tool Control)

Main screen structure SY field In the upper section of the main screen, the time of day is shown. To the left, errors and warning symbols are shown. If more than 2 symbols are shown, the time is removed. If more than 4 symbols are to be displayed, they are shifted by one symbol to the left approx. every 10 seconds (see chapter 3.1.5.3, "Warning symbols in the SY field" on page 13).

3 - 12

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operating and control elements

EC field The EC window displays the error codes for existing electrical errors in the excavator's electronic system (line errors, sensor errors, etc.). A maximum of 7 error codes are displayed simultaneously. If more than these 7 errors are present, an arrow next to the error code window points to additional error codes in the list.

Press the Up or Down button.

The error code window will be shifted in the selected direction in the error code list.

INF field The INF field displays information temporarily, in both text and 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 conditions on the machine. (see chapter 3.1.5.4, "Information symbols in the INF field" on page 14).

TI field In this field, on the bottom right, the machine operating hours, the daily operating hours and the currently selected work tool are shown.

The ® symbol indicates that a flow limitation is active for the pumps (siehe "Menu Status of hydraulic pumps and electrical inputs and outputs" auf Seite 22).

3.1.5.2

Menu navigation in the event of an error display If an error is recognized as "new" in the SY field, the display returns to the main screen. The relevant error display is activated.

Depending on the error (level of urgency), the buzzer will sound either continuously or intermittently. This symbol will be displayed in the INF field.

Danger!

If the displayed error is not remedied immediately, personnel could be injured or the machine could be damaged.

Remedy (or have the error remedied) immediately.

To turn the buzzer off, press the Back button.

The error will be acknowledged and saved.

3.1.5.3

Warning symbols in the SY field An error code in the form of "E 5xx" will be assigned to each of the following symbols.

Each arsing error will be stored via the relevant error code.

E 502 Coolant level low This symbol appears if the coolant level drops below the water sensor level.

The buzzer sounds simultaneously.

Bring the engine to low idle immediately.

Shut down the engine as quickly as possible.

Find and fix the leak.

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 13

Control, operation

Operating instructions

Operating and control elements

Caution!

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

E 503

Coolant overheat

This symbol appears simultaneously with the P2 Coolant temperature display.

E 504 Hydraulic oil level low This symbol appears if the oil level in the hydraulic tank drops below the minimum level.

The buzzer sounds simultaneously.

Bring the engine to low idle immediately.

Shut down the engine as quickly as possible.

Find and fix the leak.

Reduce the tank pretension.

Only add hydraulic oil via the return filter.

E 505 Hydraulic oil overheat This symbol appears if the hydraulic oil temperature in the tank exceeds 98 °C. Bring the engine to low idle immediately.

Shut down the engine as quickly as possible.

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

E 511 Overvoltage This symbol appears if the operating voltage exceeds 30 volts for at least 0.5 seconds.

Quick coupler (option) This symbol appears during the unlocking process or when the lock bolts are retracted. No error codes are displayed.

3.1.5.4

Information symbols in the INF field Preheating On This symbol appears as long as the preheating process is actuated.

Preheating Off Preheating will stop automatically after about 20 seconds and the symbol Preheat off appears for approx. 2 seconds on the main screen.

Manual Diesel RPM adjustment This symbol appears if rocker switch S71 for manual throttle control is switched to the Manu position.

3 - 14

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operating and control elements

Travelling forward This symbol appears if travel direction switch S30 is set to travel forward.

Travelling reverse This symbol appears if travel direction switch S30 is set to travel reverse.

Oscillating axle lock active This symbol appears if the selector of the oscillating axle lock S75 is turned to position 1 and the operating brake is applied simultaneously or the safety lever is raised.

Oscillating axle lock automatic active This symbol appears if the selector of the oscillating axle lock S75 is turned to position A and the operating brake is applied simultaneously or the safety lever is raised.

Service required This symbol appears if a service interval is due.

Turn the ignition on.

The required service interval will be displayed for approx. 10 seconds instead of the operating hours.

Confirm error This symbol appears if a machine error (E5xx) has occurred and the buzzer sounds simultaneously.

Parking brake and swing gear brake operation changed This symbol appears if switch S73 is in the emergency position.

Note "Increased attention required": Operation changed This symbol appears if switch S73 is in the emergency position.

Servo control operation changed This symbol appears if switch S73 is in the emergency position.

Overload warning device (option) This symbol appears if the maximum permissible load carrying capacity of the machine has been reached.

No overload warning device available This symbol appears if switch S18 (overload warning device) is pressed, but either no overload warning device is available on the machine or if it is not released.

Outrigger monitoring (option) This symbol appears as long as the outriggers are not fully retracted.

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 15

Control, operation

Operating instructions

Operating and control elements

3.1.5.5

Information read out via screen Main screen menu selection:

Fig. 3-8

Main screen

Press the Menu button on the main screen.

The list of accessible menus is displayed.

Fig. 3-9

Press the arrow key Down or Up. The following or previous o black background.

be displayed on screen with a

The selected menu is displayed with a black background, the Reset daily operating hours menu is used here as an example.

Press the Menu button again.

The sub menu for the function selected is displayed.

Press the Back button.

The sub menu will be aborted.

3 - 16

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operating and control elements

Symbol

Description Reset daily operating hour meter

Confirm service interval

Tool control - Select flow limitation according to attachments (e.g. hammer) Operating hours and machine data

Status of hydraulic pumps and electrical inputs and outputs

Recorded and stored errors

Set the time of day

Tab. 3-1

Overview of menu options

Menu - Reset daily operating hour meter The daily operating hour meter can be reset to 0 using this menu.

Fig. 3-10

Resetting the daily operating hour meter

To set the daily operating hour meter to 0: Press the Up arrow key.

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

Press the Menu button.

The operating hours will be reset to 0.

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

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 17

Control, operation

Operating instructions

Operating and control elements

To exit the sub menu: Press the Back button.

The sub menu will be aborted.

The work speed of the excavator attachment for the "SF - Mode" can be set via this menu.

Fig. 3-11

Menu - Work speed in "Super Finish" mode

To set the work speed:

During the adjustment, the SF-mode is active. The work speed of the excavator attachment can be checked immediately.

Press the Up or Down arrow key and set the desired work speed.

Press the Back button.

The sub menu will be aborted.

The selected work speed is stored.

During operation, the SF-mode is activated with switch S354 (SF).

Press switch S354.

The flow reduction is activated.

The LED 1 in the switch lights up.

The symbol ®appears in the S1 field on the main screen (see Fig. 3-8) Press switch S354 again.

The flow reduction is deactivated.

The LED 1 in the switch turns off.

If the symbol turns black = 100% (maximum performance)

Menu - Confirm service interval This menu is used for information regarding service intervals and to confirm completed service work.

3 - 18

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operating and control elements

Fig. 3-12

Menu - Service intervals

The operating hours for the next service interval (in this example, "500 hrs.") and the current operating hours ("478 hrs.") are displayed in the menu.

A pending service interval 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.

Service work has been carried out.

Press the Up arrow key.

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

Press the Menu button.

The current operating hour will be confirmed for the last completed service interval.

Service work has not been carried out.

Press the Back button.

The sub menu will be aborted.

Menu "Tool Control" Selection of adjustments for work tool In this menu, the predefined pressure and flow settings are assigned for the work tool (activation of foot pedals, e.g. for hydraulic hammer or grapple).

A

Caution!

Incorrect preselection of the pressure and flow setting can result in damage to the work tool (e.g. hydraulic hammer) or in limited function (e.g. mill cutter).

Fig. 3-13

A 904 C-Litronic / 8720337

Menu "Tool Control"

MJFCIFSS

3 - 19

Control, operation

Operating instructions

Operating and control elements

EV1 = Oil quantity 1 EV6 = Pressure

EV2 = Oil quantity 2 (from A 934 B LI)

A blackened field shows the active option. By moving the arrow, a new option is selected and activated with the Menu button.

In the example (see Fig. 3-13), Option 3 is initially aktive.

Press the Up or Down arrow key.

A different, predefined option (1 to 10) can be selected (e. g. when an attachment is changed).

Press the Menu button.

The selection is confirmed.

The selected option is activated, the symbol is blackened (in the example Option 1).

To exit the sub menu: Press the Back button.

The sub menu will be aborted.

In the main menu, the selected work tool is shown (e. g. "Option 1"), the selected pressure - flow combination is available.

The work tool is operated with reduced oul pressure / with reduced oil quantity.

Fig. 3-14 1

Main screen, indication of selected work tool

selected option (work tool)

2

Symbol "R" appears if the work tool is operated with the pressure / flow reduction.

Note!

If desired, LIEBHERR or Service can place special descriptions for the work tools, for example "Hammer" or "Grapple".

Menu - Operating hours Pages 1 to 3 provide an overview of the operating hours of individual components, processes and operating modes.

3 - 20

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operating and control elements

Fig. 3-15 Page 1 provides the operating time in hours for:

Fig. 3-16 Press the Menu button.

Page 2 is displayed.

Page 2 provides the operating time in hours for:

Press the Menu button again.

Page 3 is displayed.

Page 3 provides the operating time in hours for: t operated via the foot pedals

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 21

Control, operation

Operating instructions

Operating and control elements

Fig. 3-17

Technical data

Press the Menu button again.

Page 4 is displayed.

The technical data menu, page 4, provides information on: for the currently installed control (ver)

Press the Menu button again.

Page 1 is displayed.

To exit the sub menu: Press the Back button.

The sub menu will be aborted.

Menu - Status of hydraulic pumps and electrical inputs and outputs Pages 1 to 3 provide information on the operating condition of hydraulic pumps.

Fig. 3-18 Page 1 shows the following for the working hydraulics: R will be displayed in the TI field of the main screen.

Here, for example, Option 1 flow limitation for attachments is active, which limits the oil flow to the user to 75 %.

When several flow limitations are activated at the same time, the one with the smallest value is decisive for the hydraulic pump. h represents the current working speed of the pump.

3 - 22

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operating and control elements

Fig. 3-19 Press the Menu button again.

Page 2 is displayed.

The current of the LR solenoid (current for performance setting) is displayed on page 2.

Press the Menu button again.

Page 3 is displayed.

The current of proportional valve EV5 for fan speed control of the hydrostatic fan drive is displayed on page 3.

Fig. 3-20

Electrical inputs

Press the Menu button again.

Page 4 is displayed.

Press the Menu button again.

Page 5 is displayed.

Pages 4 and 5 provide an overview of the status of different electrical inputs.

A"

" means "Input not active".

A"

" means "Input active".

An "NC" beneath the terminal description means that the software for the corresponding input is deactivated.

M4 / Time (or B19 / Time) in the last line of pages 4 / 5 refers to the delay setting for intermittent wipers or for the sensor controlled low idle automatic.

To exit the sub menu: Press the Back button.

The sub menu will be aborted.

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 23

Control, operation

Operating instructions

Operating and control elements

Error menu (operating errors and electrical system errors)

Fig. 3-21

Recorded errors menu

There are 3 choices in this menu: list Exxx, machine errors recorded by the sensors are listed. list E-elec , all main screen wire errors saved during operation are listed. list S-Exxx, all errors, which appeared when the service plug was connected, are listed.

To select the desired error type: Press the Down or Up arrow key.

The following or preceding error type will be displayed with a black background.

Press the Menu button.

The submenu on a black background will be displayed.

If more than 6 error codes are present, arrow key Down or Up can be used to scroll to the next page.

Machine error list Exxx:

Fig. 3-22

Error list (Fig. left) and Error incidence (Fig. right) menu

Select list Exxx.

Press the Menu button.

The first page of the sub menu appears.

All errors and their error codes are listed on the first page.

Use the Down or Up arrow key to select the desired error code.

Press the Menu button again.

The second page of the sub menu appears.

3 - 24

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operating and control elements

Operating hours and the duration of the first and last ten incidences of the selected error will be listed on the second page.

Press the Back button.

The first page of the sub menu appears.

Press the Back button again to select another error type or press the Down or Up arrow key to select a new error code. s*: Error was indicated by a buzzer and was acknowledged using the Back button.

The duration is given in seconds. m*: Error was indicated by a buzzer and was acknowledged using the Back button.

The duration is given in minutes.

Note!

Only operating errors with an error code E 5xx will be displayed in the list Exxx menu.

Wire error list E-elec.:

Fig. 3-23

Incidence of electrical error (Fig. left) and Error statistics (Fig. right)

Select list E-elec..

Press the Menu button.

The sub menu appears.

All electrical errors with error code are listed.

The "Test" column displays the number of errors which have occurred since the last deletion.

The hour information "reset test at x Hrs" (e. g. 12 hrs.) indicates the operating hour when the "Test" column was deleted.

Press the Back button.

A different error type may be selected.

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 25

Control, operation

Operating instructions

Operating and control elements

Other errors list S-Exxx:

Fig. 3-24

Call up menu Service operation error list

No information will be displayed in this menu as long as the service plug is not plugged in.

Fig. 3-25

Set the time of day

After calling up the menu, the right number is marked Change the number by pressing the arrow keys Up or Down.

Press the Menu button.

The mark jumps one digit to the left.

Repeat the procedure until the correct time of day is set.

Press the Back button.

The new time of day is confirmed, the travel menu is shown again.

3 - 26

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

3.2 Operation 3.2.1 3.2.1.1

Entering or leavi Entering Caution!

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

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

Do not use the control levers as handholds.

Never jump off the machine.

Fig. 3-26

3.2.1.2

Climb up using the handholds

Getting in

Fig. 3-27 1

Door - exterior

Door handle

2

Latch

11 Door lock

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

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

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 27

Control, operation

Operating instructions

Operation

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

3.2.1.3

Getting out

Fig. 3-28 3

Door - interior

Door handle on door lock

4

Lever for the latch

Shut down the machine and raise the safety lever.

Push the door handle 3 on the lock down.

Open the door fully and secure it in latch 2.

Climb out facing the machine.

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

Move the lever 4 next to the cab frame outward.

The door is now unlocked.

Close the door.

3.2.2

Safety lever

Fig. 3-29

Safety lever

For safety purposes, the left control panel is equipped with a safety lever.

3 - 28

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

Caution!

The safety lever must always be raised into its uppermost position (see arrow) when entering or exiting the cab.

When the safety lever is raised, the servo control circuit is disabled. This means that: joystick or foot pedals, are operated.

S35 turns off.

S16 lights up).

S16.

S17 lights up).

S17.

S75 will be locked (symbol appears on the monitoring screen).

When the safety lever (up / down) is lowered to its lowest position, the swing gear brake, the parking brake and the oscillating axle lock and their switches S16, S17, S35 and S75 will return to their original condition and the servo control devices will be active.

Before the operator starts working, he must lower the safety lever to its lowest po-

Fig. 3-30 tion)

A 904 C-Litronic / 8720337

1

Upper horizontal adjustment

4b Rear seat incline adjustment

7

Lumbar support adjustment

2

Lower horizontal adjustment

5

8

Seat heater

Seat suspension adjustment

MJFCIFSS

3 - 29

Control, operation

Operating instructions

Operation

3

Armrest adjustment

6

Lumbar support adjustment

10 Backrest adjustment

4a Front seat incline adjustment

This will avoid unexpected movements of the machine.

3.2.3.1

Adjusting the armrests

Fig. 3-31

Adjusting the armrests

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

The armrests incline upwards.

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

The armrests incline downward.

3.2.3.2

Adjusting the seat and backrest

Fig. 3-32

Adjusting the seat and backrest

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

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

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

3 - 30

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

3.2.3.3

Adjusting the horizontal seat position

Fig. 3-33

Horizontal seat adjustment

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

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

3.2.3.4

Adjusting the seat suspension

Fig. 3-34

Adjusting the seat suspension

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

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 31

Control, operation

Operating instructions

Operation

3.2.3.5

Adjustments on switch arrangement (air- cushioned opera-

Fig. 3-35 To adjust the vibration damper: Press button 5 (+ or -) and set the vibration system according to body weight.

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

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

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

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

3.2.3.6

Putting on / releasing the safety belt

Fig. 3-36

Safety belt

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

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

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

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

3 - 32

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

Danger!

The safety belt is designed to protect the operator.

Before starting the machine, always fasten the safety belt.

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

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

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

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

3.2.3.7

Vibration damper The seat complies with ISO 7096.

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

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

3.2.4

Adjusting the steering column

Fig. 3-37

Steering column

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

Press the release lever 2 down with the foot.

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

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

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 33

Control, operation

Operating instructions

Operation

3.2.5

Front windshield

Fig. 3-38

Front windshield

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

Pull pin 1 in and down.

The window is unlocked.

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

3.2.6

Sun visor

Fig. 3-39

Sun visor, front windshield and cab roof

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

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

The sun visor can be adjusted as desired.

Press button 2 (red).

The sun visor rolls up by itself.

3 - 34

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

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

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

Fig. 3-40 By pulling the bracket 1 on the inside of the rear window, the rubber weather strip 2 can be released and removed.

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

3.2.8

Interior illumination

Fig. 3-41

Interior illumination

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

Push the slide regulator to the right.

Light 2 is turned on.

Push the slide regulator to the left.

The spot light 3 is turned on.

Push the sliding regulator to the center position.

The interior illumination is turned off.

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 35

Control, operation

Operating instructions

Operation

3.2.9

Fire extinguisher (option)*

Fig. 3-42

Fire extinguisher / First-aid kit

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

3.2.10

Windshield wiper

3.2.10.1

Windshield wiper With the ignition turned on, the windshield wipers are activated by pressing the switch S14.

Press switch.

Intermittent function.

LED I in the switch lights up.

Press switch again.

Continuous operation.

LED C in the switch lights up.

LED I in the switch turns off.

Press switch again.

Windshield wiper is turned off.

LED C in the switch turns off.

Adjusting the interval time for the intermittent function The interval time for the intermittent function can be set when the ignition is on by pressing switch S14.

Press the switch until the windshield wiper is turned off (LED I in switch turns off) Press and hold switch.

LED I in the switch blinks.

Release the switch when the desired interval time has been reached.

The interval time can be set to between 2 and 10 seconds.

3.2.10.2

Windshield washing system With the ignition is turned on, press the button S11 to activate the electric windshield washing system.

3 - 36

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

Press and hold button down.

Water will be sprayed onto the front windshield through nozzles.

The windshield wiper runs in continuous operation.

Release the button.

The water flow stops.

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

3.2.10.3

Windshield washing fluid container

Fig. 3-43

Windshield washing fluid container

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

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

Quantity: see Lubrication Chart

3.2.10.4

Window wiper on the cab roof (option)

Fig. 3-44

Window wiper on cab roof

With the ignition turned on, press the switch S218 in the right control panel to activate the windshield wiper on the cab roof.

Press switch S218.

The windshield wiper on the cab roof runs continuously.

Press switch S218.

The windshield wiper on the cab roof is turned off.

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 37

Control, operation

Operating instructions

Operation

3.2.11

Lighting

Fig. 3-45

3.2.11.1

Arrangement of lights

1 2

Parking and head light Attachment headlights

4 5

Rotating beacon (option) Headlights on counterweight (option)

3

Front roof headlight (option)

6

Rear roof headlight (option)

Parking light and low beam light The low beam light (with tail light) is turned on by pressing switch S22.

Press switch.

Parking and tail light are turned on.

Left LED in the switch lights up.

Press switch again.

Low beam and tail light are turned on.

Right LED in the switch lights up.

Left LED in the switch turns off.

Press switch again.

Lighting is turned off.

Right LED in the switch turns off.

3.2.11.2

Attachment headlight, front Front roof headlight (option) With the ignition turned on, the front roof and attachment headlights are turned on by pressing switch S10.

Press switch.

Work headlight is turned on.

LED 1 in the switch lights up.

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Operating instructions

Control, operation Operation

Press switch again.

Work headlight is turned off.

LED 1 in switch turns off.

Roof headlight is turned on. (Option) LED 2 in switch lights up.

Press switch again.

Work headlight and roof headlight are turned on.

LEDs 1 and 2 in the switch light up.

Press switch again.

Work headlight and roof headlight are turned off.

LEDs 1 and 2 in the switch turn off.

3.2.11.3

Rotating beacon (option) With the ignition turned on, press switch S41 to turn the rotating beacon on.

Press switch.

Rotating beacon blinks.

LED in the switch lights up.

Press switch again.

Rotating beacon is turned off.

LED in the switch turns off.

3.2.11.4

Headlights on counterweight (option) With the ignition turned on, the headlights on the counterweight are turned on by pressing switch S276 in the right control panel.

Press switch.

Headlight on counterweight is turned on.

Light in switch lights up.

Press switch again.

Headlight on counterweight is turned off.

LED in the switch turns off.

3.2.11.5

Rear roof headlight (option) With the ignition turned on, the rear roof headlights on the counterweight are turned on by pressing switch S275 in the right control panel.

Press switch.

Rear roof headlight is turned on.

Light in switch lights up.

Press switch again.

Rear roof headlight is turned off.

LED in the switch turns off.

3.2.12 3.2.12.1

Heating and Air conditioning system Overview 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.

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Control, operation

Operating instructions

Operation

Fig. 3-46

Control panel of Air conditioning system

Control buttons

Main screen displays

If the control panel identifies an error, a blinking error number played.

will be dis-

Note!

In the event of an error, please contact LIEBHERR Service.

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MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

3.2.12.2

Turning the control panel on

Fig. 3-47

Turning the control panel on

Turn the system on using button 4.

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

The heating and air-conditioning in the cab is operating. The heat output or the fan speed will be controlled automatically if the AUTO (20) symbol is activated.

3.2.12.3

Setting the desired cab temperature

Fig. 3-48

Setting the desired cab temperature

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

Use button 2 to increase the temperature.

Use button 3 to reduce the temperature.

The adjusted temperature will remain until the next change is made.

Turn on the air conditioner to cool the cab.

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Control, operation

Operating instructions

Operation

Press button 7 to adjust the heat output manually.

The heater symbol will blink for 5 seconds.

As long as the heater symbol is blinking, use button 2 or 3 to increase or decrease the heat output manually.

Press button 7 to return to automatic operation.

3.2.12.4

Air conditioning

Fig. 3-49

Air conditioning

Turn on the air conditioner using button 1.

The symbol 15 will be activated.

The compressor will now be turned on by the control unit, if required, and automatically controls the heater and air conditioner RPM. To dehumidify the cab, turn on the air conditioning system when heating the cab.

Press the REHEAT button 6.

Symbol 14 is activated.

In this case, turn on the air conditioner until the windows are no longer fogged.

After 10 minutes, the REHEAT function turns off automatically.

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MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

3.2.12.5

Air circulation and fresh air

Fig. 3-50

Air circulation and fresh air

The heating and air conditioning system can be switched on to air circulation or fresh air operation.

Press button 8 to open / close the fresh air vent.

Symbol 13 indicates that the fresh air vent is closed.

Press button 5 to set the fan speed manually.

The fan symbol blinks for 5 seconds.

As long as the fan symbol is blinking, use button 2 or 3 to increase or decrease the fan output manually.

Press button 5 to return to automatic operation.

3.2.12.6

Air duct Regulation of the air flow is made by using buttons 9 - 12 (see Fig. 3-50) and via rotating and closable air vents.

