system

5.14.1Low and high voltage circuit

Danger!

For any maintenance or repairnearthe LOW andHIGH VOLTAGE circuit,personnelhavetobecertifiedandqualifiedaccordingtotheircompetencesandauthorized bytheir employer to work on anelectrical installation. Current practices have to respect local safety regulations for electrical installations (wear of adapted PPE, works on electrical installation, lockout procedures, etc...).

Always use adapted tools for the voltage.

Any work or maintenance on the LOW and HIGH VOLTAGE circuit or boxes must be done with power totally disconnected and the concerned electrical circuit must be locked out according to local regulations by the electrician.

For any repair for a fault with HIGH VOLTAGE > 1000V, the excavator must be completelydisconnectedfromthenetwork.Onlyelectricalpersonnelareallowedto operate according to local regulations.

ForanyrepairforafaultwithLOWVOLTAGE<1000Vtill24V,minimumapproach distanceforanyconductiveobjectmustbeobserved.Forlowtensionelectricalcabinetandrepairwithpowerswitchedon,electricalpersonnelareunderobligationto disconnect any accessible conductive object and to border the working area with banner, safety nets, fences, etc...

5.14.2Standby heating supply

By pushing the button S184 («Control OFF») inside the cabin or any emergency switch, main breaker Q2A in high voltage electrical box S1 will open. High voltage stillsuppliesS1transformerT5Mforanti-condensationheatersandfor-40°Cheating system (optional).

Danger!

Standbysupplypresenceonmachine.Beforeanymaintenanceorworkonelectric HV/LV installation, the electric supply of the machine must be totally locked out at field switch.

Standard lockout procedure to disconnect totally the excavator: Locate power station supply and distribution. Stop excavator, disconnect excavator from the network at field switch. Check voltage presence on excavator supply line. Earth and short-cut the supply line. Lockout and tag out at field switch. Identify (i.e. check that ignition of Open S1. Open Q1A manual switchand use red lever to earth the uppercarriage. Close S1 and keep key in a safe place.

5.14.324V circuit

To ensure trouble free operation of the excavator, the electrical system must be in good condition. The gauges, indicators and components of the electrical system should be checked regularly for proper function (refer to «Control and maintenance chart»).

Always replace burnt out fuses and bulbs. Do not repair fuses. Check for bare and damaged wires, whichcould cause damage to the electrical system or a fire. Check for loose, dirty or corroded connections.

5.14.4Notes on the electrical system

Danger!

Risk of injury due to formation of sparks. Avoidsparksandnakedflamewhenchargingbatteriesorworkingonthebatteries.

Always wear protective goggles and gloves.

Burnt-outfusesandbulbsshouldbereplacedimmediatelywhenthecauseofthe defect has been corrected.

Correct defects such as loose connections, abraded cables or badly fastened clamps immediately.

Disconnectthebatterieswhen workingontheelectricalsystem orwhencarrying out electric arc welding on the machine.

Danger!

Risk of injury due to formation of sparks. Disconnect the negative terminal (-) first and connect it last.

5.14.5Main battery switch

Caution!

Take particular care with machines with built-in independent heating. Only switch off the main battery switch is over.

5-51 Main battery switch

Before starting any work on the electrical system, including welding work on the machine, switch the main battery switch to position 0

Whenwashingthemachine,covertheelectricalunits(particularlythegenerator, cabling, electronic components and measured value sensor) to prevent water penetrating.

Note!

Batteries can become flat if the machine is out of service for longer periods. Beforelayingupthemachine forlongerperiods,switchthemainbattery switch to position 0 (off).

5.14.6Battery care

Thebatteriesmustalways bekeptcleantoensurethattheyareabletofunction perfectly.

Particularcareshouldbetakentocleanthepoleendsandcableterminals A regularlyandtothencoverthemwithathicklayerofacidproofgrease(seeFig.5-52).

Danger!

Bent rubber hoses on the central gas outlet increasethe risk of explosion! Thehydrogencontainedinthebatteriesshouldnotbeallowedtobuildupintheaccumulator box and must be able to escape via the rubber hoses. The central gas outlet hoses must be routed without kinks.

Check the condition of the hoses regularly, particularly after installing a battery (see Fig. 5-52).

The fluid level in the cells should be 10 to 15 mm above the top of the plate. Only distilled water must be used for any refilling.

5-52 Battery care

From time to time, measure the acid concentration C using an acid tester. When the battery is fully charged, the unit weight is 1.28 kg/l (31.5°Bé).

Ifthe acid tester displaysa lower value,thebatteries arevirtually flat and should be charged if necessary.

5.14.7Electrical components location

5.14.8Electrical boxes and cab pressurization

The aeration devices are installed as follows:

The air filters for electrical boxes and cab pressurization must be cleaned regularly. Clean the air filters: Press to open the dust discharge valve 5. Replace the main element and the safety element of the air filter system. For maintenance intervals, refer to the «Control and maintenance chart».

5.15Heating/air-conditioning system

The excavator has a heating and an air conditioning system as standard. The heating system operates with a heater under the cab floor. The air conditioning system has the elements that follow:

Note!

Incaseofrepairatcondenserorreceiver,therefrigerantmustberemovedandcollected in an applicable tank The collectedrefrigerant can be cleaned and re-prepared by refrigerant manufacturers.

For maintenance intervals, refer to the «Control and maintenance chart».

5.15.1Heating system

Iffiltersaredirty,theairflowinbothheatingandairconditioningsystemsisreduced. This results in the forming of frost and system shut-off.

Removeandcleantheheatexchanger2andthefreshairfilter3atintervalsspecified in the «Control and maintenance chart».

Do not operate the machine, even briefly, without the filters 3 because, in this case, the heat exchanger 2 will quickly become blocked.

Clean and change the fresh air filter: Remove the fresh air filter 3

Note!

Never wash the filter elements with hot water or a steam jet. Never wash the filter elements with acids or aggressive solvents. If damaged or in a bad condition, replace the filter elements.

Clean the filter elements.

The container which is filled with the coolantmixturefor theheater is installed in the cab elevation.

Fill the container with coolant mixture: Remove the filler cap 1 to add coolant mixture. Forcoolantmixturespecificationsandquantity,refertosection«Operatingmaterial chart».

The heating system has also a preheating unit installed in the cab elevation which makes the coolant mixture warm.

No maintenance is necessary for the preheating unit. Butiftheheatingsystemisstoppedforalongtime,makesurethatthepreheating unit (with pump) stays always filled with coolant mixture or preservative fluid.

5.15.2Air-conditioning system

Switch on the air conditioning system for approximately 10 minutes every 2 or 3 weeks, regardless of the season.

During the warm season, perform checks or maintenance works that follow:

Filter check:

Check and clean the recirculated air filter 2 located in the roof of the cab.

Air conditioning unit check:

Check condition of receiver 5 and filter/dryer 6

If there is corrosion, rust or mechanical damage formation on the receiver 5 (on mountingconsoles,connectingparts,...),itmustbereplacedimmediatelybyreasonsofexplosions.Whilereplacing,takecareofthemountingdirection.Theexit is marked with an "A" and the top side is marked with "OBEN".