A 904 C-Litronic / 8720337

MJFCIFSS

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Control, operation

Operating instructions

Operation

Fig. 3-51

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

The air vents are located on the seat console 8a, on the right control panel 8b, on the front windshield 8c and on the rear wall of the cab 8d. The open position of the corresponding vent is shown by an arrow in the display.

To obtain optimal comfort: In heater operation, open the air vents in the legroom area 8a, the right control panel 8b and possibly the front windshield 8c.

In air conditioner operation, open the air vents in the rear wall of the cab 8d and the right control panel 8b.

The best heating or cooling effect is achieved when using the air circulation function.

Note!

To prevent the starter motor and the battery from overloading, turn on the air conditioner only after the Diesel engine is running.

If the machine is used for a longer period of time without using the air conditioner, operate the compressor every 2 weeks by pressing the REHEAT button 6 (see Fig. 3-49) .

3 - 44

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

3.2.12.7

Operation with auxiliary heater (option)

Fig. 3-52

Operation with auxiliary heater

Note!

The auxiliary heater can only be operated when the ignition is turned off.

It is not possible to make manual adjustments in auxiliary heater operation.

Turn on the auxiliary heater.

When the Diesel engine is running, the auxiliary heater is turned off automatically.

3.3 Operation 3.3.1 3.3.1.1

Safety instructions Bringing the machine safely into service

locked. he inside and outside mirrors are clean.

Secure all doors and windows to prevent unintentional movement. the surrounding area with the horn before starting the machine. and the other items to ensure comfortable and safe working conditions.

A 904 C-Litronic / 8720337

MJFCIFSS

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Control, operation

Operating instructions

Operation

sition during operation. ed heaters only in sufficiently ventilated areas. Before starting the machine in a closed area, make sure the ventilation is sufficient.

Always follow all regulations valid for the current job site.

3.3.1.2

Starting the machine safely and instruments for proper function, bring all controls into neutral position and raise the safety lever. started by sounding the horn.

manual. trols for their proper indication. e engine only if there is sufficient ventilation. If necessary, open doors and windows to ensure sufficient fresh air supply. can cause the controls to be unresponsive.

check travel and swing brake, the steering function as well as the turn signals and lights.

3.3.1.3

Shutting down the machine safely

chine and secure it with wedges to prevent it from rolling off.

ized use.

3.3.1.4

Towing the machine safely operating manual. move the machine away from a dangerous place. towing the machine, check all cables, hooks and couplers for safety and stability. have a sufficient tensile strength and must be attached on the designated towing hooks on the undercarriage.

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

3 - 46

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

missible speed and distance. turn the machine to its previous state. service.

3.3.2 3.3.2.1

Starting / shutting down the machine General notes Note!

When using the machine from a specific height above sea level and in connection with corresponding ambient temperatures, the performance and service life of the Diesel engine with turbo charger is significantly influenced.

Under these conditions, there is also an increased risk of overheating the coolant circuit and the hydraulic oil.

To avoid damaging LIEBHERR Diesel engines, the engine output must be reduced when operating in the following environmental conditions (sea level and ambient temperature):

Pay attention to both the coolant circuit and the hydraulic oil cooling simultaneously.

3.3.2.2

Activities before starting Caution!

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

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

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

Location of locks: see Maintenance chapter Caution!

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

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

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

the hydraulic tank*.

A 904 C-Litronic / 8720337

MJFCIFSS

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Control, operation

Operating instructions

Operation

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

3.3.2.3

Starting the Diesel engine Switch positions of ignition key

Fig. 3-53

Ignition switch

0

Neutral position

2

Preheating

1

Contact position

3

Starting position

P

Parking position

Turning the electrical system on

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

Turn the ignition key to contact position 1.

As soon as the ignition is turned on, an automatic check of the keypad and the monitoring screen takes place.

Note!

If no automatic check of the keypad and monitoring screen is carried out when the ignition key is in the contact position, check if the battery master switch is set to "On".

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

All indicator lights must light up for a brief period, except for two LEDs of switch S22 (headlight).

The LIEBHERR logo appears on the monitoring screen.

3 - 48

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

Service interval display

Fig. 3-54

Service interval request

After the automatic check, any service interval that may be due will be indicated by a graphic symbol.

Instead of the operating hour information, the number of hours for the service interval required will now be displayed.

The service interval request will turn off after approx. 8 seconds.

Electronic immobilizer (option) In addition to the standard immobilizer, the machine can be equipped with an electronic immobilizer. The electronic immobilizer acts as an anti-theft device.

Fig. 3-55

Electronic immobilizer

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

The LED turns off.

A signal tone sounds.

Turn the electrical system on.

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

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

When the ignition is switched off, the immobilizer activates itself automatically after 30 seconds.

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

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MJFCIFSS

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Control, operation

Operating instructions

Operation

3.3.2.4

Starting the engine Note!

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

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

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

Wait at least 1 minute before repeating the starting procedure.

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

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

Turn the ignition key to starting position 3.

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

Indicator lights H2, H12 and H24 must turn off (H23 turns off after a short delay).

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

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

Turn the ignition key to position 2.

The symbol Preheating ON appears on screen.

The symbol is displayed on the main screen for approx. 20 seconds.

When the symbol Preheating END (2 seconds) appears, turn the ignition key to the starting position 3.

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

Postheating the engine Turn the ignition key to position 2 as soon as the engine is running after the starting procedure.

Symbol appears on the main screen.

Release the ignition key.

Note!

Do not preheat an engine which is at operating temperature.

Starting procedure at ambient temperatures below -18 °C For starting at temperatures below -18 °C, it is recommended to equip the machine with the original LIEBHERR cold start aid (see Starting aids).

The cold start aid can be operated from the cab and replaces preheating.

3 - 50

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

3.3.2.5

Throttle control and mode functions

Fig. 3-56

Throttle control and mode functions

The previously selected engine RPM will be displayed on the LED chain P4. It is divided into 10 speed levels.

To adjust the engine RPM, press arrow keys S228 or S229.

- or Press the mode switch S86.

Performance selection (adjustment) using the mode button Four different modes can be selected by pressing switch S86.

L sensitive lifting of loads) F E P: POWER mode (RPM level 10)

Using the arrow keys to adjust throttle control To increase the RPM: Press switch S228.

RPM will be increased by one level.

A second LED to the right lights up in the P4 display.

To decrease the RPM: Press switch S229.

RPM will be decreased by one level.

A second LED from the right turns off in display P4.

A blinking LED above switch S86 identifies an intermediate stage of the selected mode.

The currently active mode will be displayed by the LED under the letter. The selected mode will be saved when the engine is shut off and will be displayed by a blinking LED above switch S86 the next time the engine is started.

After starting the Diesel engine, the RPM preselection is either in level 1 (Diesel engine at low idle) or in level 3, if a warm-up phase is required for the Diesel engine.

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Control, operation

Operating instructions

Operation

Press the mode switch S86.

The mode selected will be used with the corresponding RPM and power.

The corresponding LED lights up permanently.

In mode E (maximum torque) and P, the Diesel engine runs at maximum power. In mode L and F, the hydraulic power is reduced.

3.3.2.6

Warm-up phase for Diesel engine and hydraulic circuit Diesel engine If the engine coolant is cold (temperature below 20 °C), the RPM is automatically set at level 3.

This procedure lasts until the coolant has reached 20 °C, but only for a maximum of 3 minutes.

Increase the engine load slowly until the second green LED (from left) lights up on display unit P2.

Note!

Idling for an extended period of time damages the engine.

Shut down the Diesel engine if the machine is not being used.

Hydraulic oil The pump output is automatically limited when the hydraulic oil is cold (temperature below 8 °C).

As soon the hydraulic oil temperature increases above 8 °C, the machine can attain full power.

3.3.2.7

Notes after starting the engine Danger!

Danger of suffocation.

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

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

Caution!

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

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

Check that all attachment functions are operating properly.

3.3.2.8

Shutting the Diesel engine down Caution!

The engine could be damaged.

Do not shut down the engine suddenly from full throttle.

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MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

First use arrow key S229 to set the engine RPM to low idle.

Only the LED on the furthest left is now turned on on display P4 (engine RPM).

Allow the Diesel engine to run at low idle for another 2-3 minutes.

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

Remove the ignition key.

3.3.3 3.3.3.1

Starting aids Cold start device (option) The cold start device supports the cold starting procedure at temperatures below 18°C. During the starting procedure, press and hold switch S210 in the right control panel.

A gas will be injected into the intake pipe to aid the cold starting procedure.

The indicator light in the switch lights up as long as the gas is injected.

As soon as the Diesel engine is running, the gas supply will be interrupted.

No gas will be injected if the Diesel engine is warm.

3.3.3.2

Fuel preheating S26 (option) The fuel filter will be electrically heated via the fuel preheating. This will prevent the fuel filter from clogging up with paraffin crystals at low temperatures.

In low ambient temperatures, the fuel preheating should be activated at least 5 minutes before starting the engine.

Press switch S26 on the right control panel before starting, with the ignition turned on.

The fuel filter will be heated electrically.

The indicator light in the switch lights up.

This will prevent the fuel filter clogging up at low temperatures.

3.3.3.3

Coolant / engine oil preheating (option) The coolant and engine oil can be preheated before starting using coolant / engine oil preheating. This will considerably shorten the Diesel engi pecially at low temperatures. This will protect the Diesel engine and reduce fuel consumption.

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MJFCIFSS

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Control, operation

Operating instructions

Operation

Fig. 3-57

Coolant / engine oil preheating

1

Indicator light - coolant preheating

4

2

Indicator light - Engine oil preheating 5

3

Fuse

6

On / off toggle switch for coolant preheating On / off toggle switch for engine oil preheating Power cable

The electrical box for the coolant / engine oil preheating is located behind the right side door.

Connect power cable 6 to stationary connection (110 - 120 V / 220 - 240 V AC).

Move toggle switch 4, Coolant / preheating.

The coolant preheating is turned on.

The indicator light 1 lights up.

Move toggle switch 5, engine oil preheating.

The engine oil preheating is turned on.

The indicator light 2 lights up.

After starting the engine, disconnect the power cable 6 on the machine.

3 - 54

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

3.3.4

Jump start procedure Danger!

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

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

3.3.4.1

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

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

Start the engine as described above.

Caution!

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

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

3.3.4.2

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

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

Check the electrical functions of the machine.

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

3.3.5 3.3.5.1

Emergency operations Emergency throttle control In normal operation, the desired RPM is entered using arrow keys S228 and S229 or via the mode switch S86 and the engine RPM is controlled correspondingly via the excavator electronics.

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Control, operation

Operating instructions

Operation

Fig. 3-58

Emergency throttle control

If there is a problem, this automatic system can be turned off.

Move toggle switch S71 to the MANU position.

The indicator light lights up.

The symbol MANU appears on the display.

Control the RPM manually.

The RPM will be controlled using toggle switch S72: L signifies: RPM reduction H signifies: RPM increase

3.3.5.2

Emergency operation If the function of the servo control and of the parking and swing gear brakes can no longer be activated due to a defect in the electronics, it is possible to bypass the electronics.

Fig. 3-59

Emergency operation (Fig. left) and emergency control display (Fig. right)

Lower the safety lever.

Move the toggle switch S73 into the emergency position.

The symbols appear on screen.

The servo control will be activated when the swing motor is running.

With operational hydraulics, the swing motor is running, the parking and swing gear brake are released.

3 - 56

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

Danger!

In this toggle switch position, S73, the servo control and the parking and swing gear brake can no longer be activated using the designated switches on the keypad.

All three functions can only be activated or deactivated using the safety lever.

Inform all personnel who are involved in the operation or maintenance of the machine about the emergency control and the changed operation.

Remedy the damage to the machine, which required the application of the emergency functions, as quickly as possible.

3.3.5.3

Emergency operation of working pumps When a problem occurs in the electrical power or regulating circuit, the pump performance is reduced to a minimum.

In this case, however, it is still possible to continue to work with reduced pump performance.

Fig. 3-60

Preparing emergency operation of working pumps

Change the lever 3 on the servo oil unit on the back of the hydraulic tank, to do so: unplug the plug connector 1 (Y50). pull off the cotter pin 2. tilt the lever 3 to a horizontal position (emergency position).

Emergency operation is established.

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MJFCIFSS

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Control, operation

Operating instructions

Operation

3.3.6

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

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

To drive on public roads, the uppercarriage and the undercarriage must be interlocked with the locking pin.

Fig. 3-61

Controls for travel

1

Retainer

7

Traveling pedal

3 6

Joystick, right Brake pedal

S30

Rocker switch travel direction

Release parking brake S16.

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

3.3.6.1

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

2. gear is preselected Press switch S42.

1. gear is engaged.

Left LED in the switch lights up.

The 1st gear is automatically engaged when a sufficiently low speed is obtained.

Press switch S42 again.

2. gear is engaged immediately.

Left LED in the switch turns off.

3.3.6.2

Creeper gear Note!

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

3 - 58

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

To obtain better traction on uphill grades and difficult terrain, the creeper gear can be engaged before or during travel.

Press switch S21.

Creeper gear is activated.

LED 1 in the switch lights up.

Press switch S21 again.

Creeper gear is deactivated.

LED 1 in switch turns off.

3.3.6.3

Travel movement Select the travel direction via the rocker switch S30 on the right joystick 3. An infinitely variable regulation of the travel speed is possible with the accelerator pedal 7.

Danger!

Before driving in reverse, make sure you can move backward safely.

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

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

Travelling forward: Push the rocker switch S30 down a.

The symbol for travelling forward appears on screen.

Press the accelerator pedal 7 down slowly.

Travelling reverse: Push the rocker switch S30 up b.

The symbol for travelling reverse appears on screen.

Press the accelerator pedal 7 down slowly.

Change travel direction only when the machine is at a standstill.

Danger!

The machine could roll away! To prevent this: Apply the operating and parking brake S16.

3.3.6.4

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

Danger!

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

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

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Control, operation

Operating instructions

Operation

Travelling on downhill grades of more than 10% Caution!

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

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

Raise the safety lever.

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

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

3.3.7

Travel warning device (option)

Fig. 3-62

Travel warning device

Actuate the travelling pedal 7.

The travel warning device turns on automatically.

An acoustical signal (warning tone) will be emitted.

Deactivating the travel warning device: Actuate the rocker switch S55 in left joystick 4.

The travel warning device is turned off.

Note!

The travel warning device can only be turned off 10 seconds after starting to travel.

If the accelerator pedal is actuated again, the travel warning device is reactivated.

3.3.8

Drive deactivation (optional extra) If the machine is equipped with an adjustable-height cab, it is possible to have a drive deactivation device fitted.

This device means that when the cab is raised: S30 does not function.

3 - 60

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

3.3.9

Travelling on public roads Note!

Travelling on public roads is subject to national regulations.

Before starting to travel, inform yourself about local requirements.

Observe all regulations and conditions.

Fig. 3-63

Required additional equipment, Germany

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

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

Clean the tire treads.

Empty the digging equipment.

Close all doors and the covers.

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

Fig. 3-64

Position of bucket for on road travel

To bring the attachment into a road travel position: Fully extend the hydraulic cylinder 4 and retract the boom adjustment cylinder 5 fully.

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Control, operation

Operating instructions

Operation

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

Fig. 3-65

Securing the grapple for on road travel

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

On undercarriage with 4 point outriggers: Place the grapple with the aid of tension ropes 1 on the undercarriage, do not remove the ropes while travelling.

Tilt the connecting link 2 up.

Secure the connecting clip 2 with two screws.

Secure the working attachments to prevent them from dropping down by closing the shut off valve 6 (see Fig. 3-64). This does not apply in the case of a pipe fracture safety device on the hydraulic cylinders (option).

Caution!

Hydraulic elements could be damaged!

Do not use the shut off valve as a shut off valve for load lifting work.

Fig. 3-66

Outrigger support and blade support when travelling on a public road

To bring the outrigger support / blade support into the road travelling position: Retract the outrigger support to the stop.

Fold the hinged support feet of the outriggers inward.

Push the blade support up to the stop.

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

3 - 62

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

Before starting to travel: Use switch S35 to turn off the control for the working hydraulic.

When the LEDs turn off, the joysticks are no longer operational.

The sensor controlled low idle automatic is deactivated.

The RPM preselection is switched to level 8.

Switch the automatic oscillating axle lock S75 to position 0.

3.3.10

Towing the machine Danger!

Danger of injury!

To tow the machine, only use a sufficiently sized rod.

Do not use a rope.

Towing the machine is problematic and is always carried out at the operator's risk.

The machine may only be towed in exceptional circumstances, e.g. in order to move the machine away from a dangerous place for repair.

Damage or accidents, which occur while towing the machine, are never covered by the manufacturer's warranty.

The towing rod must be attached on the intended tow coupling on the undercarriage.

The following values may not be exceeded when towing:

Preparation for towing depends on the function of the parking brake, the Diesel engine, the control and the hydraulic system.

The parking brake must be released during towing.

3.3.10.1

Towing with the Diesel engine running Press switch S16.

LED in the switch turns off.

Parking brake is released.

The indicator light H20 turns off on the monitoring screen.

If the parking brake cannot be released, the solenoid valve Y6 might have failed. In this case, turn in the valve by hand (emergency operation).

A 904 C-Litronic / 8720337

MJFCIFSS

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Control, operation

Operating instructions

Operation

Fig. 3-67

Solenoid valve Y6 (parking brake) on "HBGV-Block"

On solenoid valve Y6, turn in the tommy screw.

The machine can be driven with the travel pedal and the travel direction switch or be towed by a tow truck.

The machine can be slowed down with the operating brake (foot pedal) and steered with the support of the servo steering.

If the electrical power supply is missing or the electronic fails, the parking brake cannot be released and the machine cannot be driven.

In this case, the distributor gear must be mechanically uncoupled for towing.

Danger!

When the distributor gear is uncoupled, the parking brake is not functioning. The machine can roll of if another brake (operating brake) is disabled.

Make sure that the machine is properly secured to prevent it from rolling off (towing rod and wedges), before the distributor gear is uncoupled.

The machine may only be towed out of the danger area!

Fig. 3-68

Disengage the distributor gear mechanically

Loosen the hex head screw 1.

Move the lever in the direction of the arrow.

3 - 64

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

Secure the lever in the new position using the hex head screw 1.

The distributor gear is mechanically uncoupled.

The machine can be towed out of the danger area.

The machine can be slowed down with the operating brake (foot pedal) and steered with the support of the servo steering.

3.3.10.2

Towing with the Diesel engine not running If the Diesel engine is not running, the distributor gear must be mechanically uncoupled for towing.

Danger!

When the Diesel engine is not running and the distributor gear is disengaged, none of the brakes (operating brake, parking brake) on the machine are functioning. The machine could roll away!

When the Diesel engine is not running, the steering is only operational with increased effort!

Make sure that the machine is properly secured to prevent it from rolling off (towing rod and wedges), before the distributor gear is uncoupled.

The machine may only be towed out of the danger area!

Fig. 3-69

Disengage the distributor gear mechanically

Loosen the hex head screw 1.

Move the lever in the direction of the arrow.

Secure the lever in the new position using the hex head screw 1.

The distributor gear is mechanically uncoupled.

The machine can be towed out of the danger area.

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MJFCIFSS

3 - 65

Control, operation

Operating instructions

Operation

3.3.11

Oscillating axle lock

Fig. 3-70

Oscillating axle lock

Locking the oscillating axle Turn switch S75 to position 1.

The symbol "Oscillating axle lock" appears on screen.

The oscillating axle is permanently locked.

The stability of the machine is increased.

Turn on the oscillating axle automatic Danger!

When the automatic oscillating axle lock automatic is turned on (switch S75 in position A), releasing the operating brake will release the oscillating axle lock.

This results in a reduction of the stability of the machine and can cause the machine to tip over when a load is lifted and the uppercarriage is turned.

For safety reasons, the oscillating axle cannot be unlocked when the system is overloaded.

If the machine has to be moved with a raised load (e.g. filled bucket, load suspended on safety hook), you must turn off the automatic oscillating axle lock and permanently lock the oscillating axle (switch S75 in position 1) before taking on the load.

Turn switch S75 to position A. The symbol "Automatic oscillating axle lock" appears on screen.

When the operating brake is applied, the oscillating axle is automatically locked in the current position and is automatically unlocked again when the operating brake is released.

Note!

When working with the excavator, we recommend to lock the oscillating axle.

If possible, unlock the oscillating axle before travelling (without a load): Turn switch S75 to position 0.

3 - 66

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Operation

3.3.12

Support

Fig. 3-71

Support variations

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

3.3.12.1

Operating the blade / outrigger support

Fig. 3-72

Operating the blade / outrigger support

The support is operated using control lever 5.

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

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

A 904 C-Litronic / 8720337

MJFCIFSS

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Control, operation

Operating instructions

Operation

3.3.12.2

Individual outrigger control (option)

Fig. 3-73

Individual outrigger control

Select the individual outrigger control via switches panel.

on the right control

S204 = Outrigger, left front S205 = Outrigger, right front S206 = Outrigger, left rear S207 = Outrigger, right rear Press the corresponding switch .

The light in the corresponding switch lights up.

Use control lever 5 to lower or raise the selected outrigger.

3.3.12.3

Blade / outrigger combination (option)

Fig. 3-74

Individual control of rear blade / front outrigger (Fig. left) and front blade / rear outrigger (Fig. right)

The selection of the blade support is made via switch S335. To select individual outrigger control, use switches for front outriggers and for rear outriggers. The switches are located on the right control panel.

Press the corresponding switch S204, S205, S206, S207 or S335.

The light in the corresponding switch lights up.

Use control lever 5 to lower or raise the outrigger or blade.

3.3.12.4

Outrigger monitoring (optional) The symbol Outrigger monitoring is displayed on the main screen as long as the outriggers are not fully retracted.

3 - 68

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Working with the machine

3.3.12.5

Dozer blade (option) A dozer blade can only be installed on the front of the machine if there no support or no outrigger support.

Danger!

The dozer blade may not be used to support the machine. Lowering the dozer blade does not increase the stability of the machine and therefore does not increase the load carrying capacity.

Only use the dozer blade for grading work and not to support the machine.

The dozer blade is also controlled using switch S335 on the right control panel.

Press switch S335.

The light in the switch lights up.

Use control lever 5 to lower a or raise b the dozer blade and support.

3.4 Working with the machine 3.4.1

Working with the machine safely lf with the peculiarities of the job site, the special regulations and warning signals. Part of the surrounding area includes, for example, the obstacles in the working or movement area, the load carrying capacity of the ground and required safeguards for the job site to shield it from public highway traffic. ground. reduced visibility and changing ground conditions. location of power lines on the job site and work particularly careful in their vicinity. If necessary, inform the responsible authorities. ment to come near cables when working near electrical overhead lines. Danger of fatal injury! Inform yourself about required safety distances.

cured. ads, paths or squares, observe the valid traffic regulations and, if necessary, first bring the machine into proper condition to meet federal and local highway standards. ions of poor visibility or darkness. machine (except on two way excavators).

are carried out immediately.

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 69

Control, operation

Operating instructions

Working with the machine

ing manual. long as the machine is still moving. d operated in such way that the stability is ensured and that there is no danger of tipping over. Only known loads may be moved with the attachments, especially in grapple operation. close as possible to the ground.

EXCEPTION: see WHEN LOADING AND UNLOADING

uphill, never sideways on a slope. e permitted speed or you could loose control over the machine. to a lower gear. When doing this, the Diesel engine must run at maximum RPM and the speed may only be reduced using the accelerator pedals. rock protection is present. e operation, etc. always use protective devices specifically designed for this purpose. overview of and whenever necessary, ask for assistance of a guide. Have only one person signal you. ator. The guide must position himself within view of the operator or be in voice contact with him. nt combination, there can be a danger of collision becab, the cab protection or the boom cylinders. To avoid damage, utmost attention is required when the bucket teeth enter this range.

3.4.1.1

Safe application in material handling operation (especially when handling timber) with a raised attachment and picked up load, for example when handling wood or timber. machine upward in vertical direction. The travel behaviour of the machine will be strongly influenced, for example reduction of dynamic stability.

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

uppercarriage in travel position. , there is a danger due to possible oscillating movements and falling of the picked up load.

3 - 70

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Working with the machine

front on the cab. is a danger of falling objects from overhead.

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

3.4.1.2

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

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

ven road surfaces endanger the stability of the machine. center of gravity) and surrounding conditions. aking, acceleration, changes in travel direction. lengthwise direction, to avoid impermissible transverse slopes of the machine. ly!

In material handling operation: must be supported and horizontally aligned. pacity of ground). Sinking of an outrigger below ground level would result in devastating consequences!

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

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MJFCIFSS

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Control, operation

Operating instructions

Working with the machine

3.4.1.3

Additional notes for machin vation lengthwise and horizontal direction. Position the uppercarriage to the undercarriage in such a way that the steps and ladders are aligned. ) in proper condition. Make especially sure that they are free of dirt, oil, ice and snow.

NOTE: To ensure that the doors open in all weather conditions, lubricate the weather strips at least every two month, or more often, if necessary, with talcum powder or silicon. Lubricate the door hinges and locks regularly. three point support, i.e. always have two hands and one foot or two feet and one hand in contact with the entry system. climbing higher. External influences, such as wind, can make it more difficult to open the door. For that reason, always guide the door by hand when opening the door. Make sure that the door is engaged when it is open, to prevent it from banging open or closed. close the door and fasten the safety belt. and climbing up the machine. undercarriage in such a way that the steps and ladders are aligned. support. Climb down until you can close the door safely. Always guide the door by hand when closing the door.

3.4.1.4

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

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

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

weight and the size of the operator. that the characteristics of the seat remain as specified by the seat manufacturer.

3 - 72

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Working with the machine

ine, especially regarding: Tire pressure, brakes, steering, mechanical connections, etc. machine in a jerky manner.

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

able terrain conditions, keep machines available and allow for sufficient time. equently used for travel, utilize special auxiliary systems for travel (if installed), which reduce the vibration for this application.

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

3.4.2

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

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

Press switch.

Sensor controlled low idle automatic is activated.

LED in the switch lights up.

Press switch again.

Sensor controlled low idle automatic is deactivated.

LED in the switch turns off.

Note!

The sensor controlled low idle automatic is turned off if the magnetic system is activated via switch S46 and the servo control S35 is turned off.

To set the reset time to low idle after the joysticks have been released: Press and hold switch.

LED in the switch blinks.

The desired time span is reached.

Release the switch.

LED in the switch lights up.

The sensor controlled low idle automatic is activated.

In each case, when a hydraulic function is actuated, the engine RPM which was previously set using the electric throttle control function will be reset automatically.

Caution!

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

A 904 C-Litronic / 8720337

MJFCIFSS

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Control, operation

Operating instructions

Working with the machine

3.4.3

Operating the swing gear Caution!

The machine is delivered in series with PCSA controls.

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

The joystick functions described here refer exclusively to PCSA controls.

3.4.3.1

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

Fig. 3-75

Turning the uppercarriage

Deflect the joystick to the left c.

The uppercarriage turns to the left.

Deflect the joystick to the right d.

The uppercarriage turns to the right.

3.4.3.2

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

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

The uppercarriage will be adequately slowed down hydraulically.

Move the left joystick 4 in the opposite direction.

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

Mechanical swing gear brake The uppercarriage can be locked in any position using this brake.

Caution!

Damage to the machine.

Apply the mechanical swing gear brake only when the uppercarriage is stationary.

3 - 74

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Working with the machine

Press switch S17.

The swing gear brake is applied.

LED in the switch lights up.

Press switch S17 again.

The swing brake is released.

LED in the switch turns off.

To check the mechanical swing gear brake: The uppercarriage must be stationary.

Press switch S17.

The swing gear brake is applied.

LED in the switch lights up.

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

The uppercarriage may not turn.

The swing gear brake function is OK.

3.4.3.3

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

Fig. 3-76

Positioning swing brake

Note!

Increased wear.

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

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

Actuate the pedal 10.

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

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MJFCIFSS

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Control, operation

Operating instructions

Working with the machine

3.4.4

Locking the uppercarriage

Fig. 3-77

Uppercarriage locking system

When travelling on public roads, for transport, when taking the machine out of service or to carry out maintenance and repair work, the uppercarriage must be locked to the undercarriage.

Danger!

Before starting the locking procedure, observe the following points: Raise the safety lever.

Ensure that the machine cannot roll away (parking brake S16 applied).

Ensure that the uppercarriage cannot be turned (swing gear brake S17 applied).

Do not actuate the swing gear when the uppercarriage is locked to the undercarriage with the locking pin.

Turn the uppercarriage to the undercarriage in the direction of travel.

Lock using the locking pin (from the toolbox).

3.4.5

Working position

Fig. 3-78

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MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Working with the machine

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

Fig. 3-79 1

Locking the oscillating axle

Retainer

6

Brake pedal

Caution!

Parking brake S16 may not be applied.

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

Preselector switch S30 for travelling forwards and reverse must be in position 0.

Press brake pedal 6 all the way down until the retainer 1 engages.

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

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

3.4.6

Operating the working attachment Caution!

The machine is delivered in series with PCSA controls.

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

The joystick functions described here refer exclusively to PCSA controls.

3.4.6.1

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

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 77

Control, operation

Operating instructions

Working with the machine

Fig. 3-80

Operating the stick cylinder

Pull the joystick back a.

The stick will be retracted.

Push the joystick forward b.

The stick will be extended.

3.4.6.2

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

Fig. 3-81

Operating the boom cylinder

Pull the joystick back g.

The attachment will be raised.

Push the joystick forward h.

The attachment will be lowered.

3.4.6.3

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

3 - 78

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Working with the machine

Fig. 3-82

Operating the bucket cylinder

Move the joystick to the left e.

The bucket will be curled in.

Move the joystick to the right f.

The bucket will be curled out.

3.4.6.4

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

Fig. 3-83

Operating the grapple cylinder

Danger!

Never allow anyone to guide the grapple by hand!

Move the joystick to the left e.

The grapple will close.

Move the joystick to the right f.

The grapple will open.

3.4.6.5

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

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MJFCIFSS

3 - 79

Control, operation

Operating instructions

Working with the machine

3.4.7

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

Fig. 3-84

Lowering the attachment when engine is not running

Turn the ignition key to contact position 1.

Turn switch S75 to position 1.

The symbol "Oscillating axle lock" appears on screen.

The oscillating axle is permanently locked.

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

Note The attachment can be lowered because of This reserve is limited and is only sufficient for small movements of the pilot controls.

Use the joystick only to lower the attachment.

3.4.8

Operate the adjustable boom cylinder The adjustable boom cylinder is operated via the foot pedals m and k.

Fig. 3-85

Operate the adjustable boom cylinder

The adjustable boom cylinder and attachments cannot be operated at the same time.

If the boom is to be adjusted, the special functions (attachments) must be turned off first.

If necessary, turn the attachment off with switch S38.

Push the foot pedal k down.

The boom moves up.

Push down foot pedal m.

The boom moves down.

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MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Working with the machine

3.4.9

Adjusting the boom to side (option)

3.4.9.1

Side adjustable gooseneck boom

Fig. 3-86

Side adjustable gooseneck boom

If necessary, turn the attachment off with switch S38.

Push the foot pedal k down.

The boom is turned to the right.

Push down foot pedal m.

The boom is turned to the left.

3.4.9.2

Height and side adjustable boom The height and side adjustable boom is operated via the foot pedals m and k. The type of change over depends on the hydraulic equipment of the machine ( add-on kit AHS 12).

Equipment variation: Add-on kit AHS 12 The machine is equipped with this version if no other equipment (such as a hydraulic hammer, scrap cuttter) must be operated except the height and side adjustable boom.

The change over of the boom is made with switch S38.

Fig. 3-87

A 904 C-Litronic / 8720337

Height and side adjustable boom

MJFCIFSS

3 - 81

Control, operation

Operating instructions

Working with the machine

To adjust the height of the boom: Switch S38 is not active.

LED in switch does not light up.

Push the foot pedal k down.

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

Push down foot pedal m.

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

To adjust boom to side: Press switch S38.

LED in the switch lights up.

Push the foot pedal k down.

The boom is turned to the right.

Push down foot pedal m.

The boom is turned to the left.

Equipment variation: Add-on kit AHS 12 and changeover spool The machine is equipped with this version if one attachment is to be operated in addition to the height and side adjustable boom.

To adjust the height of the boom: Switch S38 is not active.

LED in switch does not light up.

Push the foot pedal k down.

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

Push down foot pedal m.

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

To adjust boom to side: Switch S38 is not active.

LED in switch does not light up.

Press switch S356.

The indicator light in the switch lights up.

The side adjustment of the boom is activated.

Push the foot pedal k down.

The boom is turned to the right.

Push down foot pedal m.

The boom is turned to the left.

3.4.10

Operate the attachment The machine can move attachments (auxiliary users) with different pressure and flow adjustments. Depending on the equipment, the control is made with add-on kits AHS 11 and AHS 12 (option).

3 - 82

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Working with the machine

A

Caution!

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

Danger!

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

Note!

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

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

Select the matching option for the work tool for pressure and flow adjustment in the operator's menu (see chapter "Tool Control").

Operate the attachment using pedals m and k.

Fig. 3-88

Operate the attachment

For a machine with adjustable boom, the foot pedals are either used for the boom or for the attachment. For that reason, if required, the function of the foot pedals must be changed over with switch S38.

For machines with gooseneck boom, this change over is not necessary.

Switch S38

Function of foot pedals

On

Operate the attachment

Off

Boom adjustment

Tab. 3-2

Function of the foot pedals m and k

Press switch S38, if necessary.

LED in the switch lights up.

The attachment is activated.

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MJFCIFSS

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Control, operation

Operating instructions

Working with the machine

Example: Operate the hydraulic hammer Push the foot pedal k down.

The hydraulic hammer is activated.

Example: Grapple, scrap cutter Push the foot pedal k down.

The working tool is closed.

Push down foot pedal m.

The working tool is opened.

3.4.11

Change over of controls (option)

Fig. 3-89

Change over of control

On request, the machine can be equipped with the "Change over controls" kit. This makes it possible to switch the "tilt bucket" (e and f) function to work tool (m and k) control.

Select the matching option for the work tool for pressure and flow adjustment in the operator's menu (see chapter "Tool Control").

If necessary, change over the control: The change over is made with key switch S405 in the right control panel.

Turn the key switch S405 to position 1.

The indicator light H322 lights up.

The control functions are changed over.

Turn the key switch S405 to position 0.

The indicator light H322 turns off.

The control returns to original function.

Function

S405 off (0)

S405 on (1)

Bucket tilt function / grapple

e+f

m+k

Work tool

m+k

e+f

Tab. 3-3

Change over of control

Actuate the work tool and the bucket tilt function (grapple) according to the selected mode.

3 - 84

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Working with the machine

Note!

The change over functions only for control of work tools. Operate the adjustable boom always via the foot pedals m and k.

3.4.12

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

Fig. 3-90

Attachment examples

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

Fig. 3-91 E

Push button on the joystick

Operation with left-hand joystick (standard)

F

Operation with left-hand and right-hand joystick (option)

G Operation with right-hand joystick (option)

Danger!

Danger of injury!

Never allow anyone to guide the grab by hand!

Press switch S19.

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

LED in the switch lights up.

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 85

Control, operation

Operating instructions

Working with the machine

Press and hold down the left-hand push button L. Grab will rotate to the left (counter-clockwise).

- or The slewing bucket is turned to the left (counter-clockwise), i. e. it moves downwards to the left.

- or Locking pins are extended.

Press and hold down the right-hand push button R. Grab will rotate to the right (clockwise).

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

- or Locking pins are retracted.

3.4.13

Magnet system (option) With a magnet system, optional equipment such as magnets for scrap handling can be operated. The magnet system is activated via switch S46.

The control is made via a push button in the right or via a switch in the left joystick (depending on the equipment).

Fig. 3-92

Operating the magnet system

Press switch S46.

The magnet system function is turned on.

If the engine RPM P4 is below level 8, then it will be automatically increased to level 8.

The engine RPM can be increased to level 10, but then it can no longer be reduced.

The sensor controlled low idle automatic S20 no longer functions.

Danger!

The magnet can loose its load in the event of a loss of current.

Always ensure that no one is standing beneath the load.

Do not press push button S6L unintentionally.

Control in the right joystick: Press the left push button S6L. The magnet is activated.

3 - 86

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Installation and removal of attachment parts

Press the left push button S6L again.

The magnet is deactivated.

Control in left joystick (American version): Push switch S55 up.

The magnet is activated.

Push switch S55 down .

The magnet is deactivated.

3.5 Installation and removal of attachment parts 3.5.1

Safe installation and removal of attachment parts roval for installation may not be installed on the machine without prior written approval by LIEBHERR. LIEBHERR must be provided with the required technical documentation necessary for this purpose. system, such as an attachment with cylinder movement, it must be ensured that different types of oil are not mixed together.

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

long as it is not safely resting on the ground or is not properly supported with wooden beams. e attachment down, shut off the engine and with the starter key in contact position actuate both joysticks as well as the the pressure in the hydraulic system. able lifting devices with sufficient load carrying capacity. ed ropes or cables. Always wear work gloves when handling wire cables. he engine off and raise the safety lever.

When working on the attachment, never align bores with your fingers, always use a suitable alignment tool. all fittings and connections are properly tightened. d and supported, close off the openings in the hydraulic circuit to prevent dirt infiltration. Permit only authorized persons near the machine or the lifting device.

3.5.2

Safe removal and installation of attachment pins lling device to push out the pins on the attachment. held by another person.

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Control, operation

Operating instructions

Installation and removal of attachment parts

of the pin and hit the screw only. first to the stop, then install the castle nut by hand until contact and tighten it only to the point where the cotter pin can be installed.

3.5.3

Installation and removal of digging tool

Fig. 3-93

Installation and removal of digging tools

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

3.5.3.1

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

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

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

3.5.3.2

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

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Operating instructions

Control, operation Installation and removal of attachment parts

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

Guide in pin 4 and secure it with plate 6.

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

Guide in pin 3 and secure it with plate 5.

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

3.5.3.3

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

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

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

Note!

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

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Control, operation

Operating instructions

Installation and removal of attachment parts

3.5.4

Installation and removal of grapple on stick

Fig. 3-94

3 - 90

Installation and removal of grapple on stick

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Installation and removal of attachment parts

Before installing a clamshell bucket or multiple tine grab, make sure that the required hydraulic lines for grapple operation are installed on the stick.

The installation and removal of the grapple must be carried out by two people.

Danger!

Danger of injury.

Ensure that the machine operator follows the hand signal given by the guide when moving the attachment.

3.5.4.1

Installing the grapple If necessary, remove the digging tool.

Retract the bucket cylinder to the stop.

Install screws 8 between connecting link 7 and the change over lever 9.

Position the grapple with fully opened shells.

Move the attachment to bring the lower mount of the stick between the bearing points of the grapple suspension 1.

Guide in pin 4 and secure it with plate 6.

Connect hydraulic hose 11 and hydraulic hose 12 for the shell cylinder supply to the pipes for the bucket cylinder.

For a grapple with a hydraulic rotating grapple drive, also connect hoses 13 and 14 to the pipes for this auxiliary device.

3.5.4.2

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

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

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

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

Carry out all work movements several times without a load (open and close the shells or turn the grapple to the left and to the right) to remove any air in the hydraulic circuits.

3.5.4.3

Removing the grapple Set down the grapple on level ground with fully opened shells.

Shut down the engine and, with the ignition key in the contact position, move the right joystick briefly to the left and then to the right to relieve the pressure in the hydraulic circuits.

To relieve the grapple rotator press the two push buttons in the left (or left and

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Control, operation

Operating instructions

Installation and removal of attachment parts

Raise the safety lever.

Disconnect hydraulic hose 11, hydraulic hose 12 and, if present, hydraulic hoses 13 and 14 from the pipes on the stick.

Close off open lines immediately to prevent dirt infiltration.

Support the grapple so that it is stable.

Remove the plate 6 and carefully knock out pin 4. If necessary, start the engine and raise the attachment slightly.

3.5.5 3.5.5.1

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

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

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

3.5.5.2

Overview

Fig. 3-95

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Mechanical quick change adapter

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Installation and removal of attachment parts

3.5.5.3

1

Locking pin (extended)

3

Crank

5

Load hook

2

Locking screw

4

Plug

6

Pick-up hook for working tool

Attaching the working tool Bring the equipment into position:

Fig. 3-96

Positioning the attachment

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

Move the stick and working tool into position.

Retract the bucket cylinder fully.

To unlock the quick change adapter: Danger!

Danger of injury!

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

Approach the quick change adapter from the side and unscrew the locking screw 2 from the locking pin 1 using the crank 3 (see Fig. 3-95).

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

Picking up the working tool:

Fig. 3-97

Picking up the working tool

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

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Control, operation

Operating instructions

Installation and removal of attachment parts

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

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

To lock the quick change adapter:

Fig. 3-98

Locking the quick change adapter

Danger!

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

Approach the quick change adapter with the utmost caution.

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

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

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

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

Screw the locking screw 2 into the locking pin.

Danger!

An incorrectly locked quick change adapter could open during operation!

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

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

Caution!

Hydraulic lines are pressurized!

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

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

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Operating instructions

Control, operation Installation and removal of attachment parts

3.5.5.4

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

Hydraulic lines are pressurized!

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

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

Extend the bucket cylinder fully.

To unlock the quick change adapter:

Fig. 3-99

Unlocking the quick change adapter

Danger!

Danger of injury!

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

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

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

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

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

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Control, operation

Operating instructions

Installation and removal of attachment parts

To place down the working tool:

Fig. 3-100 Placing the work tool down Slowly retract the bucket cylinder and place the working tool down on the ground.

The new working tool can be picked up.

3.5.5.5

Using the quick change adapter for load lifting work

Fig. 3-101 Mechanical quick change adapter The quick change adapter is equipped with two integrated load hooks. The machine may only be used for load lifting work if the safety devices required for this purpose are present and functioning correctly (see The maximum load carrying capacity of each individual load hook is stated on the quick change adapter. The load carrying capacity of the quick change adapter or the integrated load hook can exceed or fall below the load carrying capacity of the carrier machine.

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

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

Danger!

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

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A 904 C-Litronic / 8720337

Operating instructions

Control, operation Installation and removal of attachment parts

3.5.6 3.5.6.1

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

Familiarize yourself with the control and operating principle of the quick change adapter before installing or removing any working tools. adapter is monitored by a visual and acoustic warning device (buzzer and indicator light). The function of the warning device should be checked daily by operating the quick change adapter. ing or unlocking procedure, stop all work at once. If the buzzer and indicator light are not activated while a deliberate locking or unlocking procedure is being carried out, stop all work at once.

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

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

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

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

3.5.6.2

Overview

Fig. 3-102 Hydraulic quick change adapter 1

A 904 C-Litronic / 8720337

Locking pin (extended)

5

Load hook

MJFCIFSS

6

Pick-up hook for working tool

3 - 97

Control, operation

Operating instructions

Installation and removal of attachment parts

3.5.6.3

Operating elements Switch S19 Use switch S19 to activate the hydraulic auxiliary device for the rotating grab drive and quick change adapter.

Press switch.

Auxiliary device is activated.

LED in the switch lights up.

Press switch again Auxiliary device is deactivated.

LED in the switch turns off.

Button S47 locking pins.

Push buttons L and R Push button L = extend the locking pins (lock) Push button R = retract the locking pin (unlock) The push buttons are located on the right-hand and /or left-hand joystick (depending on the machine configuration):

Fig. 3-103 Push button on the joystick E

Operation with left-hand joystick (standard) G Operation with the right-hand joystick (option)

F

Operation with left-hand and righthand joystick (option)

Screen symbol "Quick coupler" The symbol appears:

3.5.6.4

Two-handed operation / retaining function For safety reasons, locking or unlocking only begins if two operating elements are activated simultaneously.

This means that button S47 must first be pressed with the one hand, and then one of the push buttons L or R must be pressed by the other hand (Two-handed operation).

After that, button S47 can be released, and the movement of the locking pins can be

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MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Installation and removal of attachment parts

maintained with the help of the push buttons L or R (retaining function).

If the direction of movement of the locking pins needs to be changed, button S47 and the corresponding push button L or R must be pressed again.

3.5.6.5

Attaching the working tool Bring the equipment into position:

Fig. 3-104 Positioning the attachment The working tool must be in a stable standing position or lying loosely on the ground.

Bring the stick and working tool into position.

Retract the bucket cylinder fully.

To unlock the quick change adapter: Press switch S19.

Quick change adapter is activated.

LED in the switch lights up.

Press and hold button S47.

Quick change adapter is activated.

Press and hold push button R until the locking pins are fully retracted.

The buzzer sounds.

The symbol "Quick coupler" appears on screen.

The quick change adapter is unlocked.

To pick up the working tool:

Fig. 3-105 Picking up the working tool Move the quick change adapter into a position that allows the working tool to be picked up with the pick-up hook.

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Control, operation

Operating instructions

Installation and removal of attachment parts

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

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

To lock the quick change adapter: Press switch S19.

Quick change adapter is activated.

LED in the switch lights up.

Press and hold button S47.

Quick change adapter is activated.

Press and hold push button L until the locking pins are fully extended.

The buzzer turns off.

The symbol "Quick coupler" disappears from the screen.

The quick change adapter is locked.

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

Release button S47.

Press switch S19.

Quick change adapter is deactivated.

LED in the switch turns off.

Caution!

Hydraulic lines are pressurized!

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

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

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

In addition, a 'working cycle' should also be performed with the working tool.

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

Danger!

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

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

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

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

Perform the working cycle.

Before starting to use the work tool (eg. grab, ditcher bucket), the special installation information in the chapter "Attaching and dismounting equipment parts" must also be observed.

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MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Installation and removal of attachment parts

3.5.6.6

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

Hydraulic lines are pressurized!

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

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

Extend the bucket cylinder fully.

To unlock the quick change adapter: Danger!

Danger of injury!

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

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

Press switch S19.

Quick change adapter is activated.

LED in the switch lights up.

Press and hold button S47.

Quick change adapter is activated.

Press and hold push button R until the locking pins are fully retracted.

The buzzer sounds.

The symbol "Quick coupler" appears on screen.