Replacethefilter/dryer6atregularintervals,atleastonceayear.Itmustbealso replaced after each opening of the refrigerant circuit. The arrow symbols on the filter/dryer must be in the direction of the expansion valve.

Inaddition,therefrigerantchargeofthesystemmustbecheckedatregularintervals,byobservingthesightglass7whiletheairconditionerisoperating.Bubbles or foam in the sight glass 7 indicate an insufficient refrigerant charge.

In this case, the system must be checked and refilled by a trained specialist. Checkthecolouroftheindicatorinthesightglass7.Iftheindicatorbecomesyellow,itmeansthatthereistoomuchhumidityinthesystem.Replacethefilter/dryer 6 immediately by a trained specialist.

Checkmounting bolts fortightness

Check condition of fans 10 and replace if necessary (defective fan). The fans must be free of dirt and damages.

Check the condenser battery 9. If necessary blow it out with pressurised air or steam, from the inner side (fan side) to the outside.

Check for possible damages on the compressor 8

Check compressor fastening.

Check condition, alignment and tension of V-belt.

5.15.3Additional maintenance operations

Check operation of evaporator blowers and condenser fans. All blowers have to be in working order in order to avoid air short circuit.

Check electric installation.

Check all hose fittings and couplings for leakage.

Check setting and function of defrosting thermostat at the evaporator coil. Checkcompressorpressureswitch.Ifthepressureatthecompressoronthelow pressure side is too high, the compressor pressure switch lights up an indicator lamps. This means that the compressor is not working well.

5.16Check mounting bolts for tightness

The mounting bolts listed below must be regularly checked and re-tightened if necessary.

Refer to «Control and maintenance chart» for checks intervals.

Note!

WheninstallingboltsofsizebiggerthanM40thethreadofthescrewmustbeslightlycoatedwithaMoS2basedgrease.Alsogreasetheboltheadsupportingsurface, unless hereafter otherwise specified.

Danger!

Due to their size, most of the below listed mounting bolts require, to be tensioned totheprescribedtorque,theuseofaspecial,hydraulicorelectricactuatedtensioning device.

Thesehightorquetensioningdevices are power tools,whichmust beoperatedby trainedmechanics,knowingthesafetyprecautionsedictedbythetoolmanufacturer and that must be observed to avoid accidents or personal injury.

Inparticular,payattentiontochoseasolidandsecurereactionpointforthetooland position the reaction arm during operation. Keep clear of the reaction arm during operation; if it must be held or steadedduring operation, use alternative means of securing the tool during operation.

Caution!

The mounting bolts of the main components (especially the bolts listed below), of thehydraulichosesandofthecounterweightmustbereplacedaftereveryremoval.

Checkmountingbolts for tightness

5.16.1Mounting bolts of the counterweight

The eight mounting bolts 5 (M42) must be torqued to 4810 Nm.

Note!

Greasetheheadandthreadof thescrew andthetwosidesof the washerwithMo-

5.16.2Threaded studs of the swing ring

The threaded studs 4 (M36) for the mounting of the swing ring 10 to the uppercarriage 11 must be tensioned to 707,5 kN.

The threaded studs 3 (M36) for the mounting of the swing ring 10 to the undercarriage 12 must be tensioned to 707,5 kN.

Torque the lock nuts 5 on the studs 3 and 4 to 600 ± 100 Nm.

To get the correct stud tension, you must use the special tensioning procedure and tool (LIEBHERR recommends that you use the special tensioning cylinder ID. 5617448 at the required hydraulic pressure of 1350 bar, or that you use the tool ID. 10444128 at the required pressure of 1500 bar).

Danger!

Thespecialtoolmustonlybeoperatedbyqualifiedpersonnel,especiallytrainedfor the use of this high pressure tensioning device and aware of the operating instructionsaswelloftherecommendationsforaccidentanddamagepreventionconcerning this tool.

Useappropriateworkingplatformsandliftingdevicesto install andhold inposition the special tool while tensioning the studs.

5.16.3Mounting boltsof hydraulic tank

5.16.4Mounting bolts of Powerpack

Refer to section «Electric motor», in this chapter.

Checkmountingbolts for tightness

5.16.5Mounting bolts of the swing gear and motor

The mounting bolts 7 (M30) of the swing gear must be torqued to 1900 Nm. The mounting bolts 8 (M24) of the swing motor must be torqued to 960 Nm.

5.16.6Mounting bolts of hydraulic pumps

Checkmounting bolts fortightness

ThemountingboltsM20ofthemainworkingpumps (P1and P2)mustbe torquedto 425 Nm.

ThemountingboltsM20ofthemainworkingpump(P3)mustbetorquedto425Nm. ThemountingboltsM20oftheswingpumps(P5.1andP5.2)mustbetorquedto425 Nm.

ThemountingboltsM20oftheoilcoolerfanpump(P6)mustbetorquedto425Nm. The mounting bolts M20 of the lubrication, pilot oil and filtration pumps (P8 and P9 and P15) must be torqued to 85 Nm.

5.16.7Mounting bolts of the cab

cab

Note!

Torqueforscrew21isgivenforinformationonly,becauseitisnotaccessiblewhen the cab is mounted.

TorqueQuantity

1 Cab mount4

12 Screw M16x70270 Nm12

21 Screw M16x45270 Nm12

26 Screw M16x70270 Nm16

A Test distance

Also measure distance A, that is the total height of cab mounts 1

If distance A is smaller than the minimum permitted distance of 134,5mm:

Checkmountingbolts for tightness

Replace the mount. The tool you use must have a minimum precision of ±0,25mm. For maintenance intervals, see control and maintenance chart.

5.16.10High voltage electrical box S1

5.16.11Elastic elements mounting bolts

1 Stud M48 x 1126457 kN2700 Nm45

The studs 1 can be tightened using the tension or the torque tightening method. In both cases, obey the related prescribed value given in the table above.

5.17Swing gear brakes

The swing gear brakes are spring-applied, pressure-released multi-plate brakes. Theyareventilatedhydraulicallyandarefullysealedandintegratedintheswinggear transmission.

Their usage purely as parking brakes makes them wear-free and therefore maintenance free.

5.18General maintenance points

5.18.1Replacing working parts

Inadditiontothenormalmaintenanceandrepairworkthatistobecarriedoutatthe givenintervals,themachineoperatorandmaintenancepersonnelcanalsocarryout the repairs referred to below: draulic unit connections (not, however, on pressure relief valves which are lead sealed at the works). lic lines and bolt connections on the hydraulic system can be replaced.

It should be noted that only original Liebherr replacement parts are to be used. This is particularly relevant for hoses and hydraulic lines, which must be preassembled at the works. For all other repairs, particularly when dismounting the counterweight, works and dealership fitters are to be consulted.

5.18.2Welding work on the machine

Welding work on all main components serving the power transmission (such as the chassisframe,rotatingplatform,equipmentpartsetc.)mayonlybecarriedoutbythe manufacturer or by an authorized workshop.

Disconnect the batteries before starting any electric arc welding work on the machine.

Always disconnect the negative terminal (-) first and reconnect it last. Switch off the main battery switch!

Neverthelessifweldingrepair shouldbedoneoncomponentswhichmaycontaininflammablegases (welded counterweight,hydraulictank, fuel tank, ...) these components must be previously and sufficiently ventilated with pressurized air to avoid all fire or explosion hazard.

Caution!

Ifhighcurrentsflowthroughthebearingsorsealingelements,thesecouldbeburnt. Move the earthing cableof the welding tool as close as possibleto thewelding surfacesothattheweldingcurrentcannotflowoverpartsliketheswingring,rotary connection, gears, bushings, bearings, hinges, joints, hydraulic hoses, sockets, rubber parts or seals.

5.19Control and maintenance chart

Caution!

Careful maintenance can only be carried out when the machine is clean. Visual checks such as crack testing are only applicable on a clean machine. Clean the machine before you start maintenance work (see also the chapter

Caution!

You must do the weekly additional maintenance tasks. Liebherr recommends that you schedule this maintenance interval carefully.

Note!

If you find damage(s) on structural components (boom, stick, bucket, central part, side frames, rotating deck, hydraulic tank, fuel tank or cabin) please fill out the «Structural Inspection» form in Service Manual - Chapter 4 In addition:

- a visual inspection is required every 500 hours, - a detailed inspection is required every year or at least every 7500 hours.

5.19.1General information

The following maintenance chart will help you to do the adequate maintenance on your excavator.

It is mandatory to follow these maintenancecharts, to keep your excavator into best and safe condition.

The pre-requisite to any claim to Liebherr for operation issues or warranty, is that these maintenance charts are strictly followed and recorded.

Itismandatorytofollowtheserequirementsinordertokeepyourexcavatorsafe,efficient andalsoforwarranty reason.Liebherris not responsibleincase ofdamage if the maintenance requirements are not correctly followed. Moreover, your machine may not be running as efficiently and productively as it could be.

For lubricants and operating fluids, refer to the Operating Manual chapter 5.3.

Two types of inspection

Visual Check riorarea,installationorassemblytodetect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary toensurevisualaccesstoallsurfacesintheinspectionarea.Thislevelofinspectionismadeundernormallyavailablelightingconditionssuchasdaylight,hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to have safe access to the area being checked.

Detailed Check item, installation or assembly to detect damage, failure or irregularity. This examination may require the use of specialized inspection techniques and/or equipments. Surface cleaning and elaborate access may also be required.

5.19.2How

To Use The Maintenance Chart

The following maintenance chart is split in 5 individual check lists:

Intervals:

00 hours, 7000 hours, ... 00 hours, 8000 hours, ...

Examples:

At 750 hours you must follow the 250 hours maintenance chart.

At 2500hours you must follow the 500 hours maintenance chart.

At 3000 hours, you must follow the 1000 hours maintenance chart.

At 6000 hours, you must follow the 2000 hours maintenance chart.

Serial Number: Fleet Number: SMU HOURS: Travel Hours:

5.19.3Daily Maintenance Schedule - P 9250 E

Completed by:

Work To Be Performed Daily

Check for first and only interval or Check for repeat interval

GENERAL HYDRAULIC SYSTEM

Doavisualcheckofall hoses,pipesandfittings foranyexternaldamage or leakage

Do a visual check of the hydraulic components for leaks and/or damages

Doa visual check of thehydraulic cylinder rods forleaks and good condition

General Fastening

General hydraulic: Do a visual check for missing, broken or loosen mounting screws of all hoses, pipes, fittings and clamps, tighten if necessary

Attachment: Do a visual check for missing, broken or loosen mounting screws of the handrails, pin covers fastening and greases connections, tighten if necessary

Uppercarriage:Doavisualcheckformissing,brokenorloosenmounting screws of the counterweight, tanks, Powerpack, control valve console, cab, cab elevation, high and low voltage boxes, catwalks, handrails, grease box, ladder, tighten if necessary

Swing gear: Do a visual check for missing, broken or loosen mounting bolts of the swing gear and hydraulic motors, tighten if necessary

ATTACHMENT

Do a visual check of the bucket teeth and wear kit for wear

Do a visual check of the grease supply at each lube point

Do a visual check of cable harness and sensors for damage

UPPERCARRIAGE

Do a visual check of the service trap for leaks or damage

Do a visual check of oil or grease for leaks

SWING GEAR

Do a visual check of the swing gears for leaks and oil level in expansion tanks

Centralized Lubrication System

Perform a complete daily maintenancegivenintheSKF /LincolnOperating Instructions

Work To Be Performed Daily

Check for first and only interval or Check for repeat interval

Do a check of the grease tank level

Electric Motor And Splitterbox

Check voltage / load gauges and lights into the cabin

Check oil level in the splitterbox

Check oil level in hydraulic tank

Hydraulic System

Clean magnetic rods of the leak oil filter (daily during the first 250 hours)

Clean magnetic rods of bypass filter (daily during the first 250 hours)

Electrical System

Presstoopendustdischargevalveonaerationdevicesforcabinandelectrical boxes

Fire Fighting System

Doavisualcheckofthefirefightingsystemcondition(refertothefirefighting system documentation)

- If any issue contact fire fighting local dealer

Follow the inspection intervals recommended by the specific Health and Safety rules existing in country and/or on mine site

START THE MOTOR TO CHECK THE FOLLOWING ACTIONS

General: Maintenance work must include the check of the correct functions of hydraulic and electric systems before starting operation

Attachment:Checkfunctionoftheworkingattachmentlubricationsystem during operation

Attachment: Check if the damping system on equipment is working correctly

Uppercarriage: Check position of the hydraulic shut-off valve

Swing Gear: Check function and operation of the swing brake

SwingRing: Check functionoftheswing ringbearinglubrication system during operation

Swing Ring: Check function of the swing ring teeth lubrication system during operation

Electricalsystem:CleanandcheckLCDscreenofthedisplayforproper function when starting

Electricalsystem:Checkindicatorlightsandgaugesonthecontrolpanel when starting

Work To Be Performed Daily

Check for first and only interval or Check for repeat interval

Electrical system: Check for warning and fault messages on display (monitoring,grease,airconditioning,...).Ifnecessaryrefertochapter4in the Operating Manual to identify and rectify faults and errors.