The quick change adapter is unlocked.

To place down the working tool:

Fig. 3-106 Placing the work tool down Slowly retract the bucket cylinder and place the working tool down on the ground.

The new working tool can be picked up.

A 904 C-Litronic / 8720337

MJFCIFSS

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Control, operation

Operating instructions

Installation and removal of attachment parts

3.5.6.7

Using the quick change adapter for load lifting work

Fig. 3-107 Hydraulic quick change adapter The quick change adapter is equipped with two integrated load hooks. The machine may only be used for load lifting work if the safety devices required for this purpose are present and functioning correctly (see chapter 'Load lifting work' or 'Overload warning device').

The maximum load carrying capacity of each individual load hook is stated on the quick change adapter. The load carrying capacity of the quick change adapter or the integrated load hook can exceed or fall below the load carrying capacity of the carrier machine.

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

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

Danger!

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

Before using for load lifting work, deactivate the quick change adapter.

LED in switch S19 has turned off.

Release button S47.

3.5.6.8

Quitting the buzzer (warning tone) The symbol "Quick coupler" on the screen and the buzzer (warning tone) indicate that the quick change adapter is not locked or is incorrectly locked.

After setting down the working tool, the buzzer (warning tone) continues to sound as long as the locking pins are not extended.

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

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

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Operating instructions

Control, operation Installation and removal of attachment parts

Press switch S349.

The buzzer is turned off.

The symbol "Quick coupler" on screen will continue to be displayed.

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

To reactivate the warning tone for the quick change adapter, extend the locking pins fully until the "Quick coupler" symbol on screen turns off.

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

3.5.7

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

3.5.7.1

Overview

Fig. 3-108 LIKUFIX

3.5.7.2

1

Protective cover on quick change adapter

4

LIKUFIX hydraulic coupling on working tool

2

Protective cover on working tool

5

Alternative hydraulic connection on working tool

3

LIKUFIX hydraulic coupling on quick change adapter

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

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Control, operation

Operating instructions

Installation and removal of attachment parts

Danger!

Malfunctions, or faulty installation or removal of a magnet, can cause contactless electric arcing.

This can result in very serious injuries to people nearby, or damage to the machine.

Do not attach any magnets while there is any malfunctioning of the electrical system.

Activate the magnetic system only with the attached magnets.

In the event of a malfunction in the magnetic system, take the machine immediately out of service, and have it repaired by qualified electricians.

Fig. 3-109 Connecting LIKUFIX In addition, note the following: Before installation, remove the protective covers on the quick change adapter 1 and the working tool 2.

Always keep hydraulic couplings 3 and 4 clean.

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

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

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

Extend the locking pins.

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

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

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

3.5.7.3

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

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Operating instructions

Control, operation General working methods

Fig. 3-110 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, the quick-change adapter must be modified by LIEBHERR Customer Service.

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

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

3.6 General working methods 3.6.1

Guidelines for minimum impact working methods To increase the service life of the machine and avoid unnecessary damage and resulting repairs, please observe the following points: perstructure when swinging into a ditch by stopping the attachment against the walls of the ditch. against the material to be removed, even lengthwise. Repeatedly hitting the work equipment against rocks or other hard material will lead to damage to the steel parts and machine components. d work tool, the work tool can hit or penetrate the cab. This could damage the cab and injure the machine operator. rocky material. This will extend the work cycles and could result in damage to the bucket as well as other machine components. dealer if special teeth for heavy or special applications are required. ill into material is not permitted.

A 904 C-Litronic / 8720337

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Control, operation

Operating instructions

General working methods

this should occur, slowly lower the machine to the ground. Do not permit the machine to drop to the ground quickly and do not catch the downward movement with the hydraulics, since this could result in damage to the machine.

3.6.2

Preparatory activities Danger!

Risk of fatal injury and damage to the machine when working.

Observe the safety information "Notes for safe working" at the beginning of these operating instructions.

Fig. 3-111 Position the machine so that the load or the digging material can be picked up over the rigid axle or the idler.

For mobile excavators, lower the support when possible and lock the oscillating axle.

Danger!

Insufficient support and machine damage.

Do not use a dozer blade to support the machine.

Fig. 3-112 Safe working Danger!

Risk of fatal injury due to slewing of the machine.

Ensure that there is no-one within the danger zone r of the machine.

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Operating instructions

Control, operation General working methods

Caution!

Risk of injury when working.

Always wear safety boots and a safety helmet and safety glasses, particularly when leaving the cab during demolition work.

Always wear the seat belt.

Use the horn to give a short warning signal before starting work.

3.6.3

Working with the backhoe bucket Danger!

Risk of fatal injury and damage to the machine when moving the backhoe bucket.

Make sure that the backhoe bucket is not moved too close to the cab.

The backhoe bucket can damage the cab and injure the machine operator.

Make sure that there is no-one in the danger zone of the backhoe bucket.

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

The travel gear could be damaged.

The machine must be in working position.

Fig. 3-113 Aligning, taking up the digging material, lifting Aligning the stick and backhoe bucket (1) Align the stick in such a way that its underside is at an angle of approx. 45° to the ground.

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

Taking up digging material (2): To lift out the digging material, slowly and evenly pull the stick in and slowly and evenly rotate the backhoe bucket simultaneously.

As soon as the stick is perpendicular to the ground, raise the boom slowly and evenly, in addition to pulling in the stick and backhoe bucket. Stopping suddenly will result in impact loads and vibrations.

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Control, operation

Operating instructions

General working methods

Lifting digging material (3): When the backhoe bucket is full or the stick can no longer be pulled in, raise the boom and backhoe bucket until the filling surface is parallel to the ground.

3.6.4

Loading the transport vehicle Danger!

Risk of fatal injury due to falling digging material.

Do not load the transport vehicle so high that the digging material falls over the walls of the vehicle.

Make sure that there is no-one within the danger zone or in the transport vehicle when loading.

Fig. 3-114 Emptying digging material If possible, the machine should be positioned higher than the transport vehicle to avoid having to lift the digging material unnecessarily.

Position the transport vehicle in such a way that it can be loaded from the rear or from the side.

Move the attachment of the machine over the loading surface of the transport vehicle.

Distribute the digging material evenly over the loading area of the transport vehicle by moving the backhoe bucket and stick out, turning the superstructure and possibly also moving the boom.

If the backhoe bucket is not sufficiently emptied or there is still digging material in the backhoe bucket, curl the backhoe bucket in and out several times to loosen the digging material.

3.6.5

Working with the hydraulic hammer Please also refer to the operating instructions provided by the manufacturer of the hydraulic hammer.

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Operating instructions

Control, operation General working methods

Danger!

The hydraulic hammer must be selected very carefully. The operation requires increased attention and caution.

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.

Use the hydraulic hammer only 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 for the attachment or 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.

Use the hydraulic hammer only with the machine in travel direction.

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 operator.

Close all windows in the cab before working.

Fig. 3-115 Hydraulic hammer The machine must be positioned in the working position on level, solid ground.

The stick may not be positioned vertically.

No cylinder may be fully retracted or extended.

Do not operate the hydraulic hammer on the same spot continually or for longer than 15 seconds.

Excessive continuous operation of the hydraulic hammer causes unnecessary overheating of the hydraulic oil.

Change the position of the machine and resume hammer operations.

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 109

Control, operation

Operating instructions

General working methods

Fig. 3-116 Permissible A and not permissible B work areas for machine with a hydraulic hammer Danger!

The stability of the machine could be affected.

When using a hydraulic hammer, only work with the machine in area A.

3.6.6

Grading Grading work can either be carried out using the digging tool or with a dozer blade (option).

Fig. 3-117 Grading The machine must be in working position.

The outriggers should be raised.

Danger!

Serious risk of injury when moving the machine.

Make sure that there is no-one within the working range of the machine.

Caution!

The machine could be damaged.

Never move the machine as long as the attachment is touching the ground.

3 - 110

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation General working methods

To grade with a backhoe bucket, place it flat on the ground (see Fig. 3-117) and move the stick slowly forward and backward. Move the boom evenly up and down while the stick is moving.

If a dozer blade is installed (option), lower the dozer blade to the ground and move slowly forward and backward with the machine.

3.6.7

Working with the grab Danger!

Risk of fatal injury and damage to the machine due to an oscillating grab.

ine could be affected.

Ensure that the grab does not swing too close to the cab.

Hold the stick in such a way that the grab cannot swing towards the machine when travelling or slowing the machine down.

Move the joystick slowly and evenly to prevent the grab from swinging.

Ensure that the grab does not swing toward any persons in the working area.

Do not lift a load if the boom and stick are extended too far and do not swing a heavy load too far to the left or right.

Observe the load chart: This shows the permissible load carrying capacities at the end of the stick, depending on working radius.

3.6.7.1

Clamshell grab (construction equipment) The machine must be in working position.

Fig. 3-118 Align the stick, close the clamshell grab, lift the digging material Align the stick (1): Open the clamshells fully.

Lower the stick perpendicular to the excavation area.

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 111

Control, operation

Operating instructions

General working methods

Closing the clamshells (2): Danger!

When closing, the shell type bucket can lift the machine. The machine could roll away!

Avoid lifting the machine when closing the grab, by raising the stick sufficiently.

Close the clamshells.

Raise the stick slightly to reduce ground pressures.

Lifting digging material (3): Close the clamshells fully.

Raise the boom.

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

Fig. 3-119 Emptying digging material Push the stick out as far as possible to avoid danger due to the oscillating grab.

Open the clamshells, dump the digging material.

3.6.7.2

Multiple tine grab (industrial equipment) The machine must be in working position.

Fig. 3-120 Taking up the load The maximum lifting capacity is attained when the load is taken up as close to the chassis as possible.

3 - 112

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation General working methods

Fig. 3-121 Transporting a load Transport the load close to the chassis, but with a sufficient safety distance to the cab (oscillating grab!) and as close to the ground as possible.

Caution!

Particularly when handling wood, it can be necessary, when working with a grab, to move the machine with raised attachment and suspended load. This will shift the center of gravity of the machine upward in vertical direction. The travel behaviour of the machine will be negatively affected.

Observe chapter 'Safe operation in material handling application'.

3.6.8

Load lifting work Load lifting work is understood to mean lifting, transporting and unloading loads using a lifting device (rope, chain etc.), where personnel are required to assist in securing and releasing the load. This includes, for example, the lifting and lowering of pipes, shaft rings or containers.

Danger!

The machine may only be operated for load lifting work if the specified safety devices are present and functioning correctly.

Machines used for load lifting work must be equipped with the following safety devices, in accordance with European standard EN 474-5: Load lifting devices to safely secure / lift a load (option) Safe lifting devices include, for example, load hooks which are mounted instead of the digging tool. Load hooks can also be replaced with safety hooks welded to the digging tool.

Overload warning device (option) The overload warning device must alert the machine operator visually or acoustically if the permitted load value according to the load chart has been reached or exceeded.

Pipe fracture safety valve on the hoist cylinders (option) The pipe fracture safety valve must meet with the requirements of ISO 8643.

Load chart inside the cab.

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 113

Control, operation

Operating instructions

General working methods

If the points referred to above are not or are only partially fulfilled, then the machine must not be used for load lifting work.

3.6.9 3.6.9.1

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

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

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

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

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

Note!

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

For backhoe bucket equipment (including bucket cylinder, change over lever and connecting link) the values on the top of the stick apply. The machine can be turned by 360° on solid, level ground if the oscillating axle is locked. If the bucket cylinder, change over lever and connecting link are removed, the values increase by an additional 300 kg. If a quick change adapter is used, the values are reduced by 235 kg (QCA 48).

For the industrial attachment, the values on the load hook apply. The machine can be turned by 360° on solid, level ground if the oscillating axle is locked.

3.6.9.2

"Simple" overload warning device Danger!

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

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

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

If the load pressure in the hoist cylinder reaches the level of the shift pressure, the pressure switch emits a signal, the warning symbol appears on screen and the buzzer sounds.

3 - 114

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Transport

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

Operation Danger!

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

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

Press switch S18.

Overload warning device is activated.

LED in the switch lights up.

Note!

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

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

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

Continue to move the joystick in the direction Raise boom.

The warning symbol must light up.

The buzzer must sound.

The switchable overload warning device consists of a constant pressure.

Note!

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

Press switch S18 again.

The overload warning device is deactivated.

LED in the switch turns off.

3.7 Transport 3.7.1

Transporting the machine safely lifting devices with sufficient capacity nd and block the chains or wheels with wedges. be sure that the loading ramp incline is less than 30° and is covered with wooden planks to prevent skidding. wheels of the machine before moving up the ramp.

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 115

Control, operation

Operating instructions

Transport

s for sensitive control (crawler excavator). he machine, if necessary, to prevent the machine from rolling backward. mp. Always hold the attachment as close as possible to the loading surface and always drive carefully up the ramp and onto the transport vehicle. limitations in transport, if the backhoe bucket attachment is installed, tilt the stick in and remove the bucket. undercarriage with the locking pin (only A-models). vent them from slipping. essure in all pressure lines, pull the ignition key and raise the safety lever.

height and weight limits. nderneath all bridges, underpasses, utility lines and in tunnels. loading procedure. Remove all chains and wedges. Start the engine as outlined in the Operating manual. Carefully drive off the loading platform down the ramp.

Keep the attachment as close as possible to the ground level. Have another person guide and signal you.

3.7.2 3.7.2.1

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

Fig. 3-122 Loading ramp The ramp incline must be fl incline angle W < = 30°.

ated climbing ability. Ramp

Have wedges ready.

Carefully place and secure wooden planks on metal ramp surfaces.

Remove ice, snow or mud from tires and ramp before starting to drive up the ramp.

3 - 116

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Transport

3.7.2.2

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

Fig. 3-123 Driving up on the flatbed trailer 1

Rigid axle

2

Steering axle

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

Danger!

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

Drive and steer with increased caution.

Align the machine precisely to the loading ramp.

Drive the machine onto the flatbed trailer.

Note

Note Have another person guide and sign you.

Carefully turn the uppercarriage by 180° (travel direction over steering axle) and lower the attachment (see Fig. 3-124).

Press switch S16.

The parking brake is applied.

LED in the switch lights up.

Fig. 3-124 Transport position - machine Shut down the engine, raise the safety lever.

Secure the uppercarriage to the undercarriage with the locking pin 3.

Lower the safety lever.

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 117

Control, operation

Operating instructions

Transport

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

Remove the ignition key and raise the safety lever.

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

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

Fig. 3-125 Securing the machine 1 2

Outrigger support, front Blade support, front

4 5

Dozer blade, rear Outrigger support, rear

3

No support, front

6

Blade support, rear

Danger!

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

Secure the machine against slipping.

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

Secure the machine with tension cables or chains at the points identified on the information sign "Latching point" (see Fig. 3-125). The loading points are identified on sign 45 on the undercarriage.

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

Transport route: Danger

Danger!

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

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

Check out the travel route before starting the trip.

3 - 118

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Control, operation Transport

3.7.3

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

Danger!

The load could slip or fall if incorrectly loaded.

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

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

Ensure that the length of the suspension gear is sufficient.

Loading a machine with a gooseneck boom:

Fig. 3-126 Suspending the machine with gooseneck boom Only use cargo handling gear which is sufficiently dimensioned or which has been specially developed by LIEBHERR for this purpose.

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

Press switch S16.

The parking brake is applied.

LED in the switch lights up.

Shut down the engine, raise the safety lever.

Secure the uppercarriage to the undercarriage using the locking pin.

Lower the safety lever.

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

Remove the ignition key and raise the safety lever.

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

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

Danger!

Standing under the raised machine is not permitted!

Raise the machine carefully with the crane and load.

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

A 904 C-Litronic / 8720337

MJFCIFSS

3 - 119

Control, operation

Operating instructions

Transport

Loading a machine with adjustable attachment:

Fig. 3-127 Suspending a machine with adjustable attachment Only use cargo handling gear which is sufficiently dimensioned or which has been specially developed by LIEBHERR for this purpose.

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

Press switch S16.

The parking brake is applied.

LED in the switch lights up.

Shut down the engine, raise the safety lever.

Secure the uppercarriage to the undercarriage using the locking pin.

Lower the safety lever.

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

Remove the ignition key and raise the safety lever.

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

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

Danger!

Standing under the raised machine is not permitted!

Raise the machine carefully with the crane and load.

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

3 - 120

MJFCIFSS

A 904 C-Litronic / 8720337

4 Malfunctions Warning and error messages: bols (see chapter "Control and operating elements").

Identification and remedy of problems and errors: tenance.

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

sible if you contact LIEBHERR Service.

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

Fig. 4-1

LIEBHERR Service

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

4.1 Error code charts Danger!

When switching over to emergency operation, the RPM can no longer be changed by using the arrow keys on the monitoring screen. The servo control, parking brake and slewing gear brake can no longer be activated.

Please also note the sub chapter "Emergency operation" in the chapter "Operating the machine".

Malfunctions

Operating instructions

Error code charts

4.1.1

Sensors

Error code

Effect

Cause

Measure / remedy

E 001

Engine oil pressure not being monitored.

Short circuit to earth Short circuit + 24 V

Check engine oil level, consult LIEBHERR Service.

E 002 E 003 E 004 E 005

Broken wire Coolant level not being monitored.

E 006 E 007 E 008

E 011

E 014

Hydraulic oil level not being monitored.

E 017

Hydraulic oil temperature not being monitored.

E 023 E 024

Short circuit to earth Short circuit + 24 V Short circuit to earth Short circuit + 24 V Broken wire

Gear oil temperature not being monitored. (from A934)

E 018 E 022

Short circuit + 24 V

Check radiator for contamination, consult LIEBHERR Service.

Check hydraulic oil level, consult LIEBHERR Service.

Broken wire

E 015 E 016

Short circuit to earth Broken wire

E 012 E 013

Short circuit + 24 V

Check coolant level, consult LIEBHERR Service.

Broken wire Coolant temperature not being monitored.

E 009 E 010

Short circuit to earth

Short circuit to earth Short circuit + 24 V Broken wire

Diesel engine RPM not being monitored, diesel engine RPM cannot be adjusted using keypad, reduced hydraulic performance.

4.1.2

Short circuit to earth Short circuit + 24 V Broken wire

Check radiator for contamination, consult LIEBHERR Service.

Check radiator for contamination, consult LIEBHERR Service.

Switch to emergency control RPM adjustment S71 and S72 and emergency operation working pumps Y50, consult LIEBHERR Service.

Regulating circuit

Error code

Effect

Cause

Measure / remedy

E 027

Faulty hydraulic performance

LR wire error at amplifier stage for performance control of hydraulic pump

Switch to emergency control RPM adjustment S71 and S72 and emergency operation working pumps Y50, consult LIEBHERR Service.

E 030

Diesel engine RPM cannot be adjusted using keypad (only A954).

EV 4 Wire error at amplifier stage of electric valve for RPM adjustment

Switch to emergency control RPM adjustment S71 and S72 and emergency operation working pumps Y50.

CAUTION: It is only possible to adjust between full RPM and low idle RPM, consult LIEBHERR Service.

E 033

Maximum fan speed

EV 5 Wire error at amplifier stage of electric valve for hydraulic fan control

Consult LIEBHERR Service.

4-2

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Malfunctions Error code charts

Error code

Effect

Cause

Measure / remedy

E 036

Flow reduction for hydraulic attachments not being carried out.

EV 1 Wire error at amplifier stage for flow regulation of hydraulic pump

Do not operate flow reduced attachments, consult LIEBHERR Service.

E 039

Flow reduction for hydraulic attachments not being carried out. (only A954, option)

EV 2 Wire error at amplifier stage for flow regulation of second hydraulic pump

Do not operate flow reduced attachments, consult LIEBHERR Service.

E 042

Operating temperature of hydraulic system not reached with positive short (only A900

EV 3 Wire error at amplifier stage of cooler control valve

Consult LIEBHERR Service.

E 045

In case of broken wire or short circuit to earth: Overheating of diesel engine and / or hydraulic system

E 046

Diesel engine RPM cannot be adjusted using keypad

4.1.3

Turn on air conditioning system, consult LIEBHERR Service.

Diesel engine RPM control motor faulty.

Switch to emergency control RPM adjustment S71 and S72 and emergency operation working pumps Y50, consult LIEBHERR Service.

Stick cylinder shut off (only with industrial or special equipment)

Error code

Effect

Cause

Measure / remedy

E 049

Stick cannot be moved

Short circuit to earth

Plug in potentiometer, consult LIEBHERR Service.

E 050

Short circuit + 24 V or cable break, potentiometer not plugged in

4.1.4

Keypad

Error code

Effect

Cause

Measure / remedy

E 302

No input possible via keypad

Coding plug is missing

Consult LIEBHERR Service.

E 303

Diesel engine RPM cannot be adjusted using keypad, reduced hydraulic performance.

No CAN bus connection between keypad and BST circuit board (message also appears if BST is not operational, e. g. if no power supply is available).

Switch to emergency control RPM adjustment S71 and S72 and emergency operation working pumps Y50, consult LIEBHERR Service.

A 904 C-Litronic / 8720337

MJFCIFSS

4-3

Malfunctions

Operating instructions

Error code charts

Error code

Effect

Cause

Measure / remedy

E 305

Malfunctions, e. g. travel brake, slewing gear brake, servo control

No CAN bus connection between keypad and ESP01 circuit board (message also appears if ESP01 is not operational)

Switch to emergency control for servo pressure circuits S73, consult LIEBHERR Service.

E 306

Malfunctions, e g. Travel direction switch, gear shift, oscillating axle lock, accessory kits

No CAN bus connection between keypad and ESP02 circuit board (message also appears if ESP02 is not operational)

Consult LIEBHERR Service.

4.1.5

Display

Error code

Effect

Cause

Measure / remedy

E 308

No display or incorrect display on screen

No connection keypad / screen or keypad not operating

Consult LIEBHERR Service.

E 309

No software compatibility between keypad and screen

4.1.6

Coding error

Error code

Effect

Cause

Measure / remedy

E 319

Diesel engine RPM cannot be adjusted using keypad, reduced hydraulic performance.

Hardware coding not matching to software coding

Switch to emergency control RPM adjustment S71 and S72 and emergency operation working pumps Y50, consult LIEBHERR Service.

E 321 E 322

No known machine type received from keypad.

Unknown hardware coding

4.1.7

Other errors

Error code

Effect

Cause

Measure / remedy

E 442

Sensor controlled low idle automatic on left joystick does not function, i.e. the engine remains in low RPM.

Short circuit + 24 V

Deactivate sensor controlled low idle automatic S20, consult LIEBHERR Service.

E 443

E 445

Short circuit to earth or broken wire

E 446

Sensor controlled low idle automatic on right joystick does not function, i.e. the engine remains in low RPM.

Short circuit to earth or broken wire

E 456

Incorrect fuel indication.

Short circuit + 24 V

E 458

4-4

Short circuit + 24 V

Short circuit to earth or broken wire

MJFCIFSS

Deactivate sensor controlled low idle automatic S20, consult LIEBHERR Service.

Check fuel level visually, consult LIEBHERR Service.

A 904 C-Litronic / 8720337

Operating instructions

Malfunctions Problems and remedies

4.1.8

Error due to warning symbols in SY field These error codes will not be displayed in the EC field of can only be read via the S-Exxx menu list.

menu. They

Error code

Effect

Cause

Measure / remedy

E 501

Indicator light H2 lights up

Diesel engine oil pressure too low

See description for indicator light.

E 502

Symbol appears

Coolant level low

See symbol description

E 503

Symbol appears

Coolant overheating

See symbol description

E 504

Symbol appears

Hydraulic oil level low

See symbol description

E 505

Symbol appears

Hydraulic oil overheating

See symbol description

E 506

Symbol appears

Distributor gear oil temperature too high (from R 934)

See symbol description

E 509

Symbol appears

Steering pump flow too low

See symbol description

E 510

Symbol appears

Brake pump flow too low or accumulator charging valve defective

See symbol description

E 511

Symbol appears

Overvoltage

See symbol description

4.2 Problems and remedies 4.2.1 Problem / error Diesel engine does not start

A 904 C-Litronic / 8720337

Diesel engine and fuel system Cause

Remedy

Fuel tank almost or completely empty

Refuel and bleed fuel system

Under pressure in tank

Remove tank cap

Fuel filter dirty

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

Ambient temperature below 0°C

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

Starter motor not pulling through

Check line connections, overhaul starter motor

Batteries have no power

Charge / replace

MJFCIFSS

4-5

Malfunctions

Operating instructions

Problems and remedies

Problem / error

Cause

Engine starts, but stops right away again or runs irregularly

Remedy

Fuel tank empty (under pressure in tank)

Refuel and bleed fuel system

Fuel filter dirty

Clean or change filter and bleed fuel system (tank)

Particularly in winter: high viscosity engine oil used

Use engine oil suitable for ambient temperature

Dry air filter dirty

Clean or change main filter element

Air in fuel system

Bleed the fuel system

Vent on fuel tank obstructed

Clean

Fuel line kinked

Check line and repair, if necessary

Diesel engine emitting grey or black smoke

Dry air filter dirty

Clean or change filter

Diesel engine continually emitting white smoke (steam)

Water in combustion chamber

Consult LIEBHERR Service

Diesel engine does not reach full RPM

Throttle control is not set to maximum value

Set throttle control to maximum value

Injection system is adjusted incorrectly

Consult LIEBHERR Service

Dry air filter dirty

Clean or replace filter

Insufficient fuel supply

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

Insufficient coolant

Add coolant, check for leaks

Water pump defective

Repair

Thermostats do not work

Change thermostats

Radiator contaminated

Clean radiator

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

Oil level too low

Correct oil level

Oil pressure display faulty

Change oil pressure switch

Diesel engine uses too much oil

External leak on Diesel engine

Retighten screws, replace seals, if necessary

Exhaust system leaking

Check exhaust system / repair

Diesel engine gets too hot

Oil in coolant or coolant in oil

Consult LIEBHERR Service

Unusual noise / sounddevelopment on exhaust side

4.2.2

Hydraulic system

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

4-6

Cause

Remedy

Shut off valve on hydraulic tank closed

Open shut off valve

Hydraulic pumps sucking air

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

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Malfunctions Problems and remedies

Problem / error

Cause

Remedy

Modes E and P show lack of power

No performance setting via proportional solenoid valve Y50

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

Hydraulic oil temperature too high

Radiator contaminated

Clean radiator

Fan or fan control defective

Remedy error / consult LIEBHERR Service

Hydraulic oil level too low

Oil loss

Repair leaks, replace hoses, add oil via return filter

No travel function

Raise safety lever

Lower safety lever

No travel direction preselected

Determine travel selection switch via travel selector switch in right joystick

Pressure switch - parking brake defective

Consult LIEBHERR Service

Parking brake not released

Release parking brake via switch

Parking brake will not release despite pressing the switch

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

Swing gear not functioning

Operating brake engaged

Release operating brake

No servo control

Lower safety lever Turn on servo control

Swing brake activated

Lower safety lever Release swing brake

No working movement

No servo control

Lower safety lever Turn on servo control

4.2.3

Consult LIEBHERR Service

No pump high pressure present

Consult LIEBHERR Service

Travel gear

Problem / error Machine does not move, neither forward nor backward

A 904 C-Litronic / 8720337

No servo pressure present

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

MJFCIFSS

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

Preselect direction of travel using switch S30.

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

4-7

Malfunctions

Operating instructions

Problems and remedies

Problem / error

Cause

Machine moves too slow

4.2.4

Incorrect gear reduction via switch S42.

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

Super Finish activated via switch S354.

Emergency control activated.

Cause

Flow display warning message

No or insufficient hydraulic oil supply

Remedy Consult LIEBHERR Service

Brakes

Problem / error

Cause

Accumulator charging pressure warning message

4.2.6

Select a different reduction via switch S42.

Deactivate creeper gear via switch S21.

Clean cab floor.

Deactivate Super Finish via switch S354. Turn off emergency control and establish normal operating conditions. Consult LIEBHERR Service.

Steering

Problem / error

4.2.5

Remedy

Problem on steering pump

Remedy Consult LIEBHERR Service

Brake accumulator defective

Electrical system

Problem / error

Cause

Remedy

Battery charge indicator light does not turn off

V- belt for alternator loose or torn

Tension or replace V-belt

Alternator defective

Replace alternator

Batteries do not charge or charge insufficiently

Batteries defective

Replace batteries

Battery connections dirty / oxidized

Clean battery connections

Cable loose or damaged

Connect or replace cable

Indicator light or display instrument not functioning or functioning incorrectly

Bulb burnt out, display instrument defective

Replace defective part

Some or all functions on instrument panel malfunction

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

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

4-8

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Malfunctions Problems and remedies

Problem / error

Cause

Diesel RPM adjustment via operating keypad (mode and arrow keys) not functioning

Remedy

Switch S20 Sensor controlled low idle automatic is activated

Touch the joystick or deactivate switch S20 Sensor controlled low idle automatic

Excavator electronic for RPM adjustment not functioning

Change the emergency function from "AUTO" to "MANU" using switch S71 in the right control panel.

RPM adjustment via switch S72.

Emergency function display appears on monitoring screen. Consult LIEBHERR Service.

No signal from RPM sensor B12

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

Permanent sensor signal

Consult LIEBHERR Service

Switch S20 is deactivated

Activate switch S20

Servo control cannot be activated via switch

Problem in excavator electrical system

Turn on emergency function via switch S73 in the right control panel Caution: Servo circuit and brake circuit can only be turned off with the safety lever. Keypad not functioning. Consult LIEBHERR Service.

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

4.2.7

Heating and Air conditioning system

Problem / error

Cause

Heater does not supply warm air

Heater fan is not running Only low air flow in cab

4.2.8

Remedy

Shut off valves for coolant line on Diesel engine closed

Open shut off valve

Engine not at operating temperature

Bring engine to operating temperature

No power supply

Check fuse and wiring / repair

Fan motor defective

Change fan motor

Outside air filter / recirculated air filter dirty

Clean air intake openings, replace outside air filter

Air vent closed

Open air vent

Work attachment

Problem / error

Cause

Remedy

Cylinder gives way under load

Piston seal in cylinder defective

Overhaul cylinder

Bearing clearance too high on attachment

Bearing points worn out

Replace bearing parts

Grapple / bucket do not move

Valve block on bucket cylinder incorrectly switched

Change over valve block

Attachment unit cannot be turned / rotated / operated

Auxiliary function has not been released

Release auxiliary function via switch S19

Lines are not connected

Connect lines

A 904 C-Litronic / 8720337

MJFCIFSS

4-9

Malfunctions

Operating instructions

Fuses and relays

4.3 Fuses and relays 4.3.1

Fuse box E50

Fig. 4-2

Fuse box E50

Fuse box E50 is located behind the left side door, above the batteries.

4.3.2

F19 F20

70 A 50 A

Preheating / refuelling pump (option) Main fuse

F22 F303

7.5 A 7.5 A

Hazard warning system Heating and air conditioning system terminal 15

F332

25 A

Starter

F350 K16-1

20 A

Heating and air conditioning system terminal 30 Engine start relay

K16-2 K288

Pulling coil relay Main relay terminal 15

K302

Preheating relay

ESP02 board

Danger!

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

Only use original fuses.

Never bypass electrical fuses.

If required, order replacement fuses from LIEBHERR.

4 - 10

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Malfunctions Fuses and relays

A 904 C-Litronic / 8720337

Fig. 4-3

Fuses and relays, ESP02 board

F1 F2

2A 2A

Parking light and tail light, left Parking light and tail light, right

F3

7.5 A

Reserve

F4

15 A

Servo control and safety lever for kits

F5

15 A

Special functions SF2, SF3 and SF4*, reserve

F6

15 A

Special function SF1*, 1 gear, oscillating axle lock, brake light

F7

15 A

Headlights

F8

7.5 A

Parking brake, servo control, creeper gear

F9

7.5 A

Windshield wiper

F10

7.5 A

Preheating, windshield washer system, rotating beacon*, rotating grapple*

F11

15 A

Reserve

F12

15 A

Reserve

F13

15 A

Excavator control

MJFCIFSS

4 - 11

Malfunctions

Operating instructions

Fuses and relays

F14

15 A

Emergency control

F15

7.5 A

Brake pressure switch

F16 F17

7.5 A 15 A

Turn signal Reserve

F18 F19

15 A 7.5 A

Reserve Cigarette lighter

F20

15 A

Reserve

F21 F22

15 A 7.5 A

Ignition switch, terminal 30 Interior lighting, horn

F23

7.5 A

Headlight, right

F24

7.5 A

Headlight, left

F250

2A

Circuit breaker for keypad terminal 15

F251

2A

K332

Circuit breaker for keypad terminal 30 Relay, headlights left and right

* Option

4 - 12

MJFCIFSS

A 904 C-Litronic / 8720337

5 Maintenance 5.1 Maintaining the machine safely 5.1.1

General Safety instructions ied out by trained expert technicians. ods for repeat checks / inspections as outlined in the Operating manual. Always use appropriate tools to carry out maintenance work. manual to see who is authorized or required to perform certain work.

The tasks listed under daily / weekly may be carried out by the machine operator or maintenance personnel after having received appropriate instructions.

The remaining tasks may only be carried out by expert technicians with appropriate training. rements set forth by the manufacturer.

This is always ensured with Original spare parts. intaining the machine. For certain work, safety glasses and protective gloves are required, in addition to a hard hat and safety boots. the machine during maintenance.

work. Make sure he knows the person who is in charge of the work. nance work on the machine on firm and level ground, with the attachment placed down and the engine shut off. re you always tighten any loosened screw connections. tenance and repairs, make sure that after completion of work, the safety devices are reinstalled and checked for proper function. hen working under the machine, make sible and attached to the starter switch.

Pull the ignition key and close the battery master switch.

5.1.2

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

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

cleaning products,

Maintenance

Operating instructions

Maintaining the machine safely

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

This applies especially to electric motors, electric components, switch boxes, plug connections and air filters. the fire warning system and the fire extinguisher do not come in contact with hot cleaning fluids when cleaning the engine compartment.

The fire extinguishing system could be actuated.

lines for leaks, loose connections, chafing and damage.

infiltrated water or cleaning fluid.

5.1.3

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

5-2

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Maintaining the machine safely

lation of welding technology. In case of doubt, contact LIEBHERR Service to discuss suitable measures.

5.1.4

Welding rk on the machine only if this is explicitly permitted. Before any welding, torching and grinding tasks, clean the machine and the surrounding area to remove dust and flammable materials.

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

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

5.1.5

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

(Danger of burning and scalding).

5.1.6

Repair able lifting devices with sufficient load carrying capacity. When replacing individual parts and larger components, attach and secure them carefully to the lifting tackle, to avoid any danger. Use only suitable and technically sound lifting devices as well as load tackle with sufficient load carrying capacity.

Do not stand or work under suspended loads. ciently sized lifting devices.

Always wear work gloves when handling wire ropes.

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

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

Wear a harness when working in great heights.

Keep handles, steps, railings, platforms, and ladders free of dirt, ice and snow. the machine is properly supported. Never use metal on metal support. is raised with the attachment, without being properly supported from below with hardwood beams. ys that any shifting weight will not endanger the stability of the machine and avoid metal to metal contact.

A 904 C-Litronic / 8720337

MJFCIFSS

5-3

Maintenance

Operating instructions

Maintaining the machine safely

pecially trained expert personnel. secure the uppercarriage to the undercarriage with the locking pin. onnel may work on the hydraulic system. can have enough pressure to penetrate the skin. before the attachment has been lowered, the engine has been shut down and the hydraulic system pressure has been relieved. Before working on the hydraulic circuit, with the ignition key in contact position, move all servo controls (joysticks and pedals) in all directions to relieve the servo pressure and the remaining pressures in the working circuits. Then relieve the pressure in the tank, as described in this operating manual.

5.1.7

Electrical system All defects, such as loose connections, burnt out fuses and bulbs, burnt or damaged wires or cables must be repaired immediately by an electrician or especially trained personnel.

gy supply, turn the machine off immediately. sion of an electrician may work on the electrical equipment of the machine, according to the electro-technical guidelines. emergency off or master switch with voltage release. Rope of the work area off with a red and white safety chain and a warning sign. Use only insulated tools. mponents, shut off the voltage and connect the supply cable to the ground and ground the components, such as the condenser, with a grounding rod. truly free of current, ground them and short circuit them. Insulate adjacent, current carrying parts. out any arc welding work on the machine.

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

5.1.8

Pressure accumulator

cidents.

system (hydraulic system including hydraulic tank, as described in this operating manual. chanical work on them.

5-4

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Maintaining the machine safely

The pressure accumulator can be damaged due to heat exposure and can rupture due to mechanical treatment. THERE IS A DANGER OF EXPLOSION! r only with nitrogen. When using oxygen or air, there is a DANGER OF EXPLOSION! ring operation, there is a danger of burning. plication before use. the pressure accumulators. Make sure that the marking remains visible.

5.1.9

Hydraulic hoses and lines d regularly, every 2 weeks, in case of suspected intentional damage immediately for leaks and external visible damage!

Any damaged parts must be replaced immediately! Escaping oil can cause injuries and fires. ess. For that reason, their service live is limited. quent causes of failure. standards, regulations and guidelines for hoses and lines at the job site must be observed. ranges of permitted use can shorten the service life ( for example in high temperatures, frequent work cycles, extremely high impulse frequencies, multi shift operation). e following conditions are found during inspection: cracks); shape of the hose or hose line, when under pressure or not under pressure, or in bends (e.g. separation of layers, blisters or bubbles); allation instructions; which reduce the strength of the fitting or the hose / fitting connection; h reduces function and strength;

pressure hoses, always attach the screws of half clamps or full flange on both ends of hose first and then tighten. with a bent fitting, always tighten the end with the bent fitting first when tightening the flanges, then the end with the straight fitting. and tightened thereafter. erly mounted. This prevents vibration and damage during operation.

A 904 C-Litronic / 8720337

MJFCIFSS

5-5

Maintenance

Operating instructions

Maintenance access doors

structures is prevented. her parts of approx. ½ of the outside diameter of the hose. The distance should not be less than 10 to 15 mm. check before initial use, that there is not chafed area over the entire area of movement.

5.2 Maintenance access doors 5.2.1

Overview of access doors

Fig. 5-1

Access doors on the machine

11 23

Center cover Right cover

46

Side door, left

51 65

Side door, right Side door, left front

The machine has 5 access doors for maintenance. The locks integrated in the handles must be unlocked before starting to travel.

Caution!

Access doors can close accidentally and trap the operator or maintenance personnel.

Always lock the access door in place with the retainer after opening.

5-6

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Maintenance access doors

Access door

Lock

Center cover

Gas pressure spring, auxiliary mechanical retainer

Right cover

Gas pressure

Side door, left

Mechanic

Tab. 5-1

5.2.2

Access to:

Access doors

Door lock

Fig. 5-2

Door lock

To stop the access doors from moving unintentionally (e.g. due to wind), open them fully and allow the door lock (see arrow) to engage.

A 904 C-Litronic / 8720337

MJFCIFSS

5-7

Maintenance

Operating instructions

Tires

5.2.3

Engine hood lock

Fig. 5-3

Engine hood lock

Unlock the engine hood using door lock 1 and pull back.

Caution!

The engine hood moves with the assistance of two gas cylinders. They hold the engine hood open. On older gas cylinders, the retaining power can drop and the engine hood could lower accidentally.

Always secure the engine hood additionally with the mechanical retainer 2.

5.3 Tires

Fig. 5-4

5-8

Exploding tire

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Tires

Danger!

Repair work on the wheels, e.g. removing tires from the rim or installing tires on the rim may only be carried out by expert personnel using the appropriate assembly tool.

If the tire inflator is operated incorrectly or carelessly, the following dangers can arise, leading to severe injury or even death:

Tires which have become flat may not be inflated. They must be repaired at a professional shop.

An incorrectly seated lock ring could burst off. Danger of injury.

When inflating the tires, use a tire inflator hose of a sufficient length with a self retaining hose valve.

When inflating the tires, stand outside of the danger zone.

Do not use different tire sizes.

5.3.1

Checking the tire pressure The air pressure in the tires has a considerable influence on the overall operational behavior of the machine. For this reason, the tire pressure should be checked regularly and corrected if necessary.

When working on the tires, ensure that the machine is positioned safely and is secured with wedges to prevent it from rolling off.

Ensure that the correct nominal tire pressure values, corresponding to the mounted tire and the machine group, are available for the tires.

Take the nominal values from the chart below.

Attach measuring equipment and correct air pressure, if necessary.

5.3.1.1

Tire pressures Size

Manufacturer

PR

bar

10.00 - 20

Continental

16

7,50

10.00 - 20

Dunlop

16

7,50

10.00 - 20

Bridgestone

14

7,50

10.00 - 20

Nokia

16

7,50

10.00 - 20

Barum

16

7,50

10.00 R 20

Michelin

11.00 - 20

Continental

16

7,50

11.00 - 20

Bridgestone

16

7,50

11.00 - 20

Nokia

16

7,50

18.00 R 19.5

Michelin

7,50

600 / 40 - 22,5

Alliance

6,00

Tab. 5-2

A 904 C-Litronic / 8720337

7,50

Tire pressures

MJFCIFSS

5-9

Maintenance

Operating instructions

Lubricants and operating fluids

5.3.1.2

Tightening torque Tightening torque of wheel lugs: 570 Nm Note!

Retighten the wheel lugs according to the inspection and maintenance schedule after each wheel change.

5.3.2

Filling with foam Note!

The running characteristics will be influenced by filling the tires with foam. Only LIEBHERR may fill the tires with foam.

5.4 Lubricants and operating fluids 5.4.1

General information to change lubricants and operating fluids Note!

The quantities given in the lubrication and operating fluid chart as well as on the lubrication chart in the cab are only guide values.

Check the level in the corresponding component after each oil change or refill.

Note!

Adhering to regulations for lubrication, level checks and changing of operating fluids guarantees a high degree of reliability and a long service life for the machine.

It is particularly important to adhere to the oil change intervals and use the specified type of lubricant.

Observe the following when using and checking lubricants and operating fluids:

Note!

Cleanliness is of the utmost importance when changing oil.

Clean all filler plugs, filler covers and drain plugs and their surroundings before opening.

If possible, drain the oil when it is at operating temperature.

Ensure that old oils are collected and disposed of in an environmentally acceptable manner, including removable oil filter cartridges.

5 - 10

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Lubricants and operating fluids

Danger!

When checking and changing lubricants and operating fluids, ensure that the following precautions are adhered to: Unless otherwise indicated, carry out all work on the machine on level, solid ground and with the engine shut down.

Whenever you access the engine compartment, always secure the cover and side doors to prevent them from accidentally falling back or closing.

Only refuel the machine when the engine is shut down, do not smoke and avoid open flames.

Turn the battery master switch to position 0 (off) and remove the ignition key.

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 11

Maintenance

Operating instructions

Lubricants and operating fluids

5.4.2

Lubrication chart

Fig. 5-5

5 - 12

Lubrication chart - A 904 C-Litronic

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Lubricants and operating fluids

Symbol

Display

Quantity (liters)*

Diesel engine

23,0

Hydraulic tank

210

Swing gear

5,0

Transmission

3,3

Rigid axle with multi-disk brake

12,5

Rigid axle with drum brake

12,0

Wheel head, rigid axle with multi-disk brake

2,0

Wheel head, rigid axle with drum brake

1,7

Steering axle

10,5

Wheel head, steering axle

2,0

General lube points Check oil level Oil change First oil change Lubrication Operating instructions

Tab. 5-3

Lubrication chart key

* = Guide values

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 13

Maintenance

Operating instructions

Lubricants and operating fluids

5.4.3 Description

Lubrication chart Medium

Symbol

Classification

Viscosity

Quantity

(liters)* Diesel engine

Engine oil

API-CG-4, CF-4 or CH-4, ACEA-E2-96, E396 or E4-98, E5-99

SAE 5W-40 SAE 10W-30 SAE 10W-40 SAE 15W-30 SAE 15W-40

23,0

Hydraulic tank

Engine oil

API-CD, APICD+SF, ACEA-E4, ACEA-E5

SAE 10W SAE 10W-30 SAE 10W-40 SAE 15W-40 SAE 20W-20 SAE 30W

210

Swing gear (as parking brake)

Gear oil

API-GL-5 MIL-L 2105 B, C or D

SAE 80W-90 or SAE 90

5,0

Swing gear (as positioning swing brake)

Gear oil

API-GL-5 MIL-L 2105 B

SAE 90 LS

5,0

Steering axle

Gear oil

API-GL-5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

10,5

Wheel heads of steering axle

Gear oil

API-GL-5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

2.0 each

Rigid axle with multi-disk brake

Gear oil

API-GL-5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

12,5

Wheel heads for rigidaxle with multi-disk brake

Gear oil

API-GL-5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

2.0 each

Rigid axle with drum brake

Gear oil

API-GL-5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

12,0

Wheel heads for rigidaxle with drum brake

Gear oil

API-GL-5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

1.7 each

Transmission

Gear oil

ZF TE-ML 07

SAE 10W-30 SAE 10W-20

3,3

5 - 14

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Lubricant and operating fluid specifications

Description

Medium

Symbol

Classification

Viscosity

Quantity

(liters)* Race and teeth of swing ring, attachment bearing

Lubricating grease

Hinges, joints, locks

Engine oil

Rubber seal on doors and covers

Silicon spray or talcum powder Tab. 5-4

High pressure grease KP2k or EP2

Consistency 2 NLGI grade

-

-

-

-

-

-

-

-

-

Lubrication chart

* = Guide values

5.4.4 Description

Operating fluid chart Medium

Symbol

Quantity

(liters)* Fuel tank

Commercially available Diesel fuel with sulphur content <= 0.5 %

350

Coolant

Anti-corrosion fluid and antifreeze Fill with DCA 4

25,0

Window washer system

Commercially available window washer fluid or denatured alcohol

-

3,0

Refrigerant Air conditioning system

R 134 a

-

1.6 kg

Refrigerant oil in A/C compressor

PLANETELF PAG SP 20

-

0,193

Tab. 5-5

Operating fluid chart

* = Guide values

5.5 Lubricant and operating fluid specifications 5.5.1

Lube oil for the Diesel engine The lube oil requirements for Diesel engines are based on the following classifications:

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 15

Maintenance

Operating instructions

Lubricant and operating fluid specifications

Classification

Specification

API classification (American Petroleum Institute)

CG-4, CF-4, CH-4

ACEA (CCMC) - classification (Association des Constructeurs Européens de l´Automobile)

E2-96 (D4), E3-96 (D5), E4-98, E5-99

Tab. 5-6

Lube oil for the Diesel engine

The engine oil for the Diesel engine can be selected according to the following graphic.