Cabin: Check if the safety lever is working properly

Cabin: Check the horn

Cabin:Checkforgreenflashlightoncontrolmoduleiffirefightingsystem is installed

Weekly Check These Steps In Addition To The Daily Requirements

UPPERCARRIAGE

Check level in reservoir for windshield washer, refill if necessary

CENTRALIZED LUBRICATION SYSTEM

PerformthecompleteweeklymaintenancegivenintheSKF / LincolnOperating Instructions

ELECTRIC MOTOR AND SPLITTERBOX

Doa visual check of the air flow, clean the inlets from thecooling system if necessary

HYDRAULIC SYSTEM

Cleanmagnetic rodsofallreturnfilters(weeklyduringthefirst250hours)

Do a visual check of the hydraulic tank air filter, clean if necessary

ELECTRICAL SYSTEM

Doavisualcheckoftheheadandfloodlight,cleanandadjustifnecessary

Do a visual check of the wiring system for damage

Check the emergency stop on the power station

Check the emergency stops on the excavator

HIGH / LOW VOLTAGE SYSTEM

DoavisualcheckoftheinsideboxesS1andS2fordustandcomponents condition

ForPersonalProtectiveEquipmentinspection,refertothePPEdocumentation

Work To Be Performed Daily

Check for first and only interval or Check for repeat interval

CheckInitials

CABIN, CABIN ELEVATION AND HEATER AIR/CONDITIONER

Operate air conditioner every week for 10 minutes

Visual check condenser unit and evaporator filter

Check refrigerant level, if necessary refill circuit

Do a detailed check of the V-belt tension for air conditioner

Comments

Work To Be Performed Daily

Check for first and only interval or Check for repeat interval CheckInitials

General comments:

Serial Number: Fleet Number: SMUHOURS: Travel Hours:

5.19.4 250 Hours Maintenance Schedule - P 9250 E

Completed by: Dateand Signature:

WORK TO BE PERFORMED AT 250, 750, 1250 HOURS, ...

Check for first and only interval or Check for repeat interval

GENERAL HYDRAULIC SYSTEM

Doavisualcheckofallhoses,pipesandfittingsforanyexternaldamageorleakage

Do a detailed check for good condition of pipes, hoses, clamps and fittings for damage and leakage

Do a visual check of the hydraulic components for leaks and/or damages

Do a visual check of the hydraulic cylinderrods for leaks and good condition

GENERAL FASTENING

General hydraulic: Do a visual check for missing, broken or loosen mounting screws of all hoses, pipes, fittings and clamps, tighten if necessary

Attachment: Do a visual check for missing, broken or loosen mounting screws of thehandrails, pin covers fastening andgreases connections,tightenif necessary

Uppercarriage: Do a visual check for missing, broken or loosen mounting screwsof thecounterweight,tanks,Powerpack,controlvalve console,cab, cab elevation, high and low voltage boxes, catwalks, handrails, grease box, ladder, tighten if necessary

Swing gear: Do a visual check for missing, broken or loosen mounting bolts of the swing gear and hydraulic motors, tighten if necessary

ATTACHMENT

Do a visual check of the bucket teeth and wear kit for wear

Do a visual check of the grease supply at each lube point

Do a visual check of cable harness and sensors for damage

Do a visual check of all parts for damages and cracks

Ifnecessaryfilloutthe"StructuralInspection"forminServiceManual-Chapter4

Do a visual check of the fastening of pin covers

Do a visual check of the non-slip surfaces for wear and damage

UPPERCARRIAGE

Do a visual check of the service trap for leaks or damage

Do a visual check of oil, or grease for leaks

Do a visual check of the non-slip surfaces for wear and damage

CheckInitials

Comments

WORK TO BE PERFORMED AT 250, 750, 1250 HOURS, ...

Check for first and only interval or Check for repeat interval CheckInitials

SWING GEAR

Do a visual check of the swing gears for leaks and oil level in expansion tanks

CENTRALIZED LUBRICATION SYSTEM

Perform a complete daily maintenance given in the SKF / Lincoln Operating Instructions

Do a check of the grease tank level

ELECTRIC MOTOR AND SPLITTERBOX

Check voltage / load gauges and lights into the cabin

Check oil level in the splitterbox

Change oil in splitterbox

Check oil level in hydraulic tank

HYDRAULIC SYSTEM

Sampleandanalysehydraulicoilandchangeoilifnecessary(iffilledwithHEES biodegradable oil)

Clean magnetic rods of the leak oil filter

Clean magnetic rods of bypass filter

Clean magnetic rods of all return filters

ELECTRICAL SYSTEM

Press to open dust discharge valve on aeration devices for cabin and electrical boxes

Do a visual check of the head and floodlights, clean and adjust if necessary

Do a visual check of electric harness, sensors for damage and/or rubbing zone

Do a detailed check of fuses and circuit breakers

CABIN

Do a detailed check of the V-belt tension for air conditioner

Do a visual check of the cabin for oil/fluids leaks

FIRE FIGHTING SYSTEM

Doavisual checkofthefirefightingsystem condition(optional equipment,refer to the fire fighting system documentation)

- If any issue contact fire fighting local dealer

Follow the inspection intervals recommended by the specific Health and Safety rules existing in country and/or on mine site

WORK TO BE PERFORMED AT 250, 750, 1250 HOURS, ...

Check for first and only interval or Check for repeat interval

Start The Motor To Check The Following Actions

General: Maintenance work must include the check of the correct functions of hydraulic and electric systems before starting operation

Attachment: Check function of the working attachment lubrication system during operation

Attachment: Check if the damping system on equipment is working correctly

Uppercarriage: Check position of the hydraulic shut-off valve

Swing Gear: Check function and operation of the swing brake

SwingRing:Checkfunctionoftheswingring bearinglubricationsystemduring operation

SwingRing:Checkfunctionoftheswingringteethlubricationsystemduringoperation

Electrical system: Clean and check LCD screen of the display for proper function when starting

Electricalsystem:Checkindicatorlightsandgaugesonthecontrolpanelwhen starting

Electrical system: Check for warning and fault messages on display (monitoring,grease,airconditioning,...).Ifnecessary refertochapter 4intheOperating Manual to identify and rectify faults and errors.

Cabin: Check if the safety lever is working properly

Cabin: Check the horn

Cabin: Check for green flash light on control module if fire fighting system is installed

WORK TO BE PERFORMED AT 250, 750, 1250 HOURS, ...

Check for first and only interval or Check for repeat interval

General comments:

Serial Number: Fleet Number: SMUHOURS: Travel Hours:

5.19.5 500 Hours Maintenance Schedule - P 9250 E

Completed by: Dateand Signature:

WORK TO BE PERFORMED AT 500, 1500, 2500 HOURS, ...

Check for first and only interval or Check for repeat interval

GENERAL HYDRAULIC SYSTEM

Doavisualcheckofallhoses,pipesandfittingsforanyexternaldamageorleakage

Do a detailed check for good condition of pipes, hoses, clamps and fittings for damage and leakage

Do a visual check of the hydraulic components for leaks and/or damages

Do a visual check of the hydraulic cylinderrods for leaks and good condition

GENERAL FASTENING

General hydraulic: Do a visual check for missing, broken or loosen mounting screws of all hoses, pipes, fittings and clamps, tighten if necessary

Attachment: Do a visual check for missing, broken or loosen mounting screws of the handrails, pin covers fastening and greases connections, tighten if necessary

Uppercarriage: Do a visual check for missing, broken or loosen mounting screws of the counterweight, tanks, Powerpack, control valve console, cab, cab elevation, high and low voltage boxes, catwalks, handrails, grease box, ladder, tighten if necessary

Swing gear: Do a visual check for missing, broken or loosen mounting bolts of the swing gear and hydraulic motors, tighten if necessary

Hydraulic: Do a detailed check for missing, broken or loosen mounting screws of pumps, motors, clamps, ..., tighten the screws

ATTACHMENT

Do a visual check of the bucket teeth and wear kit for wear

Do a visual check of the grease supply at each lube point

Do a visual check of cable harness and sensors for damage

Do a visual check of all parts for damages and cracks

Ifnecessaryfilloutthe"StructuralInspection"forminServiceManual-Chapter4

Do a visual check of the fastening of pin covers

Do a visual check of the non-slip surfaces for wear and damage

UPPERCARRIAGE

Do a visual check of the service trap for leaks or damage

Do a visual check of oil or grease for leaks

CheckInitials

Comments

WORK TO BE PERFORMED AT 500, 1500, 2500 HOURS, ...

Check for first and only interval or Check for repeat interval

Do a detailed check of all structural parts for damages and cracks

Ifnecessaryfilloutthe"StructuralInspection"forminServiceManual-Chapter4

Do a visual check if the fan guards are in place and secured

Do a visual check of the non-slip surfaces for wear and damage

SWING GEAR

Do a visual check of the swing gears for leaks and oil level in expansion tanks

Sample and analyse gear oil, change oil if necessary

Change gear oil (if filled with COB-1 gear oil)

Change gear oil (if filled with COB-2, COB-3 or COB-4 gear oil)

SWING RING

Doadetailedcheckofthegreasesupply(outletofnewgreasearoundtheswing ring)

Centralized Lubrication System

Perform a complete daily maintenance given in the SKF / Lincoln Operating Instructions

Do a check of the grease tank level

Every 7500 hours, perform a complete 7500 hours Maintenance Echelon given in the SKF / Lincoln Operating Instructions

Electric Motor And Splitterbox

Check voltage / load gauges and lights into the cabin

Check oil level in the splitterbox

Sample and analyse splitterbox oil

Do a visual check of the splitterbox breather for clogging, replace if necessary

HYDRAULIC SYSTEM

Drain water sediment from hydraulic tank

Check oil level in hydraulic tank

Sample and analyse hydraulic oil and change oil if necessary

Clean magnetic rods of the leak oil filter

Clean magnetic rods of bypass filter

Clean magnetic rods of all return filters

Replace filter element of the return filters

Replace filter element of the leak oil filter

Replace control oil filter element

WORK TO BE PERFORMED AT 500, 1500, 2500 HOURS, ...

Check for first and only interval or Check for repeat interval

Replace swing pumps replenishing oil filter elements

Doavisualcheckoftheoilcoolerprotectionfilters,cleanorreplaceifnecessary (optional equipment)

Replace filter elements of bypass filter

Electrical System

Press to open dust discharge valve on aeration devices for cabin and electrical boxes

Replacemainelementonaerationdevicesforcabinandelectricalboxes(atleast once a year)

Replacesafetyelementonaerationdevices for cabin and electrical boxes,after 3 services of main element

Do a visual check of the head and floodlights, clean and adjust if necessary

Do a visual check of electric harness, sensors for damage and/or rubbing zone

Do a detailed check of fuses and circuit breakers

Do a visual check of wiring system damage

Check battery electrolyte level (refill if necessary) and clean battery terminals

Clean up the electric rotary connection

Check the carbon brushes of electric rotary connection, replace if necessary

Lubricate the contact bow of the slip ring

Grease the bearings of the slip ring

Do a detailed check of the V-belt tension for air conditioner

Do a visual check of the cabin for oil/fluids leaks

Operate air conditioner every week for 10 minutes

Do a visual check of the condenser unit and evaporator filter

Do a visual check of the refrigerant level, if necessary refill circuit

Replace if necessary the air conditioner filter/dryer (at least once a year)

Yearly check condition of the refrigerant receiver, if necessary replace it

Lubricate all doors seals with silicone or talc (before cold season)

Do a visual check of the AC for leaks or rubbing hoses or pipes

Fire Fighting System

Doavisual check ofthefirefighting systemcondition(optional equipment,refer to the fire fighting system documentation)

- If any issue contact fire fighting local dealer

WORK TO BE PERFORMED AT 500, 1500, 2500 HOURS, ...

Check for first and only interval or Check for repeat interval

Follow the inspection intervals recommended by the specific Health and Safety rules existing in country and/or on mine site

Start The Motor To Check The Following Actions

General: Maintenance work must include the check of the correct functions of hydraulic and electric systems before starting operation

Attachment:Checkfunctionoftheworkingattachmentlubricationsystemduring operation

Attachment: Check if the damping system on equipment is working correctly

Uppercarriage: Check position of the hydraulic shut-off valve

Swing Gear: Check function and operation of the swing brake

SwingRing:Checkfunctionof theswingringbearinglubricationsystem during operation

SwingRing:Checkfunctionoftheswingringteethlubricationsystemduringoperation

Electrical system: Clean and check LCD screen of the display forproper function when starting

Electricalsystem:Checkindicatorlightsandgaugesonthecontrolpanelwhen starting

Electrical system: Check for warning and fault messages on display (monitoring, grease,air conditioning, ...).Ifnecessary refer tochapter 4inthe Operating Manual to identify and rectify faults and errors.

Cabin: Check if the safety lever is working properly

Cabin: Check the horn

Cabin: Check for green flash light on control module if fire fighting system is installed

WORK TO BE PERFORMED AT 500, 1500, 2500 HOURS, ...

Check for first and only interval or Check for repeat interval

General comments:

Serial Number: Fleet Number: SMU HOURS: Travel Hours:

5.19.6 1000 Hours

Maintenance Schedule - P 9250 E

Completed by: Date and Signature:

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ...

Check for first and only interval or Check for repeat interval CheckInitials

GENERAL HYDRAULIC SYSTEM

Doavisualcheckofallhoses,pipesandfittingsforanyexternaldamageorleakage

Do a detailed check for good condition of pipes, hoses, clamps and fittings for damage and leakage

Do a visual check of the hydraulic components for leaks and/or damages

Do a visual check of the hydraulic cylinder rods for leaks and good condition

GENERAL FASTENING

General hydraulic: Do a visual check for missing, broken or loosen mounting screws of all hoses, pipes, fittings and clamps, tighten if necessary

Attachment: Do a visual check for missing, broken or loosen mounting screws of the handrails, pin covers fastening and greases connections, tighten if necessary

Uppercarriage: Do a visual check for missing, broken or loosen mounting screws of the counterweight, tanks, Powerpack,control valveconsole, cab, cab elevation, high and low voltage boxes, catwalks, handrails, grease box, ladder, tighten if necessary

Swing gear: Do a visual check for missing, broken or loosen mounting bolts of the swing gear and hydraulic motors, tighten if necessary

Swingring:Doadetailedcheckformissing,brokenorloosenmountingscrews and protective nuts of swing ring, tighten the bolts

Hydraulic: Do a detailed check for missing, broken or loosen mounting screws of pumps, motors, clamps, ..., tighten the screws

Attachment

Do a visual check of the bucket teeth and wear kit for wear

Do a visual check of the grease supply at each lube point

Do a visual check of cable harness and sensors for damage

Do a visual check of all parts for cracks

-Ifnecessaryfilloutthe"StructuralInspection"forminServiceManual-Chapter 4

Do a visual check of the fastening of pin covers

Do a visual check of the non-slip surfaces for wear and damage

Comments

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ...