Fig. 5-6

5.5.1.1

Engine oil for use as lube oil for the Diesel engine

Oil change intervals for the turbocharged engine Conditions of use

Sulphur content in fuel

Oil change interval dependent on oil viscosity: CH-4 CG-4 CF-4 E2-96 (D4)

E3-96 (D5) E4-98 E5-99

Climate normal to -10 °C

up to 0.5 % above 0.5 %

250 hrs.

125 hrs.

500 hrs.

250 hrs.

below -10 °C

up to 0.5 % above 0.5 %

125 hrs.

-

250 hrs.

125 hrs.

Tab. 5-7

Oil change intervals for the turbocharged engine

Oil change intervals for Diesel engine depend on the following criteria: at 500 operating hours when using initial fill oil of quality E3-96. every 500 operating hours. e zone, sulphur content in fuel and oil quality(see Tab. 5-7) and oil filter should be changed at least once a year.

5 - 16

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Lubricant and operating fluid specifications

5.5.2

Fuel Diesel fuels should meet the minimum requirements of the below listed, approved fuel specifications.

The sulphur content should not exceed 0.5 % . A higher sulphur content will affect the oil change intervals and the engine life.

5.5.2.1

Lubricity Decreasing sulphur content has raised the problem of Diesel fuel lubricity. It has been shown that Diesel fuels containing the maximum permitted European sulphur limit of 0.05 % can cause wear in the fuel injection system (particularly for distributortype injection pumps). fuel lubricity must be < 400 µm according to the HFFR (60°) test.

Suppliers should supply the additives as the responsible party for the fuel quality. It is not recommended that customers add secondary lubricity additives.

5.5.2.2

Flow improvement by adding petrol (regular gasoline) When ambient temperatures are below approx. 0 °C, the flow properties of summer Diesel fuels can become insufficient due to paraffin separation.

The same also occurs in winter Diesel fuels used in temperatures below -15 °C. Frequently, Diesel fuels with additives with a use temperature of up to -20 °C are offered.

To avoid malfunctions, Diesel fuel must be mixed with regular gasoline or petroleum at lower temperatures.

Adding regular gasoline should be viewed as an emergency remedy and must not exceed 30 % by volume.

Super petrol (Super or premium gasoline) may not be used for mixing. Engine performance can be reduced depending on the additives mixed in for cold weather conditions. For this reason, additions to the mixture should be kept as low as possible by taking the current ambient temperatures into account.

Danger!

For safety reasons, mix fuel only in the fuel tank.

Note!

When refuelling, the specifically lighter additional fuel should be added before the Diesel fuel. Then run the engine until the mixed fuel is distributed through the entire fuel system (see Tab. 5-9).

Approved fuel specifications DIN EN 590 ASTM D 975 - 89a 1 D and 2 Further fuel specifications only after consultation with LIEBHERR Diesel engine development.

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 17

Maintenance

Operating instructions

Lubricant and operating fluid specifications

Mixing ratio Diesel fuel / regular gasoline Ambient temperature °C

Summer Diesel fuel %

Additive regular gasoline %

0 to -10

70

30

-10 to -15

50

50*

-15 to -20

-

-

-20 to -25

-

-

Tab. 5-8

Mixture ratio summer Diesel fuel / regular gasoline

Ambient temperature °C

Winter Diesel fuel %

Additive regular gasoline %

type -15 °C

type -20 °C

for type -15 °C

for type -20 °C

0 to -10

100

100

-

-

-10 to -15

100

100

-

-

-15 to -20

70

100

30

-

-20 to -25

50

70

50*

30

Tab. 5-9

Mixing ratio winter Diesel fuel / regular gasoline

* If an addition of 50 % is required, use only petroleum (no regular gasoline).

5.5.2.3

Additives to Diesel fuel (flow improver) Commercially available flow improvers can also improve th cold weather conditions. When using them, follow the manufacturer dosage and usage requirements.

5.5.3

Hydraulic oil

5.5.3.1

Mineral oil Engine oils corresponding to the following specifications and regulations are specified: Single-grade oils:

API - CD / CCMC - D4 / ACEA - E1 Mercedes-Benz regulations, Page no. 226.0 and 227.0

Multi grade oils:

API - CD + SF / CCMC - D5 / ACEA - E3 Mercedes-Benz regulations, Page no. 227.5 and 228.3

Tab. 5-10 Specified engine oils for use as hydraulic oil The engine oil for use as hydraulic oil can be selected according to the following chart.

5 - 18

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Lubricant and operating fluid specifications

Fig. 5-7

Engine oils for use as hydraulic oil

Warm-up guidelines At temperatures up to 10 °C below the given limit (black bar), the following warm-up guidelines apply: After starting the engine, regulate the Diesel engine only to approx. 1 / 2 of the rated speed. Operate the hydraulic cylinder and motors, move cylinder briefly against the stop. Warm-up duration approx. 10 minutes.

At even lower temperatures: Preheat the oil tank before starting the engine.

5.5.3.2

Environmentally friendly hydraulic oils Note!

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

The environmentally friendly hydraulic oils recommended by LIEBHERR are limited to oils with a synthetic ester basis with a viscosity according to ISO VG 46.

The initial oil fill is carried out at the factory according to an approved list. Use of an environmentally friendly hydraulic oil must first be coordinated with LIEBHERR. Plant-based oils are not to be used due to their insufficient temperature properties.

The use of bypass filters is required.

5.5.3.3

Hydraulic oil monitoring Note!

Environmentally friendly hydraulic fluids should generally be checked at regular intervals through an oil analysis.

Oil analysis is recommended for mineral oils.

Machines in normal use: at least every 500 operating hours Machines in dust intensive use: at least every 250 operating hours LIEBHERR recommends that oil analyses be carried out by the WEAR CHECK Company and that oil changes are performed on the basis of the lab report (see also customer service and product information).

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 19

Maintenance

Operating instructions

Lubricant and operating fluid specifications

5.5.3.4

Hydraulic oil monitoring in normal use

Fig. 5-8

Taking an oil sample in normal use

h

Operating hours

2

Second oil sample

1

First oil sample

3

additional oil samples every 500 operating hours

Oil change according to analysis and lab report.

Change intervals for hydraulic oil return filter (20.5 µm): first after 500 operating hours, additional changes every 1000 operating hours.

5.5.3.5

Hydraulic oil monitoring in dust intensive use

Fig. 5-9 h 1

Taking an oil sample in dust intensive use

Operating hours First oil sample

2 3

Second oil sample additional oil samples every 250 operating hours

Oil change according to analysis and lab report.

Change intervals for hydraulic oil return filter (10 µm): first after 500 operating hours, additional changes every 500 operating hours.

5.5.3.6

Notes on reducing hydraulicoil contamination in dust intensive use If the machine is generally operated with the hydraulic hammer, or if it is used under similar circumstances (heavy dust occurrence), there is the risk that the hydraulic oil will become contaminated more than usual.

To prevent early wear of hydraulic components, the oil change intervals (and intervals between oil samples) should be reduced and the following regulations should also be observed: hours. dges must be used instead of the usual 20 / 5 µm filter cartridges. must be replaced with a 2 µm fine filter (fineness of standard filter is 7 µm).

5 - 20

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Lubricant and operating fluid specifications

ed every time the hydraulic oil is changed (every 500 operating hours).

Note!

Machines fitted with a hydraulic hammer at the factory and retrofitted hydraulic hammer kits feature these 10-µm filter cartridges and 2-µm breather filters.

5.5.4

Gear oil Gear oils must correspond to the specifications

.

Engine oils used in gears must correspond to the specifications .

For viscosity classes SAE 80 and SAE 90 according to MIL-L-2105 D, oil of viscosity class SAE 80W90 can also be used.

5.5.5

Lubricating grease and other lubricants Grease

Description / manufacturer

Lubricating grease for the swing ring / general lube points

The grease must correspond to specification KP2k, consistency 2 or NLGI grade according to DIN 51818 and DIN 51825 or EP 2 according to NF-T-60 132.

The grease must consist of a lithium complex and have a VKA value of at least 2300 N according to DIN 51350 and ASTM D 2596.

Contact spray for slip rings

Cramolin

Lubricant for pistons, piston nuts and piston bearing installations on hydraulic cylinders

Gleitmo 800

Special anti-corrosive fluid for installation areas of sealing elements on hydraulic cylinders

Castrol-Tarp

Anti-corrosion grease for exposed piston rods (for cylinders that are not moved often or during transport)

Liebherr special grease CTK

Tab. 5-11 Lubricating grease and other lubricants

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 21

Maintenance

Operating instructions

Lubricant and operating fluid specifications

5.5.6

Coolant To improve coolant quality, water filter attachments are used for LIEBHERR Diesel engines.

Due to this measure, the coolant is filtered again in the bypass flow and is cleaned of dirt and rust particles, which could result in leaks on the coolant pumps.

A chemical additive in the filter (DCA 4) also protects the cooling system and parts which are in contact with coolant, such as the coolant pump, cylinder liners etc. from cavitation, corrosion, sediment and foaming.

5.5.6.1

Coolant with DCA 4 (DIESEL COOLANT ADDITIVES) Ambient temperature to

Part water in %

Part anti-corrosion fluid / antifreeze in %

-37 °C / -34 °F

50

50

-50 °C / -58 °F

40

60

Tab. 5-12 Mixing ratio water / anti-corrosion fluid / antifreeze The coolant must contain a minimum of 50 % anti-corrosion fluid / antifreeze year round. This corresponds to an antifreeze protection up to -37 °C and ensures sufficient protection from corrosion.

In case of coolant loss, it must be ensured, when adding coolant, that this amount does not fall short of 50 % by volume.

Note!

Do not use more than 60 % anti-corrosion / antifreeze fluid!

At a higher percentage, the cooling effect and antifreeze protection would actually be reduced.

During maintenance work, check the mixing ratio of the coolant and the DCA 4 concentration.

Note!

2 years.

0.3 and 0.8 units per liter.

5.5.6.2

Anti corrosion fluid In exceptional circumstances and at temperatures which are continually above freezing, e. g. in tropical areas, where no approved anti-corrosion fluid / antifreeze is available, a mixture of water and water soluble anti-corrosion fluid may be used as coolant.

Using DCA 4 without anti-corrosion fluid / antifreeze To protect the cooling system from corrosion, about twice the quantity of DCA 4 must be used compared to the mixing ratio of water and DCA 4 (see Tab. 5-13).

5 - 22

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Lubricant and operating fluid specifications

Note! annually.

0.6 and 1.06 units per liter.

Using other water soluble anti-corrosion fluids Note! annually.

7.5 % anti-corrosion fluid and 92.5 % water.

Overview of approved water soluble anti-corrosion fluids

5.5.6.3

Product description

Manufacturer

DCA 4 Diesel Coolant Additives

Fleetguard

Caltex CL Corrosion Inhibitor Concentrate

Caltex

Chevron Texaco Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free

Chevron Texaco

Havoline Extended Life Corrosion Inhibitor (XLI)

Arteco

Total WT Supra

Total

Refilling the cooling system Before adding new coolant, make sure that the coolant system is clean and flush if necessary.

When filling for the first time or refilling the cooling system after repair work, DCA 4 in liquid form must be mixed with the coolant, in addition to the DCA 4 concentration contained in the water filters.

Cooling system content (liters)

Required amount of liquid DCA 4 (can* or liter)

DCA 4 water filter Description

24 - 39

3

or

1.4

WF 2071

40 - 59

4

or

1.9

WF 2072

60 - 79

5

or

2.4

WF 2073

80 - 115

8

or

3.8

WF 2073

Tab. 5-13 Filling quantities - Cooling system * = 0.5 liter each

5.5.6.4

Change intervals for the DCA 4 water filter The DCA 4 water filter must be changed every 500 operating hours.

If there is no coolant loss in the cooling system, then, for change intervals of 500 operating hours, there is sufficient DCA 4 concentration in the cooling system.

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 23

Maintenance

Operating instructions

Lubricant and operating fluid specifications

5.5.6.5

Regulations for fresh water quality To prepare the coolant, use clean water, which is not too hard. Often, but not always, drinking water meets these requirements. Sea water, brackish water, brine and industrial wastewater are not suitable.

Fresh water quality when using anti-corrosion fluid / antifreeze Content

Quantity

Sum of alkaline earths (water hardness)

0.6 to 3.6 mmol / l (3 to 20 °d)

ph value at 20 °C

6.5 to 8.5

Chloride-ion content

max. 80 mg / l

Sum of chloride + sulphate

max. 100 mg / l

Fresh water quality when using coolant with DCA 4

5.5.6.6

Content

Quantity

Sum of alkaline earths (water hardness)

0.6 to 2.7 mmol / l (3 to 15 °d)

ph value at 20 °C

6.5 to 8.0

Chloride-ion content

max. 80 mg / l

Sum of chloride + sulphate

max. 80 mg / l

Approved anti-corrosion fluid / antifreeze Concentrate, undiluted

Product description

Manufacturer

Country

Agip Antifreeze Plus

Agip Petrol S.p.A., Rome

I

Agip Langzeit-Frostschutz

Autol-Werke GmbH, Würzburg

D

Antigel DB 486

Sotragal S.A., St. Priest

F

Aral A

Aral AG, Bochum

D

Avia Frostschutz APN (G48-00)

Deutsche Avia-Mineralöl GmbH, Munich

D

BP Antifrost X 2270 A

Deutsche BP AG, Hamburg

D

BP Napgel C 2270 / 1

BP Chemicals LTD., London

GB

Caltex Engine Coolant DB

Caltex UK Ltd, London

GB

Caltex Extended Life Coolant

Caltex UK Ltd, London

GB

Castrol Anti-Freeze O

Deutsche Castrol Vertriebs GmbH, Hamburg

D

Century F.L. Anti-Freeze

Century Oils, Hanley, Stoke-on-Tent

GB

Chevron DEX-COOL Extended Life Anti-Freeze / Coolant

Chevron Texaco, San Ramon, CA

USA

DEUTZ Kühlschutzmittel 0101 1490

Deutz Service International GmbH, Cologne

D

Esso Kühlerfrostschutz

Esso AG, Hamburg

D

5 - 24

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Lubricant and operating fluid specifications

Product description

Manufacturer

Country

Fircofin

Fuchs Mineralölwerke GmbH, Mannheim

D

Frostschutz Motorex (G48-00)

Bucher & Cie, Langenthal

CH

Frostschutz 500

Mobil Oil AG, Hamburg

D

Glacelf Auto Supra

Total Nederland N.V., Den Haag

NL

Glycoshell AF 405

Shell Deutschland GmbH, Hamburg

D

Glycoshell N

Shell Deutschland GmbH, Hamburg

D

Glysantin (G 48-00)

BASF AG, Ludwigshafen

D

Havoline XLC

Arteco, Gent

B

Havoline DEX-COOL Extended Life Anti-Freeze/ Coolant

Chevron Texaco, San Ramon, CA

USA

Igol Antigel Type DB

Igol France, Paris

F

Labo FP 100

Labo Industrie, Nanterre

F

Motul Anti-Freeze

Motul SA, Aubervilles

F

OMV Kühlerfrostschutzmittel

OMV AG, Schwechat

A

Organifreeze

Total Deutschland GmbH, Düsseldorf

D

OZO Frostschutz S

Total Deutschland GmbH, Düsseldorf

D

Total Antigel S-MB 486

Total Deutschland GmbH, Düsseldorf

D

Total Frostfrei

Total Deutschland GmbH, Düsseldorf

D

Veedol Anti-Freeze O

Deutsche Veedol GmbH, Düsseldorf

D

Wintershall Kühlerschutz

Wintershall Mineralöl GmbH, Düsseldorf

D

Tab. 5-14 Approved anti-corrosion fluid / antifreeze (concentrate, undiluted)

50:50 premix (water: anti-corrosion fluid / antifreeze) Product description

Manufacturer

Country

Liebherr Anti-Freeze APN Mix Ident-Nr. 8611045

Liebherr

D

Caltex Extended Life Coolant Pre-Mixed 50/50 (ready-to-use-version)

Caltex UK Ltd, London

GB

Chevron DEX-COOL Extended Life Prediluted 50/50 Anti-Freeze/Coolant

Chevron Texaco, San Ramon, CA

USA

Havoline XLC, 50/50

Arteco, Gent

B

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 25

Maintenance

Operating instructions

Diesel engine

Product description

Manufacturer

Country

Havoline DEX-COOL Extended Life Prediluted 50/50 Anti-Freeze/Coolant

Chevron Texaco, San Ramon, CA

USA

Organicool 50/50

Total Deutschland GmbH, Düsseldorf

D

Tab. 5-15 Approved anti-corrosion fluid / antifreeze / 50:50 premix

5.6 Diesel engine 5.6.1

Checking the oil level in the Diesel engine Danger!

Danger of burning.

The engine oil is hot when at or near operating temperature.

Do not allow your skin to come into contact with hot oil or components containing hot oil.

The machine must be in level position.

Shut down the engine.

Wait until the oil has collected in the oil pan.

Fig. 5-10

Oil level marks on the dipstick

Check the oil level in the engine.

The oil must leave a mark between the min and the max marks on the dipstick.

5.6.2

Changing the Diesel engine oil Note!

Change the oil only if the engine is warm.

5 - 26

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Diesel engine

Fig. 5-11

Drain valve on oil pan, oil filter cartridges, oil filler fitting

To drain the oil (A): Install the supplied oil drain hose 1 to the drain valve on the oil pan.

Catch oil in a suitable container.

To change the oil filter cartridges (B): Unscrew the oil filter cartridges.

Clean the sealing surface on the filter bracket.

Danger!

Danger of burning.

Avoid skin contact with the hot oil when removing the oil filter cartridges.

Lubricate the rubber seal ring on the new oil filter cartridges with oil.

Install the new filter element until the seal ring is touching on the filter head.

Use the oil filter wrench to tighten the oil filter cartridges by hand a half turn.

To add oil (C): Add the oil to the oil filler fitting until the level reaches the upper mark on the dipstick.

Quantity, oil specification and oil change intervals: see Lubrication and maintenance schedule.

5.6.3

V-belt for A/C compressor and alternator installation The Diesel engine is equipped with a tensioning device for the V-belt. This is self-

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 27

Maintenance

Operating instructions

Diesel engine

tensioning and is therefore maintenance-free. The V-belt should be checked regularly for wear and replaced, if necessary.

Fig. 5-12

Replacing the V-belt

To replace the V-belt: To replace the V-belt, a ratchet equivalent to DIN 3122 D12.5 (1/2") is required.

Rotate the tensioning device counterclockwise completely against the spring force.

Remove the V-belt.

Place the new V-belt on the belt pulleys for the crankshaft, A/C compressor, alternator and change over pulley, with the tensioning device rotated counterclockwise.

Move the tensioning device clockwise into the tensioned position.

Note!

When replacing the V-belt, check the tensioning pulley and change over pulley for ease of movement. Replace defective tensioning pulleys and change over pulleys immediately.

5.6.4

Oil separator

Fig. 5-13

5 - 28

Replacing the oil separator

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Cooling system

1 2

Oil separator Vent hole

4 5

O-ring Hose clamp

3

Mounting clamp

6

Hose

A damaged oil separator (e.g. dented cover) may not function correctly.

In the event of damage or if oil vapour emits from the vent hole 2, replace the oil separator.

Replace the oil separator every two years.

To replace the oil separator: Loosen the mounting clamp 3.

Loosen the hose clamp 5.

Push the hose 6 back.

Remove the oil separator 1.

Insert a new O-ring 4 in the oil separator.

Reinstall the oil separator 1 and tighten the mounting clamp 3.

Push on the hose 6.

Tighten the hose clamp 5.

5.7 Cooling system 5.7.1

Checking and cleaning the cooling system

Fig. 5-14

Cleaning the cooling fins

The machine is equipped with a combination oil / water cooler.

Optimum cooling can only be achieved if the cooler is kept clean.

Check the engine, fan and cooler for damage and clean if necessary.

If required, clean the cooling fins with compressed air or a steam jet (from inside to the outside, see arrow).

In case of leaks, change the pressure relief valve 6 (expansion tank lock ring).

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 29

Maintenance

Operating instructions

Cooling system

Check the condition and seals of the connector hoses between the radiator and engine the as well as the coolant hoses regularly.

5.7.2

Checking the coolant level Danger!

Danger of burns due to hot coolant.

The engine cooling system is hot and pressurized when at or near operating temperature.

Avoid touching coolant or coolant-bearing parts.

Check the coolant level only when the engine has cooled off sufficiently.

Turn the cap a half turn.

In this position, relieve any pressure that may be present. After equalizing the pressure, slowly open the cap all the way.

Fig. 5-15

Expansion tank

The coolant must always be visible in the sight gauge (arrow).

Add coolant if necessary.

Close the cap.

After adding coolant, allow the engine to run for a short time with the heater turned on and then recheck the coolant level.

5.7.3

Coolant antifreeze and anti-corrosion fluid The system must be filled with antifreeze year round.

At delivery, the coolant contains antifreeze for temperatures up to -37 °C (this corresponds to approx. 50 % antifreeze).

Quantity: see Lubrication Chart Keep the concentration of anti-corrosion additive in the cooling system constant, particularly when refilling.

Check this concentration each time larger amounts of coolant are lost or at regular intervals. If necessary, add anti-corrosion additives to the coolant.

If no coolant is lost, only change the coolant filter regularly.

5 - 30

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Cooling system

5.7.4

Changing water filters The water filter contains an anti-corrosion additive in paste form, which assures the

Fig. 5-16

Water filter

The water filter must be replaced every 500 operating hours: Close the shut off valves (arrows) on the filter housing.

Unscrew the filter element.

Lubricate the seal ring on the new filter element lightly with oil.

Install the new filter element until the seal ring is touching on the filter head.

Note!

The filter element can be damaged.

Do not use any tools to tighten the filter element.

Tighten the filter element by hand with a half turn.

Open the shut off valves again.

5.7.5

Changing the coolant Danger!

Danger of burns due to hot coolant.

Change the coolant only when the engine is cold.

Fig. 5-17

A 904 C-Litronic / 8720337

Shut off valves in cooling circuit

MJFCIFSS

5 - 31

Maintenance

Operating instructions

Cooling system

When changing the coolant, observe the following points: shut off valves for the heater circuit closed.

contact position.

5.7.5.1

Draining the coolant

Fig. 5-18

Draining the coolant

To drain the coolant at the radiator: Open the cap 6 on the expansion tank and remove the cap on the drain valve 1 on the radiator.

Install the supplied drain hose on the drain valve.

Drain the coolant into a suitable container.

To drain the coolant at the Diesel engine: Remove the cap on the drain valve 2 on the oil cooler plate of the engine.

Install the supplied drain hose on the drain valve.

Drain the coolant into a suitable container.

Fig. 5-19

5 - 32

Drain plugs for the cooling circuit

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Cooling system

Caution!

To completely empty the engine (when deactivating the machine for a longer period etc.), the coolant must also be drained at the water pump.

Remove the drain plug 3 on the water pump.

Drain the coolant into a suitable container.

5.7.5.2

Refilling the coolant and bleeding the cooling circuit Close drain valve 1 on the radiator.

Close drain valve 2 on the engine.

Close drain valve 3 on the water pump.

Open the shut off valves for the cooling circuit (see Fig. 5-17).

Open the regulating valve on the heater unit all the way.

Open the fitting 4 on the water collecting line.

Add coolant via the filler neck 6 until the upper edge of the sight gauge on the expansion tank.

Close the fitting 4 as soon as coolant starts to emerge.

Close the cap again.

Allow the engine to run for approx. 20 minutes at engine load.

If necessary, cover the cooling system partially so that the opening temperature of the thermostats is exceeded.

The overheating indicator may not come on.

The water temperature indicator on the monitoring screen must remain below the red area.

Remove the cover on the cooling system again, if it was added.

Allow the engine to continue to run at a low idle for approx. one minute.

Check the coolant level in the expansion tank again and add more coolant, if necessary.

Open the cap.

Add coolant via the filler neck 6 to the center of the sight gauge on the expansion tank.

Close the cap again.

If the coolant level sensor actuates during operation, check the coolant level (refill, if necessary).

Carry out the bleeding procedure as described above.

Caution!

The engine could be damaged.

If the coolant temperature or coolant level indicator turns on, bring the engine immediately to low idle.

Shut down the engine.

Check the coolant level and add coolant, if necessary.

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 33

Maintenance

Operating instructions

Fuel system

5.8 Fuel system Danger!

Danger of explosion!

Avoid open flames when working on the fuel system and when refuelling.

Do not smoke.

5.8.1 5.8.1.1

Refuelling Fuel tank cap

Fig. 5-20

Fuel tank cap

Unscrew tank cap 1 Add fuel via the strainer.

5.8.1.2

Electric refuelling pump (option)

Fig. 5-21

Electric refuelling pump

The electric refuelling pump is used to It is located under the cover on the front of the hydraulic oil and fuel tank. The operating unit 3 is removable.

5 - 34

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Fuel system

For refuelling and storing hoses, proceed as follows: Insert the free end of the suction hose 1 in the fuel supply tank.

Open the shut off valve 2 (positionB).

Use switch S25 (green) to turn on the refuelling pump to pump fuel into the fuel tank of the machine.

The pump turns off automatically as soon as the maximum fill level is reached.

The refuelling pump can be turned off at any time using switch S59 (red).

Caution!

Do not let the pump run dry.

Ensure that the fuel level does not drop below the suction level of the suction hose.

Close the shut off valve 2 (positionA).

Make sure that no fuel remains in the suction hose 1 before storing the hose.

Roll up the suction hose 1 and place it in the storage compartment.

Close the cover again.

5.8.2

Draining the water from the fuel tank

Fig. 5-22

Draining the water from the fuel tank

To drain the fuel tank and the fuel system daily: Place a suitable container underneath the tank.

Unscrew the drain valve 28 on the underside of the fuel tank.

Drain the water until fuel emerges.

Close the drain valve 28 again.

If conditions of use and fuel quality permit, the maintenance interval can be increased to once a week.

Note!

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

The indicator P3 shows the fuel reserves.

When the red bar P3.1 light up, then there is still low reserve quantity in the tank.

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 35

Maintenance

Operating instructions

Fuel system

If the fuel level in the tank is low, refill the tank before starting to work.

5.8.3

Emptying and cleaning the fuel tank

Fig. 5-23

Fuel tank

The tank bottom is equipped with a drain valve 28.

Place a suitable container underneath the tank.

To drain off the water, turn the drain plug on the drain valve 28 by two turns until fuel, which contains no water, emerges.

Close the plug again.

To empty, remove the tank cap 96 and the drain valve 28 and catch the fuel in a suitable container.

Check the fuel tank and fill strainer 97 regularly for contamination.

If necessary, replace the fill strainer 97 and / or flush the fuel tank.

5.8.4

Draining and changing fuel filter cartridges

Fig. 5-24 1

Fuel filter cartridges

Fuel pre-filter

2

Fuel fine filter

3

Screw cap

To empty the fuel filter cartridge water separator: Place a suitable container underneath the tank.

Open the screw cap 3 of the fuel pre-filter cartridge 1 daily.

5 - 36

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Fuel system

Drain off water until fuel starts to flow out.

Close the plug.

To change fuel filter cartridges: Unscrew fuel filter cartridge.

Lubricate the rubber seal ring on the new fuel filter cartridge with oil.

Install the fuel filter cartridge.

Bleed the fuel system.

Intervals: see Inspection and maintenance schedule.

5.8.5

Bleeding the fuel system

Fig. 5-25

Bleeding the fuel system

To bleed the fuel filter: Loosen the bleeder screw 1 (E <- ) on the filter console and back out the screw by 2-3 threads.

Operate the hand pump 2 until fuel free of air bubbles emerges.

Tighten the bleeder screw 1 on the filter console.

To bleed the fuel lines: Place a suitable container underneath the tank.

Loosen the fuel line 3 from the fuel filter on the injection pump (see arrow).

Operate the hand pump 2 until fuel free of air bubbles emerges.

Retighten fuel line 3.

To bleed the overflow valve: Place a suitable container underneath the tank.

Loosen the overflow valve 4.

Operate the hand pump 2 until fuel free of air bubbles emerges.

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 37

Maintenance

Operating instructions

Dry air filter

Retighten overflow valve 4.

To bleed injection lines: Place a suitable container underneath the tank.

Loosen the union nuts of the injection lines at the injection valves.

Operate the starter until fuel free of air bubbles emerges.

Tighten the union nuts.

Start the engine.

If the engine does not start, repeat the bleeding procedure.

5.9 Dry air filter Maximum engine protection against premature wear due to dust is only possible if the air filter is serviced at regular intervals.

The dry air filter is designed in such a way that it offers maximum protection at long maintenance intervals.

For safety reasons, we do not recommend to wash out filter elements.

Fig. 5-26

Vacuum indicator

The vacuum indicator 9 saves the maximum underpressure on the filter outlet during Diesel engine operation.

The appearance of the red display strip in alarm window 10 indicates that the maximum permissible underpressure of 50 mbar has been reached.

Replace the main element.

Press the reset button 11 to clear the saved underpressure setting.

Fig. 5-27

5 - 38

Dust discharge valve extractor slot

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Dry air filter

Push the extractor slot on the dust discharge valve open by hand once a week to prevent it from sticking due to humidity and dust.

5.9.1

Changing the main element Caution!

Only replace the main element when the maximum permissible intake underpressure has been reached, or at least once a year.

Installing and removing the main element too often could damage the seals between the filter element and the filter housing.

Only replace the safety element after every third change of the main element, or at least once a year.

Before installing a new element, carefully clean the seal and the seal contact surface in the housing.

Fig. 5-28

Changing the filter cartridges

1

Filter housing cover

4

Safety element

2

Filter housing

5

Dust discharge valve

3

Main element Remove the cover 1 with the engine shut down.

Remove the contaminated main element 3.

Clean the interior of the air filter housing and the sealing surface in the housing with a damp cloth.

Caution!

Dirt could enter the engine air intake!

Do not clean the housing by blowing it out with compressed air.

Insert the new main element and ensure that it seals and is positioned correctly.

Close the filter housing 2 with cover 1.

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 39

Maintenance

Operating instructions

Hydraulic system

5.9.2

Changing the safety element Note!

Replace the safety element after replacing the main filter cartridge three times or at least once a year.

Replace the safety element immediately if a visual inspection has shown that the safety element is very dirty.

Remove the main element 3.

Remove the safety element 4.

Clean the interior of the air filter housing carefully with a damp cloth.

Clean sealing surfaces in the housing and inspect for any damage.

Insert the new safety element 4 carefully.

Insert the main filter cartridge 3 and ensure that it seals and is positioned correctly.

Close the filter housing 2 with cover 1.

5.9.3

Checking the filtered air line

Fig. 5-29

Checking the filtered air line

Check the filtered air line between the filter outlet and the engine suction pipe 8 for damage and leaks each time the filter element is replaced.

If necessary, retighten the tension clamp screws 7.

5.10 Hydraulic system Maintenance work on the hydraulic system is restricted mainly to the hydraulic tank.

All other system components do not require special maintenance.

The pipe and hose network should be checked at regular intervals for leaks.

5 - 40

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Hydraulic system

Note!

Strict cleanliness is of particular importance for the hydraulic system.

For this reason, the intervals given

5.10.1

Preparatory activities

Fig. 5-30

Machine position for checking the oil level of the hydraulic system

When checking the oil level or adding oil:

fully extended (bucket and stick fully pulled in),

5.10.2

Checking the oil level in the hydraulic tank

Fig. 5-31

Hydraulic tank oil level

When the machine is in the inspection position, the oil level may not be below the center mark on the sight gauge.

If this is not the case, add oil via the return filter until the level reaches the center mark.

The upper mark MAXI shows the maximum oil level if all cylinders are fully retracted.

The lower mark MINI shows the minimum oil level if all cylinders are fully extended.

If the oil level drops below the lower mark MINI, the symbol appears on screen when the lowest quantity is reached.

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 41

Maintenance

Operating instructions

Hydraulic system

5.10.3

Relieving the pressure in the hydraulic system Danger!

A fine stream of oil can penetrate the skin when under high pressure and cause serious injury.

Before working on the hydraulic system, always relieve the pressure.

Do not check for leaks with bare hands.

Note the following points: The machine must be in the position described above.

Turn switch S75 to position 0 The oscillating axle is released.

Shut down the engine.

Move the pilot control devices (joystick and pedals) in all directions (with the ignition key in contact position).

Danger!

The hydraulic oil is hot when at operating temperature and could be pressurized.

Do not allow your skin to come into contact with hot oil or components containing hot oil.

Fig. 5-32

Relieving the pressure in the hydraulic system

Back out the breather filter 1 by a maximum of one turn.

The pressure in the hydraulic system is relieved.

The breather filter 1 can be turned manually if the safety pin 2 is inserted. An open end spanner can be used if the filter does not open easily.

5 - 42

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Hydraulic system

5.10.4

Emptying and refilling the hydraulic tank

Fig. 5-33 1

Draining and refilling the hydraulic oil

Breather filter

2

Return filter

3

Drain valves

If possible, always fill and empty the hydraulic system using a filler unit.

To drain the oil: The pressure in the hydraulic system must be relieved.

Back out the breather filter 1 by a maximum of one turn.

The pressure in the hydraulic system is relieved.

Remove the cover of the return filter 2.

Install the drain hose to the drain valves 3 in the tank bottom and let the oil flow out into a suitable container.

To refill the hydraulic oil: Back out the breather filter 1 by a maximum of one turn.

The pressure in the hydraulic system is relieved.

Remove the cover of the return filter 2.

Refill the oil through the filter cartridge until the level reaches precisely the center mark on the sight gauge.

Tighten the breather filter 1.

Install the cover of return filter 2.

Caution!

After each hydraulic oil change, bleed the hydraulic pumps.

To drain off condensate water (only for mineral oils): Drain the condensate regularly.

Place a suitable container underneath the tank.

Keep the drain hose on the drain valves 3 (see Fig. 5-33) until oil contains no more water.

Interval: see Maintenance schedule

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 43

Maintenance

Operating instructions

Hydraulic system

5.10.5

Return filter The return filter is located on the top of the hydraulic tank.

Fig. 5-34

Return filter

1

Cover

5

Magnetic rod

2 3

Hex head screw Gasket

6 7

Filter element Protective cylinder

4

Bypass cage

The magnetic rod 5 of the return filter must be cleaned at fixed intervals (see maintenance chart) and the glass fiber filter element 6 replaced.

Note!

When working in dust intensive conditions, please observe the special regulations for filter change.

To clean the magnetic rod or replace the filter element: The pressure in the hydraulic system must be relieved.

Unscrew the four screws on the filter cover and lift out the cover 1 and magnetic rod 5.

Carefully clean the magnetic rod to remove any dirt particles.

Remove the used filter cartridge 5 using the bracket.

Vertically insert the new filter cartridge into the tank, using the bracket and press down lightly. Then place the bracket on the side on the tank ring.

Caution!

Ensure that the filter cartridge is vertically positioned in the tank.

Center the cover unit and bypass cage 4 on the filter element 6 and set it on top.

When doing this, ensure that the gasket 3 is positioned correctly and is in good condition.

5 - 44

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Hydraulic system

Note!

The filling hole of the hydraulic tank is equipped with a protective cylinder 7. This prevents objects from getting into the hydraulic tank. The protective cylinder can be removed from the filling hole, if required.

Note!

Each time you replace the filter element 6, also replace the pressure filter cartridge that is integrated in the servo oil unit.

5.10.6

Servo oil filter The pressure filter 11 is part of the servo oil unit 1 which is located on the rear of the hydraulic tank.

Fig. 5-35

Servo oil unit

1 2

Servo oil unit Mounting stud

12 13

Filter element Filter element seal ring

10

Pressure accumulator

14

Filter housing

11

Pressure filter

15

Filter housing seal ring

Note!

It is not permitted to clean the filter element.

Change the filter element each time the filter housing is opened.

To replace the filter element: The pressure in the hydraulic system must be relieved.

Unscrew the filter housing 14 from pressure filter 11 and remove filter element 12.

Clean the filter housing.

Oil the thread and sealing surfaces on filter housing 14 and on servo oil unit 1 as well as seal rings 13 and 15 with hydraulic oil.

Carefully push the new filter element 12 onto the mounting stud 2.

Screw filter housing 14 on completely and turn back by hand 1/4 turn (approx.

90°).

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 45

Maintenance

Operating instructions

Hydraulic system

5.10.7

Servo circuit The joysticks do not require special maintenance.

Inspect the pipe network as well as connections on all components (pressure accumulator, pressure limiting valve, pressure filter etc.) regularly for leaks.

Danger!

The pressure accumulator 10 (see Fig. 5-35) ensures that the servo circuit has enough pressure for a few movements, even after the Diesel engine has been shut down.

Before working on the servo circuit, the control pressure must be relieved as follows: Place the attachment on the ground.

Shut down the engine.

Operate both joysticks (with ignition key in contact position).

5.10.8

Bleeding the hydraulic pump

Fig. 5-36

Hydraulic pump

After working on the pump or after changing oil in the hydraulic system, the hydraulic pump must be bled.

Loosen the leak oil hose slightly and allow the air to escape.

As soon as hydraulic oil emerges with out air bubbles, tighten the leak oil hose again.

Before operating the pump for the first time, after repairing or replacing the pump, the pump housing must be filled with hydraulic oil via the same connection.

5.10.8.1

Unscrew the suction hose to the pump The shut off valve on the hydraulic tank to the suction hose has two positions: a open b closed If the suction hose must be removed on the pump or the hydraulic tank, close the shut off valve on the hydraulic tank b.

Relieve the pressure in the hydraulic system.

Remove the plug 1 at the fitting on the pump side of the suction hose.

Drain the hydraulic oil from the pump and suction hose.

5 - 46

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Hydraulic system

After completion of the repair, turn the shut off valve to its starting position a and lock.

Retighten the breather filter on the hydraulic tank.

5.10.8.2

Breather filter on the hydraulic tank

Fig. 5-37

Breather filter on the hydraulic tank

The pressure in the hydraulic system must be relieved.

Replace the filter 1 and retaining pin 2 each time the hydraulic oil is changed (see "Inspection and maintenance schedule").

Note!

When working in dust intensive conditions, please observe the special regulations for filter change.

5.10.9

Servicing the hydraulic cylinder

5.10.9.1

Checking the piston rod bearing

Fig. 5-38

Piston rod bearing

Note When a leak occurs on the piston rod bearing of a hydraulic cylinder (arrow), then the seal kit must be replaced by a LIEBHERR mechanic.

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 47

Maintenance

Operating instructions

Hydraulic system

5.10.9.2

Protecting the piston rods

Fig. 5-39

Machine with piston rods retracted

When the machine is out of service for more than 4 weeks and particularly for transport by sea, the following measures must be taken: Position or transport the machine in such a way that the piston rods are fully retracted.

Cover any exposed piston rods with a thick layer of acid free anti-corrosion grease.

Grease specification: see "Lubricants and operating fluids" For sea transport, check the preservation of the piston rods again after loading.

Cover piston rods with anti-corrosion grease also if a cylinder is used with a low stroke for certain applications, and the piston rod is not regularly covered with hydraulic oil (e.g. cylinder on basic boom when working above ground).

Regularly check the condition of little moved hydraulic cylinders.

5.10.10

Replacing hydraulic hoses

Fig. 5-40

High pressure hose with SAE fitting

Danger!

A defective hydraulic hose can cause accidents and injuries.

Replace defective hydraulic hoses (bubbles, moisture, damaged top edge etc.) immediately.

Install new hydraulic hoses without torsion.

Ensure that the hydraulic hose is not twisted when mounting.

Installed high pressure hoses with SAE connections have a nominal diameter of 16, 20 or 25.

5 - 48

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Changing the oil on components

Tighten the mounting screws of SAE fittings with the following tightening torques. :

Screw

Grade

Torque

M10

10.9

68 Nm

M12

10.9

117 Nm

M14

10.9

185 Nm

Tab. 5-16 Tightening torques for SAE fittings

5.11 Changing the oil on components 5.11.1

General notes The machine must be in level position.

Shut down the engine.

Wait for a short time until the oil has collected in the oil pan.

If possible, drain the oil when it is at operating temperature.

5.11.2

Swin gear - oil change

Fig. 5-41

Changing the oil on the swing gear

1

Drain valve

3

Oil container

2

Drain hose

4

Cap

To drain the oil: Remove the cap 4.

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 49

Maintenance

Operating instructions

Changing the oil on components

Unscrew the cover of the drain valve 1 via the opening on the base plate of the swing platform.

Screw the provided drain hose 2 on the drain valve and allow the oil to flow into a suitable container.

Remove the hose 2.

Reinstall the cover of the drain valve 1.

To add the oil: Add the oil via the tank 3 until the level reaches the MAX mark.

Reinstall cover 4.

Fig. 5-42 1

Changing the oil in the transmission

Oil drain plug

2

Oil filling and oil filler plug

To drain the oil: Remove the oil filler plug 2.

Remove the oil drain plug 1.

Drain the oil into a suitable container.

Install the oil drain plug 1.

To add the oil: Add the oil until the oil level reaches bore 2.

Install the oil filler plug 2.

5 - 50

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Changing the oil on components

5.11.4

Steering and rigid axle - oil change

Fig. 5-43 1

Changing the oil on the steering axle and rigid axle

Oil drain plug

2

Oil filling and oil filler plug

To drain the oil: Remove the oil filler plug 2.

Remove the oil drain plug 1.

Drain the oil into a suitable container.

Install the oil drain plug 1.

To add the oil: Add the oil until the oil level reaches bore 2.

Install the oil filler plug 2.

To drain the oil:

Fig. 5-44

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

Turn the wheel head until the plug is located exactly vertically beneath the center of the wheel.

Remove the plug and drain the oil to flow into a suitable container.

Reinstall the plug.

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 51

Maintenance

Operating instructions

To add the oil: Turn the wheel head until the level mark line is exactly horizontal.

Add the oil up to the bottom edge of the bore.

Reinstall the plug.

Check the wear on the multi-disk brake at least once a year.

The wear on the multi-disk brake can be checked without removing the planetary carrier or disks (see Service manual).

Check brake wear also in case of the following problems:

5.13 Electrical system 5.13.1

Notes for electrical system Danger!

Danger of injury due to spark formation.

Avoid sparks and open flame when charging batteries or working on the batteries.

Always wear safety glasses and protective gloves. correct function at regular intervals.

Burnt out fuses and bulbs must be replaced immediately after the cause of the defect has been rectified.

Fix any problems, such as loose connections, chaffed wires or incorrectly attached clamps immediately.

Disconnect the batteries when working on the electrical system or when carrying out electric arc welding on the machine.

Danger!

Danger of injury due to spark formation.

Disconnect the negative terminal (-) first and connect it last.

5 - 52

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Electrical system

5.13.2

Battery master switch Caution!

Be especially careful with machines with built-in auxiliary heater.

Turn the battery master switch only off when the auxiliary heater's after-run is completed.

Fig. 5-45

Battery master switch

Before starting any work on the electrical system, including welding work on the machine, switch the battery master switch to position 0.

When washing the machine, cover the electrical components (particularly the alternator, generator, wiring, electronic components and transmitters) to prevent moisture penetrating.

When cleaning the engine with a water / steam jet, do not hit electric sensors such as oil pressure switches directly with water or steam.

Otherwise moisture could penetrate and lead to contact corrosion and the failure of the transmitters.

Oil pressure switches are not watertight due to the necessary membrane ventilation.

Note!

Battery can discharge if the machine is out of service for longer periods of time.

Before a longer down time, switch the battery master switch to position 0 (off).

5.13.3

Battery care The battery must always be kept clean to ensure proper function.

Especially the pole ends and battery terminals A must be cleaned regularly and then covered with a thick layer of acid free grease (see Fig. 5-46).

Danger!

Bent rubber hoses of central degasification increase the risk of explosion!

The hydrogen created in the batteries may not be allowed to build up in the battery compartment and must be able to escape through the rubber hoses. The hoses of the central degasification must be routed without kinks.

Check the condition of the hoses B regularly, especially after installing a battery (see Fig. 5-46).

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 53

Maintenance

Operating instructions

Electrical system

The fluid level in the cells should be 10 to 15 mm above the top of the plate. Use only distilled water when refilling.

Fig. 5-46

Battery care

From time to time, measure the acid concentration C using an acid tester.

When the battery is fully charged, the specific weight is 1.28 kg/l (31.5° Bé).

If the acid tester displays a lower value, then the battery is more or less discharged and must be recharged, if necessary.

5.13.4

Slip ring assembly (option)

Fig. 5-47

Slip ring assembly

Slip ring assemblies are sensitive to moisture. An oxide layer can form on the conductive surfaces, which restricts the flow of current. Electrical users in the undercarriage will no longer be supplied sufficiently with current, which can lead to malfunctions.

To prevent this, it is recommended that the following work is carried out every 500 operating hours.

Unscrew the lock nuts 1.

Remove the slip ring housing 2.

Clean the oxidation off the slip ring assembly (use a cleaning spray if necessary).

Replace damaged (corroded) wire lugs.

Spray "Cramolin" contact spray on all slip ring elements.

5 - 54

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Heating and Air conditioning system

Replace the housing 1.

Fasten the housing 1 evenly with lock nuts 2.

5.14 Heating and Air conditioning system The machine is equipped with a combined heating and air-conditioning system as standard.

5.14.1

Recirculated and fresh air filter

Fig. 5-48

Recirculated air filter

Fig. 5-49

Fresh air filter

The air flow in the heating and air conditioning system is reduced when the filters are dirty and this frequently results in the system icing up or shutting down.