Check for first and only interval or Check for repeat interval

Uppercarriage

Do a visual check of the service trap for leaks or damage

Do a visual check of oil or grease for leaks

Do a detailed check of all structural parts for cracks

-Ifnecessaryfilloutthe"StructuralInspection"forminServiceManual-Chapter 4

Doadetailed checkandlubricatethecovers,doors hinges,locks as well as service trap cylinders bushings and swivel pins

Do a visual check if the fan guards are in place and secured

Do a visual check of the non-slip surfaces for wear and damage

SWING GEAR

Do a visual check of the swing gears for leaks and oil level in expansion tanks

Sample and analyse gear oil, change oil if necessary

Change gear oil (if filled with COB-2, COB-3 or COB-4 gear oil)

SWING RING

Doadetailedcheckofthegreasesupply(outletofnewgreasearoundtheswing ring)

Centralized Lubrication System

Perform a complete daily maintenance given in the SKF / Lincoln Operating Instructions

Do a check of the grease tank level

Every 1000 hours, perform a complete 1000 hours Maintenance Echelon given in the SKF / Lincoln Operating Instructions

Electric Motor And Splitterbox

Check voltage / load gauges and lights into the cabin

Check oil level in the splitterbox

Sample and analyse splitterbox oil

Do a visual check of the splitterbox breather for clogging, replace if necessary

Replace filter in splitterbox breather

Drain water sediment from hydraulic tank

Check oil level in hydraulic tank

HYDRAULIC SYSTEM

Sample and analyse hydraulic oil and change oil if necessary

CheckInitials

Comments

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ...

Check for first and only interval or Check for repeat interval

Clean magnetic rods of the leak oil filter

Clean magnetic rods of bypass filter

Clean magnetic rods of all return filters

Replace filter element of the return filters

Replace filter element of the leak oil filter

Replace the hydraulic tank air filter

Replace control oil filter element

Replace swing pumps replenishing oil filter elements

Doavisualcheckoftheoilcoolerprotectionfilters,cleanorreplaceifnecessary (optional equipment)

Replace filter elements of bypass filter

Check and adjust primary and secondary pressure relief valves

Electrical System

Press to open dust discharge valve on aeration devices for cabin and electrical boxes

Replacemainelementonaerationdevicesforcabinandelectricalboxes(atleast once a year)

Replace safetyelement onaerationdevicesfor cabinandelectrical boxes,after 3 services of main element

Do a visual check of the head and floodlights, clean and adjust if necessary

Do a visual check of electric harness, sensors for damage and/or rubbing zone

Do a detailed check of fuses and circuit breakers

Do a visual check of wiring system damage

Check battery electrolyte level (refill if necessary) and clean battery terminals

Checkthefunctionofanti-condensingheatersfromS2box(currentofcontinuity)

Clean up the electric rotary connection

Check the carbon brushes of electric rotary connection, replace if necessary

Lubricate the contact bow of the slip ring

Grease the bearings of the slip ring

Cabin

Do a detailed check of the V-belt tension for air conditioner

Do a visual check of the cabin for oil/fluids leaks

Operate air conditioner every week for 10 minutes

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ...

Check for first and only interval or Check for repeat interval CheckInitials

Do a visual check of the condenser unit and evaporator filter

Do a visual check of the refrigerant level, if necessary refill circuit

Replace if necessary the air conditioner filter/dryer (at least once a year)

Yearly check condition of the refrigerant receiver, if necessary replace it

Lubricate all doors seals with silicone or talc (before cold season)

Do a visual check of the AC for leaks or rubbing hoses or pipes

Doavisualcheckofthelocksandhingesondoorsandwindows(lubricateifnecessary)

Do a detailed check of the cabin rubber mounts

Fire Fighting System

Doavisual check ofthefirefighting systemcondition(optional equipment,refer to the fire fighting system documentation)

- If any issue contact fire fighting local dealer

Follow the inspection intervals recommended by the specific Health and Safety rules existing in country and/or on mine site

Start The Motor To Check The Following Actions

General: Maintenance work must include the check of the correct functions of hydraulic and electric systems before starting operation

Attachment:Checkfunctionoftheworkingattachmentlubricationsystemduring operation

Attachment: Check if the damping system on equipment is working correctly

Uppercarriage: Check position of the hydraulic shut-off valve

Swing Gear: Check function and operation of the swing brake

SwingRing:Check functionoftheswingringbearinglubricationsystemduring operation

SwingRing:Checkfunctionoftheswingringteethlubricationsystemduringoperation

Electrical system: Clean and check LCD screen of the display for proper function when starting

Electricalsystem:Checkindicatorlightsandgaugesonthecontrolpanelwhen starting

Comments

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ...

Check for first and only interval or Check for repeat interval

Electrical system: Check for warning and fault messages on display (monitoring, grease,air conditioning, ...).Ifnecessary refer tochapter 4inthe Operating Manual to identify and rectify faults and errors.

Cabin: Check if the safety lever is working properly

Cabin: Check the horn

Cabin: Check for green flash light on control module if fire fighting system is installed

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ...

Check for first and only interval or Check for repeat interval

General comments:

Serial Number: Fleet Number: SMU HOURS: Travel Hours:

5.19.72000 Hours MaintenanceSchedule - P 9250 E

Completed by: Date and Signature:

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ...

Check for first and only interval or Check for repeat interval CheckInitials

GENERAL HYDRAULIC SYSTEM

Doavisualcheckofallhoses,pipesandfittingsforanyexternaldamageorleakage

Do a detailed check for good condition of pipes, hoses, clamps and fittings for damage and leakage

Do a visual check of the hydraulic components for leaks and/or damages

Do a visual check of the hydraulic cylinder rods for leaks and good condition

GENERAL FASTENING

General hydraulic: Do a visual check for missing, broken or loosen mounting screws of all hoses, pipes, fittings and clamps, tighten if necessary

Attachment: Do a visual check for missing, broken or loosen mounting screws of the handrails, pin covers fastening and greases connections, tighten if necessary

Attachment:Doadetailedcheckformissing,brokenorloosenmountingscrews of the handrails, pin covers fastening and greases connections, tighten the screws

Uppercarriage: Do a visual check for missing, broken or loosen mounting screws of the counterweight, tanks, Powerpack,control valveconsole, cab, cab elevation, high and low voltage boxes, catwalks, handrails, grease box, ladder, tighten if necessary

Uppercarriage: Do a detailed check for missing, broken or loosen mounting screws of the counterweight, tanks, Powerpack,control valveconsole, cab, cab elevation, high and low voltage boxes, catwalks, handrails, grease box, ladder, tighten the screws

Swing gear: Do a visual check for missing, broken or loosen mounting bolts of the swing gear and hydraulic motors, tighten if necessary

Swinggear:Doadetailedcheckformissing,brokenorloosenmountingboltsof the swing gear and hydraulic motors, tighten the bolts

Swingring:Doadetailedcheckformissing,brokenorloosenmountingscrews and protective nuts of swing ring, tighten the bolts

Electric motor: Do a detailed check for missing, broken or loosen mounting screws of the splitterbox, tighten the screws

Electricmotor:Every2000hours(ortwiceayear),doadetailedcheckformissing, broken or loosen mounting screws of parts subject to vibration and various elements securing the electric motor, tighten the screws

Comments

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ...

Check for first and only interval or Check for repeat interval

Hydraulic: Do a detailed check for missing, broken or loosen mounting screws of pumps, motors, clamps, ..., tighten the screws

Attachment

Do a visual check of the bucket teeth and wear kit for wear

Do a visual check of the grease supply at each lube point

Do a visual check of cable harness and sensors for damage

Do a visual check of all parts for cracks

-Ifnecessaryfilloutthe«StructuralInspection»forminServiceManual-Chapter

4

Do a visual check of the fastening of pin covers

Do a visual check of the non-slip surfaces for wear and damage

Do a detailed check of all the anchor points and the tightening of the handrails mounting screws, only by authorized specialist personnel (at least once a year)

UPPERCARRIAGE

Do a visual check of the service trap for leaks or damage

Do a visual check of oil or grease for leaks

Do a detailed check of all structural parts for cracks

-Ifnecessaryfilloutthe«StructuralInspection»forminServiceManual-Chapter

4

Doadetailed checkandlubricatethecovers,doors hinges,locks as well as service trap cylinders bushings and swivel pins

Do a visual check if the fan guards are in place and secured

Do a check of the global view around machine (including mirrors)

Do a visual check of the non-slip surfaces for wear and damage

Do a detailed check of all the anchor points and the tightening of the handrails mounting screws, only by authorized specialist personnel (at least once a year)

SWING GEAR

Do a visual check of the swing gears for leaks and oil level in expansion tanks

Sample and analyse gear oil, change oil if necessary

Change gear oil (if filled with COB-1 gear oil)

Change gear oil (if filled with COB-2, COB-3 or COB-4 gear oil)

Measure the axial play of the output shaft bearing, replace if necessary

SWING RING

Doadetailedcheckofthegreasesupply(outletofnewgreasearoundtheswing ring)

CheckInitials

Comments

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ...

Check for first and only interval or Check for repeat interval

Do a detailed check of the meshing of the swing gears with the swing ring

Do a detailed check of the swing ring teeth for damage

Do a detailed check of the swing ring axial play

Centralized Lubrication System

Perform a complete daily maintenance given in the SKF / Lincoln Operating Instructions

Do a check of the grease tank level

Every 1000 hours, perform a complete 1000 hours Maintenance Echelon given in the SKF / Lincoln Operating Instructions

Electric Motor And Splitterbox

Check voltage / load gauges and lights into the cabin

Check oil level in the splitterbox

Sample and analyse splitterbox oil

Change oil in splitterbox

Do a visual check of the splitterbox breather for clogging, replace if necessary

Replace filter in splitterbox breather

Greasethemotorbearing.RefertotheManualofsafety,installationandmaintenance of the electric motormanufacturer.

Clean the cooling tubes

Every 4000 hours (or at least twice a year), perform a general inspection of the electric motor given in the Manual of safety, installation and maintenance of the electric motor manufacturer

Every8000hours,performadetailedinspectionoftheelectricmotorgiveninthe Manualofsafety,installationandmaintenanceoftheelectricmotormanufacturer

Every 40000 hours (or at least every 5years), perform a complete inspection of the electric motor given inthe Manual of safety, installationand maintenance of the electric motor manufacturer

Hydraulic System

Drain water sediment from hydraulic tank

Check oil level in hydraulic tank

Sample and analyse hydraulic oil and change oil if necessary

Change hydraulic oil

Clean magnetic rods of the leak oil filter

Clean magnetic rods of bypass filter

Clean magnetic rods of all return filters

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ...

Check for first and only interval or Check for repeat interval

Replace filter element of the return filters

Replace filter element of the leak oil filter

Replace the hydraulic tank air filter

Replace control oil filter element

Replace swing pumps replenishing oil filter elements

Replacethecontrolvalveshighpressurefilters,replacefilterelementsaftereach replacement or repair of a working pump and check the internal surface of the filter housing

Doavisualcheckoftheoilcoolerprotectionfilters,cleanorreplaceifnecessary (optional equipment)

Replace filter elements of bypass filter

Do a detailed check of the oil coolers, clean if necessary

Do a visual check of the coolingfan blades, replace if necessary

Check and adjust primary and secondary pressure relief valves

Do a detailed check of mounting of components (pumps, motors, ...)

Every4000hours(oratleastonceayear),allhydraulicpumpsmustbechecked and adjusted by trained and qualified Liebherr personnel

Every 4000 hours (or at least once a year), check the pressure of the hydraulic accumulatorsandfillifnecessary:usethespecialtoolwhichisdedicatedforthis purpose

Every 8000 hours, replace following high pressure (HP) hoses:

CheckInitials

Comments ive circuit, including HP pilot hoses.

Electrical System

Press to open dust discharge valve on aeration devices for cabin and electrical boxes

Replacemainelementonaerationdevicesforcabinandelectricalboxes(atleast once a year)

Replacesafetyelementonaerationdevices for cabin and electrical boxes,after 3 services of main element

Do a visual check of the head and floodlights, clean and adjust if necessary

Do a visual check of electric harness, sensors for damage and/or rubbing zone

Do a detailed check of fuses and circuit breakers

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ...

Check for first and only interval or Check for repeat interval

Do a visual check of wiring system damage

Check battery electrolyte level (refill if necessary) and clean battery terminals

Do a test of all emergency stops (with electric motor stopped only)

Make sure that the display goes off after each test

Checkthefunctionofanti-condensingheatersfromS2box(currentofcontinuity)

Clean up the electric boxes S1 and S2 and check the air filter, replace if necessary

Clean up the electric rotary connection

Check the carbon brushes of electric rotary connection, replace if necessary

Lubricate the contact bow of the slip ring

Grease the bearings of the slip ring

Check the high voltage cable fixing and sheath

Doadetailedcheckformissing,brokenorloosenmountingscrewsoftheelectric rotary connection, tighten the screws

CABIN

Do a detailed check of the V-belt tension for air conditioner

Do a visual check of the cabin for oil/fluids leaks

Operate air conditioner every week for 10 minutes

Do a visual check of the condenser unit and evaporator filter

Do a visual check of the refrigerant level, if necessary refill circuit

Replace if necessary the air conditioner filter/dryer (at least once a year)

Yearly check condition of the refrigerant receiver, if necessary replace it

Lubricate all doors seals with silicone or talc (before cold season)

Do a visual check of the AC for leaks or rubbing hoses or pipes

Doavisualcheckofthelocksandhingesondoorsandwindows(lubricateifnecessary)

Do a detailed check of the cabin rubber mounts

Do a detailed check of the heater exchanger and filter for leaks

Fire Fighting System

Doavisual checkofthefirefightingsystemcondition (optional equipment, refer to the fire fighting system documentation)

- If any issue contact fire fighting local dealer

Follow the inspection intervals recommended by the specific Health and Safety rules existing in country and/or on mine site

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ...