1and3 every 500 operating hours. rking in dust intensive conditions. without these filters, since the heat exchanger 6 will be clogged quickly (see Fig. 5-50).

To clean and change the recirculated and fresh air filters: To remove the recirculated air filter 1 ward.

Open the quick connections 2 by a quarter turn.

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 55

Maintenance

Operating instructions

Heating and Air conditioning system

Remove the recirculated air filter 1.

Remove the deflector 4.

Remove the fresh air filter 3.

Note!

Never wash the filter elements with hot water or a steam jet.

If damaged or in a bad condition, replace the filter elements.

Blow out the filter elements 1 and 3 with compressed air or clean in cold or lukewarm water.

5.14.2

Heating system Carry out the following maintenance work on the heating system annually before the start of the heating period: oolant circuit, the hose connections on the heat exchanger, the seals on the shut off valves and the hose clamps. rosion fluid / antifreeze in the coolant.

Fig. 5-50

Heating unit with solenoid valve

To bleed the heating system: To bleed, remove the red cap of the breather valve via the opening A (see arrow).

Push the valve in to allow the air to escape.

To clean solenoid valve 5: Annually, before the start of the heating period, remove and clean solenoid valve 5 (Y46) for the hot water supply.

Clean the solenoid valve also if the heating performance is insufficient.

Rinse out the solenoid valve membrane with water.

Make sure that the compensating hole on the membrane is not blocked with dirt.

To check the heat exchanger: Check the heat exchanger fins 6 annually for damage.

Blow out with compressed air if dirty.

5 - 56

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Heating and Air conditioning system

Align the fins if necessary.

5.14.3

Air conditioning system Switch on the air conditioning system for approx. 10 minutes every 2 or 3 weeks, regardless of the season.

During the operating period, the following maintenance work must be carried out every 500 operating hours:

Fig. 5-51

A/C compressor (left) and condenser (right)

To check the condenser: Check the condenser 8 for contamination.

If necessary, fold down the condenser 8 and blow it out with compressed air, from the inside to the outside (blower side).

Make sure that the condenser fins are clean.

If heavily contaminated, overpressure forms in the air conditioning circuit and the air conditioning system turns off automatically.

To check the A/C compressor: Tighten the mounting screws 7 on the A/C compressor and the bracket on the engine.

Check the condition of the compressor V-belt.

Fig. 5-52

A 904 C-Litronic / 8720337

Dryer-accumulator unit

MJFCIFSS

5 - 57

Maintenance

Operating instructions

Heating and Air conditioning system

To check the dryer-accumulator unit: With the Diesel engine running and the air conditioning system turned on, check the refrigerant level in the sight gauge 10 of the dryer-accumulator unit 9.

Note!

If there is insufficient refrigerant, the white floater ball 11 is at the bottom of the sight gauge.

If the cooling effect is diminishing, have the system refilled by a refrigeration technician.

Determine the degree of moisture of the desiccant in dryer-accumulator unit 9.

To do this, check the color of the indicator pearl 12 in the sight gauge.

If the pearl is blue, the degree of moisture in the air conditioning circuit is OK. If, however, the pearl is pink, then the dryer-accumulator unit is saturated with moisture.

Change dryer-accumulator unit 9 immediately.

Check the condition of dryer-accumulator unit 9 visually.

If it is found that dryer-accumulator unit 9 is rusty or damaged (e. g. on the mounting on the console, or on the hose connection), replace dryer-accumulator unit 9 (pressure tank).

In the last two cases and at least once a year, the dryer-accumulator unit 9 must be replaced by a technician trained in air conditioning systems.

The A/C circuit must be emptied, checked for leaks and refilled. Check the hose lines for abrasion, replace and, if necessary, retighten the hose connections.

Fig. 5-53

Fan motor on the heating /air-conditioning unit

Additional maintenance work: The following maintenance work must also be carried out at least once a year by a technician trained in air conditioning systems: Check the function of the fan motor 13 (M13).

Check the function of the air flaps in the heating / air-conditioning system.

Check the electrical connections for tight seating (good contact).

Check the electrical lines for abrasions.

Check the defrost thermostat 14 (B43) in the evaporator (for function, tight seating and damage).

Check the function of the pressure switch B44 on the dryer-accumulator unit 9 (see Fig. 5-52).

5 - 58

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Lubricating the machine

5.15 Lubricating the machine Note!

When lubricating the machine with a manual grease gun, the required effort is reduced significantly if the grease is pumped in slowly.

5.15.1

Semi-automatic central greasing system The machine is equipped with a central greasing system.

The superstructure and the equipment do not need manual greasing. The bearing points connected to the greasing system can be greased during operations by starting the greasing process.

The chassis is not connected to the automatic greasing system and must be manually greased.

Fig. 5-54

Central greasing pump, semi-automatic

1

Grease container

4

Lubricating nipple for manual intermediate greasing

2

Adapter (refilling the grease container with a filler pump 6)

5

Safety valve

3

Lubricating nipple container

6

filler pump

Starting the greasing process: Greasing is done using switch S84. While the switch is pressed, the electric pump pumps grease to the connected bearing points.

The greasing process should be started once per work shift.

Press switch S84.

Indicator light in the switch flashes.

Grease is delivered to the connected bearing points.

Allow the switch to go on flashing until grease emerges from the bottom end of the hydraulic jacks.

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 59

Maintenance

Operating instructions

Lubricating the machine

Note!

The time needed for greasing depends on the temperature of the grease and of the components connected to the greasing system. In extremely low outside temperatures: up to 30 minutes.

Press switch S84 again.

Indicator light in the switch goes out.

The greasing process is completed.

Fig. 5-55

Monitoring pin on the main distributor

When greasing, the grease delivery can be checked by the continual up and down movement of the monitoring pin. If the monitoring pin is not moving, the following defects are possible: e (grease flows out of safety valve 5). e of a grease which is too viscous. tor's supply circuit.

Find and rectify the cause of the problem immediately.

If the greasing pump is defective, the attached oiling points can be greased centrally with a greasing pump via lubricating nipple 4.

To refill the grease container: The grease container must be checked once a week and refilled if necessary.

Note!

In order to avoid contamination and damage, the grease container should remain closed.

Do not remove the cover of the grease container when refilling.

Refilling the grease container is normally done via adapter 2.

Insert a grease cartridge in the filler pump 6 supplied, connect the pump to the adapter 2 and squeeze the contents of the grease cartridge into the container.

If the filler pump 6 or grease cartridge are not available, the grease container can be refilled using a greasing pump or a grease gun via lubricating nipple 3.

After the grease container has been refilled, an intermediate greasing must be carried out.

Intermediate greasing: Automatic: Start the greasing process with switch S84.

5 - 60

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Lubricating the machine

or Manually: Lubricate the lubricating points via lubricating nipple 4.

Carry out intermediate greasing until grease emerges from the bottom end of the hydraulic jacks.

5.15.2

Fully automatic central greasing system (optional extra) On request, the machine can be fitted with a central greasing system that functions fully automatically.

The superstructure and the equipment do not need manual greasing. The bearing points connected to the greasing system are greased at regular intervals during operations.

The chassis is not connected to the automatic greasing system and must be manually greased.

Fig. 5-56

Central greasing pump, fully automatic

1

Grease container

5

Lubricating nipple for manual intermediate greasing Safety valve

2

Adapter (refilling the grease container with filler pump 9)

6

3

Lubricating nipple container

7/8 LED, green / red

4

Button for manual intermediate greasing

9

filler pump

After switching on the machine, the indicator light in button S84 illuminates. The green LED 7 on the grease gun lights up for about one second, signalling operational readiness.

The greasing process begins automatically after a pause and stops when all bearing points have been greased without the operator having to become involved.

Throughout the greasing process, button S84 and green LED 7 are continuously illuminated.

If there is a malfunction, both button S84 and LEDs 7 and 8 flash simultaneously. The following defects are possible:

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 61

Maintenance

Operating instructions

Lubricating the machine

e (grease flows out of safety valve 6). e of a grease which is too viscous. tor's supply circuit.

Find and rectify the cause of the problem immediately.

When the greasing system is functioning, additional greasing with the greasing pump can be carried out at any time by pressing button S84 on the right-hand control panel or by pressing button 4 on the greasing pump.

If the greasing pump is defective, the attached oiling points can be greased centrally with a greasing pump via lubricating nipple 5.

To refill the grease container: The grease container must be checked weekly and refilled if necessary.

Note!

In order to avoid contamination and damage, the grease container should remain closed.

Do not remove the cover of the grease container when refilling.

Refilling the grease container is normally done via adapter 2.

Insert a grease cartridge in the filler pump 9 supplied, connect the pump to the adapter 2 and squeeze in the contents of the grease cartridge.

If the filler pump 9 or grease cartridge are not available, the grease container can be refilled using a greasing pump or a grease gun via lubricating nipple 3.

After the grease container has been refilled, an intermediate greasing must be carried out.

Intermediate greasing: Automatic: Press button 4. or Manually: Lubricate the lubricating points via lubricating nipple 5.

Carry out intermediate greasing until grease emerges from the bottom end of the hydraulic jacks.

5 - 62

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Lubricating the machine

5.15.3

Lubricate king pin bearing, oscillating pin

Fig. 5-57

Lube points

Caution!

Do not use too much grease on the steering knuckle bearings.

Grease each bearing point with two strokes.

Grease the bearing points via the grease fittings with a manual grease gun.

5.15.4

Central lubrication of undercarriage (option) With the central lubrication of the undercarriage, only the lube points on the steering knuckle and the pins of the oscillating axle are lubricated via a central grease fitting.

Fig. 5-58

Central lubrication system - undercarriage

The central grease fitting is located behind the toolbox on the right step.

Pump 0.08 cm³ per working hour (approx. 2 strokes per week / per shift) with the manual grease gun in the tool box into the grease fitting.

5.15.5

Lubricating the digging tool / bucket tilt device Digging tools and the bucket tilt device are not greased via the central lubrication system. The grease points on the digging tool or the change over lever / connecting link must be greased manually. The corresponding lube points are marked in red.

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 63

Maintenance

Operating instructions

Lubricating the machine

Fig. 5-59

Lubrication of digging tool

In normal use, each lube point must be greased weekly until clean grease emerges on the corresponding bearing point.

In severe applications, for example when handling material that causes wear, when working under water or in multiple shifts, the lubrication must be made daily or for each shift.

5.15.6

Lubricating the grapple (option) The grapple is not lubricated via the central lubrication system. It must be regularly greased manually. The corresponding lube points are marked in red.

Fig. 5-60

Lubrication of grapple

In normal use, each lube point must be greased daily or per shift until clean grease emerges on the corresponding bearing point.

In severe applications, the lubrication interval should be shorted accordingly.

5 - 64

MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Quick change systems

5.16 Quick change systems 5.16.1

Lubricate the mechanical quick change adapter (option) The mechanical quick change adapter is not lubricated via the central lubrication system. The bearing points must be greased using the grease gun.

Fig. 5-61

Lubrication of mechanical quick change adapter

Grease the bearing points via the grease fitting with a grease gun.

Note!

If the mechanical quick change adapter is greased when the pin is extended, the hollow area between the locking pins fills with grease and the pins can no longer be retracted.

Make sure that the locking pins are retracted during the lubrication procedure.

5.16.2

Hydraulic quick change adapter (option) Lubricating the quick change adapter: The hydraulic quick change adapter is not greased via the central lubrication system.

The bearing points must be greased using the grease gun.

Fig. 5-62

Lubricating the quick change adapter

Grease the locking pins 1 via the grease fitting with a grease gun.

A 904 C-Litronic / 8720337

MJFCIFSS

5 - 65

Maintenance

Operating instructions

Quick change systems

Note!

The hydraulic quick change adapter cannot be sufficiently greased if the locking pins are extended.

Make sure that the locking pins are retracted during the lubrication procedure.

Cleaning the strainer:

Fig. 5-63

Cleaning the strainer

The filter disc 12 in the fittings between the connecting hoses and the hydraulic cylinder must be checked for blockages and cleaned, if necessary, every 2000 operating hours.

Remove the cover 20 and the screws 21 from the quick change adapter.

Remove the fittings and hydraulic hoses from the hydraulic cylinder 10.

Screw out the outer mounting assembly 13 using a suitable tool (e g. a tack).

Remove the filter disc 12, check it and clean or replace it, if necessary.

Place the filter disc 12 on the inner mounting assembly 11 and mount the outer mounting assembly 13.

Connect the fittings and hydraulic hoses to hydraulic cylinder 10.

Attach the cover 20 with the screws 21 on the quick change adapter.

5.16.3

LIKUFIX (option) Cleaning LIKUFIX The LIKUFIX hydraulic coupling system is mostly maintenance-free.

We recommend cleaning the system at regular intervals. This will prevent dirt adhering and icing up.

If the system is kept properly clean, the seals are very durable.

Remove thick dirt and dust, and if necessary, clean all coupling parts and the sealing surfaces with a clean, oil-soaked cloth.

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A 904 C-Litronic / 8720337

Operating instructions

Maintenance Quick change systems

Replacing the sealing ring

Fig. 5-64

Replacing the seal

If leaks occur at the coupler plugs (A, see arrows), replace the sealing rings.

Use a screwdriver to push down the sealing plate on the coupler plug and lift out the defective sealing ring with a pointed object (B).

Press the new sealing ring together and place it on the sealing plate with 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 snap into the groove (E).

Remove the screwdriver (F).

The sealing plate must move upwards. If necessary, press the sealing ring down again until the sealing plate is moveable.

Maintaining the electric clutch The system can be fitted with an optional electric clutch (for example to operate a magnet).

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Maintenance

Operating instructions

Parking and swing gear brake

Fig. 5-65 1

Electric clutches

Electric clutch upper part

2

Electric clutch lower part

The following maintenance work must be carried out every 50 operating hours: Switch off magnetic system (if present).

If necessary, remove the working tool.

Switch off the diesel engine Clean the contacts on the electric clutch 1 and 2 with a dry cloth, if necessary use some contact spray (Cramolin).

Check the electric clutches and their threaded cable connections for tight seating.

Check the contacts for wear and tear (for example traces of burning).

Checked the contacts of the upper part 1 for any movement: It must be possible to push the contacts in a little against the spring tension.

Check that the seals on the electric clutch contacts (see arrow) are present and intact.

If you notice any defects, have them rectified immediately.

5.17 Parking and swing gear brake Both the parking brake on the transmission and the swing gear brake are negative acting, wet multi-disk brakes.

They are vented hydraulically and are fully sealed and integrated in the transmission or swing gear.

Their usage purely as parking brakes makes them wear-free and therefore maintenance free.

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MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance General Maintenance points

5.18 General Maintenance points 5.18.1

Replacing wear parts In addition to the normal maintenance and service work, which have to be carried out in the given intervals, the following repairs can also be made by the machine operator or maintenance personnel: the pipe and hose system and on connections of hydraulic components (but not on pressure relief valves which are sealed with a lead seal at the factory). lic lines and fittings on the hydraulic system can be replaced.

It should be noted that only original LIEBHERR spare parts are to be used.

This is particularly true for hoses and hydraulic lines, which must be preassembled at the factory. For all other repairs, particularly when removing the counterweight, factory or dealer mechanics must be consulted.

5.18.2

Replacing the teeth on the digging tool Determine the degree of wear of the teeth visually.

With heavily worn teeth, considerably greater force will be required for the digging tool to penetrate the digging material. The teeth must be replaced in time to prevent damage to the tooth adapter.

Do not work with the machine if teeth on the digging tool are missing or are heavily worn.

To install and remove the teeth:

Fig. 5-66

Replacing the teeth

Use a hammer and driver 1 to knock out the wedge 2 (A ).

Remove the old tooth.

Place a new rubber wedge retainer 3 on the tooth retainer (B).

Push the new tooth on the adapter.

Use the hammer to knock in the wedge 2 (C).

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Maintenance

Operating instructions

Inspection and maintenance schedule

5.18.3

Welding work on the machine Welding work on all main components serving for power transmission (such as the undercarriage frame, swing platform, attachment parts etc.) may only be carried out by the manufacturer or by an authorized workshop.

Disconnect the battery before starting any electric arc welding work on the machine.

Always disconnect the negative terminal (-) first and reconnect it last.

Turn the battery master switch off!

Caution!

If high currents flow through the bearings or sealing elements, they could be burnt.

Move the grounding cable of the welding tool as close as possible to the welding area, so that the welding current cannot flow over parts, such as the swing ring, joints, bearings, bushings, rubber elements or seals.

5.19 Inspection and maintenance schedule Caution!

Careful maintenance can only be carried out when the machine is clean. In particular, visual inspections, such as for cracks, can only be made on a clean machine.

Clean the machine before starting any maintenance work (see also the chapter

Note!

The daily maintenance tasks, which the machine operator has to carry out, include a function check of the brakes (swing gear, operating and parking brake), steering and the electrical and hydraulic systems.

Additionally, a visual check must be made for leaks on the engine, hydraulic system, transmission and axles.

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MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Inspection and maintenance schedule

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 904 C Litronic By maintenance personnel (machine operator)

By authorized expert personnel

First and only interval Repeat interval Special interval every 250 hours

Note

First and only interval Repeat interval

DIESEL ENGINE Check oil level and oil pressure in engine Check coolant level and coolant temperature Check air filter via maintenance indicator Check and drain water separator on fuel filter Drain off water and sediment on fuel tank Empty dust collector on air filter (shorten or extend interval as necessary) Check and clean cooler, pressure relief valve, coolant hose, fan Check condition of V-belt Replace lube oil filter cartridge Replace engine oil

1)

Check oil, cooling and fuel system for leaks and condition Replace water filter cartridge (at least 1 x annually) Check anti-corrosion fluid / antifreeze in coolant (replace coolant every 2 years) Check intake and exhaust system for leaks and condition (first time at 500 hrs.)

Check and adjust throttle control Check / adjust valve clearance Check engine bracket and oil pan mounting Check flame glow system (before start of winter) Replace fuel fine filter cartridge (or as necessary)

4)

Replace fuel pre- filter cartridge (or as necessary)

4)

Replace main element of air filter (according to maintenance indicator / annually) Replace safety element of air filter (every third change of main element / annually)

Never clean!

Replace oil separator (every 2 years) Check / adjust injection valve (every 3000 hrs. or in case of drop in performance)

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Maintenance

Operating instructions

Inspection and maintenance schedule

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 904 C Litronic By maintenance personnel (machine operator)

By authorized expert personnel

First and only interval Repeat interval Special interval every 250 hours

Note

First and only interval Repeat interval

HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod in return filter (daily during first 300 hrs.)

Replace filter element in return filter (first time at 500 hrs.)

2)

Replace filter unit on servo oil unit Check mounting of components Clean hydraulic oil cooler (and as necessary) Drain off water in hydraulic tank (when using environmentally friendly fluids, max. 0.1 % part of water permissible, insert bypass filter, take oil sample) Check hydraulic system for leaks and function Check / adjust servo, primary and secondary pressures Replace hydraulic oil in tank (or optimize interval with oil analysis)

2), 3)

Replace breather filters on hydraulic tank

2)

ELECTRICAL SYSTEM Check indicator lights and displays when turning on Check lighting Check acid concentration and level and wire terminals and pole ends on batteries Spray slip rings on rotary connection (if present) with Cramolin contact spray Check function of entire system and components SWING GEAR Check oil level and look for leaks Check function and action of swing gear brake Check mounting of gear and oil motor Replace gear oil (first time at 500 hrs.)

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MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Inspection and maintenance schedule

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 904 C Litronic By maintenance personnel (machine operator)

By authorized expert personnel

First and only interval Repeat interval Special interval every 250 hours

Note

First and only interval Repeat interval

SWING RING Check mounting screws for tight seating and entry of swing gear pinion TRANSMISSION Check oil level and look for leaks Check function of gear shift and parking brake Check mounting of transmission, oil motor and drive shafts Replace gear oil (first time at 500 hrs.)

AXLES Check oil level and look for leaks Check mounting tightness of wheel lugs Check mounting tightness of axles Lubricate steering knuckle bearing (weekly / monthly, depending on application) Replace oil of differential and planetary gear, front and rear (first time at 500 hrs.) if travel share exceeds 30 % of total operating hours: Replace oil of differential, front and rear (first time at 500 hrs.)

Replace oil of planetary gear, front and rear Check wear on multi-disk brake (1 x annually or as necessary) STEERING Check for leaks and function Check mounting tightness of components and steering parts OSCILLATING AXLE SUPPORT Check for leaks and function Check mounting tightness of cylinders

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Maintenance

Operating instructions

Inspection and maintenance schedule

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 904 C Litronic By maintenance personnel (machine operator)

By authorized expert personnel

First and only interval Repeat interval Special interval every 250 hours

Note

First and only interval Repeat interval

BRAKE SYSTEM Check system for leaks and check accumulator pressure, brake pressure and control switch Check function and action

Check / refill washing fluid in windshield washer system container Check function of heater (before start of winter) Check heating system for leaks Check door and window hinges as well as locks Check water inlet valve for function and dirt, clean if necessary AIR CONDITIONING SYSTEM Turn on air conditioning system regularly (at least 1 x every 14 days) Check condenser for contamination, blow out if necessary Clean recirculated / fresh air filter, replace if necessary, shorten maintenance interval for dust intensive application Check mounting screws and compressor drive belt Check dryer collector unit (moisture, filling and condition), replace if necessary Check evaporator unit, clean if necessary Check electrical lines for abrasions and plug connections for tight seating Check overpressure switch for function Check cooling performance after opening or repair, or as necessary Replace dryer collector unit annually, check A/C circuit for leaks and replace refrigerant and refrigerant oil Have function of air flaps and defrost thermostat checked annually by an A/C specialist

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MJFCIFSS

A 904 C-Litronic / 8720337

Operating instructions

Maintenance Inspection and maintenance schedule

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 904 C Litronic By maintenance personnel (machine operator) First and only interval Repeat interval Special interval every 250 hours

By authorized expert personnel

Note

First and only interval Repeat interval

UNDERCARRIAGE + UPPERCARRIAGE + ATTACHMENTS Lubrication of bearing points via central lubrication point

3.5 cm³/ hr.

Lubrication of bearing points (undercarriage and attachments) (depending on application and daily in multi-shift operation) Visually check wear condition of teeth Check parts for cracks Check mounting tightness of counterweight and tank Check line and screw connections for tight seating Check cover hinges, quick connections and gas cylinders on hoods Point out appropriate use of attachment Have machine lubricated according to lubrication schedule by the machine operator and point out any operating errors.

HYDRAULIC QUICK CHANGE ADAPTER Check function of visual and acoustic warning devices Check extended position of locking pins visually Check condition of hydraulic hoses and of wiring harness Lubricate locking pins Clean strainer MECHANICAL QUICK CHANGE ADAPTER Check extended position of locking pins visually Lubricate locking pins Tab. 5-17 Inspection and maintenance schedule 1 2 3 4

A 904 C-Litronic / 8720337

Engine oil change intervals can be shortened depending on temperature, fuel and oil quality.

Observe shortened maintenance intervals in dust intensive application.

When using environmentally friendly hydraulic fluids, the maintenance interval is to be determined by regular analysis.

Shorten the maintenance interval depending on application (e.g. dust intensive application, barrel refuelling).

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