Check for first and only interval or Check for repeat interval

Start The Motor To Check The Following Actions

General: Maintenance work must include the check of the correct functions of hydraulic and electric systems before starting operation

Attachment:Checkfunctionoftheworkingattachmentlubricationsystemduring operation

Attachment: Check if the damping system on equipment is working correctly

Uppercarriage: Check position of the hydraulic shut-off valve

Swing Gear: Check function and operation of the swing brake

SwingRing:Check functionoftheswingringbearinglubricationsystemduring operation

SwingRing:Checkfunctionoftheswingringteethlubricationsystemduringoperation

Electrical system: Clean and check LCD screen of the display for proper function when starting

Electricalsystem:Checkindicatorlightsandgaugesonthecontrolpanelwhen starting

Electrical system: Check for warning and fault messages on display (monitoring, grease,air conditioning, ...).Ifnecessaryrefer to chapter 4intheOperating Manual to identify and rectify faults and errors.

Cabin: Check if the safety lever is working properly

Cabin: Check the horn

Cabin: Check for green flash light on control module if fire fighting system is installed

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ...

Check for first and only interval or Check for repeat interval

General comments:

6.1Visual check of the hydraulic hoses

6.1.1Preface

Thissectiondescribestheprocedureforthevisualcheckofthehydraulichoses escapes from a pinhole and it can go through the skin and contaminate the blood. edical treatmentis necessary immediately. available safety protection. vice Manual.

Note!

These instructions have been written for the maintenance personnel of the machine.

Theactivitiesdescribed in this section may onlybe carried out by speciallytrained personnel.

Theinstructionsaretobereadandusedcarefullybyallpersonswhocarryout work with or on the machine before putting the machine into service for the first time and later, at regular intervals.

Theinstructionsmustbecompletedbyinformationoncurrentnationalregulationsfor accident prevention and protection. In addition, authorized specialist rules for safe and correct working procedures are also to be observed.

However, should you require any further explanations or information, LIEBHERR technical documentation, sales school and customer service departments are available for your convenience.

Danger!

Fluid injection injuries have to be treated immediately!

Visual check of the hydraulic hoses

6.1.2General information

Components description

1 Rubber cover

2 Reinforcement layer

3 Inside rubber tube

4 Crimp fitting

5 Nipple

6 Nipple wire trap area

7 Sealing zone

8 Damping zone

For this document, the terms that follow are available: hose is a hydraulic tube. It is made by: hoseassemblyisahosewithfittingsattachedatthetwoends.Thefittingsare made by: 4 5

Marking of the components

The hose and the hose assembly are marked with the general data given below.

Hose marking

The hose is marked on the rubber cover with: se (i.e. 2Q13 = second quarter of 2013)

Hose assembly marking

The hose assembly is marked on the fittings with:

Visual check of the hydraulic hoses

Normal conditions of use

Danger!

Itisnecessarytoreplacethehydraulichosesatspecifiedintervalstomaintaintheir maximum operating performance and to reduce the risk of personal injury and/or machine damage.

Obey the replacement intervals given below.

Natural ageing

Hydraulic hoses and hose assemblies undergo a process of natural ageing. Thus, their service life has a limit: stobeytherequirementsgiveninthesection "Replacement of the hydraulic hoses" of this manual.

When you check a hose assembly or you install a new one, refer to the date of assembly marked on the hose assembly fittings.

Operating stress

Thehydraulichosesmustalsoberegularlyreplacedbecauseoftheoperatingstress. Forthereplacementintervalsgiveninworkinghoursofthehydraulichoses,refer to the section "Control and maintenance chart" of this manual.

Mounting instructions

Refer to the Operating Manual.

6.1.3Components functions

This section gives the function of the different main components of a hydraulic hose assembly.

Insiderubber tube

The inside rubber tube keeps the conveyed fluid in the hose. It is resistant against thefluidandthetemperatureofthefluid.Internaldamagestothistubecanbecaused by contamination of the hydraulic circuit.

The inside rubber seals the hose but it has no pressure stability.

Reinforcement layer

Thereinforcementlayer,madeupofsomesteellayerswithrubberinbetween,holds the internal pressure.

The reinforcement layer is theonly componentof the hose whichgives thehose the pressure stability. The hose has a minimum burst pressure (static) and a maximum operating pressure (dynamic). The maximum operating pressure is usually at least four times lower than the minimum burst pressure because dynamic pressures fatigue the reinforcement layer more quickly than static pressures.

The value of the burst pressure and the operating pressure will be lower if the reinforcement layer has one of the damages that follow:

The inside rubber can also be damaged if the reinforcement layer moves.

Rubber cover

The rubber cover protects the reinforcement layer from the ambient conditions (UV, ozone, different liquids) and from mechanical effects (scrubbing, corrosion).

Anyrub,cutorribintherubbercovermeansthattheprotectionisnolongersatisfactory and the reinforcement layer is subject to a potential destruction.

Nipple

Thenippleisnecessaryto connecta hydraulichoseto anothercomponent. Thenipple is resistant to all the mechanical forces and bending stress caused by the pressurepulsationsinthehose.Thus,itisimportanttohaveagoodcontactbetweenthe nipple and the hose.

Cracks on the nipple cause its fast failure.

Crimp fitting

To make sure that the assembly is correctly sealed, the crimp fitting presses the inside rubber tube onto the nipple. In addition, if the hose has a wire trap area, the crimp fitting clamps the reinforcement layer in between the nipple and the crimp fitting.

Ifthe hoseassemblystarts to leak at the end of the crimp fitting, the causes that follow are possible:

6.1.4Recommendations for hose assembly maintenance

Severity levels

Hose assembly damages can be divided into three severity levels: For each severity level, there are special actions to do at specific intervals.

Checks and recommendations

The sections that follow give: makeanestimateofthedamageseverity level

Visual check of the hydraulic hoses

Minordamage

If you find a minor damage:

Daily

Examine the hose assembly. Monitor if the deterioration increases. In case of rubbing, move the hose assembly to make sure there is no more contact.

Check all necessary conditions forthe possible replacement of the defective part(s)(e.g. part in stock, time of delivery).

Rubber cover is rubbed -Reinforcement layer is not corroded or not rubbed - No sign of oil

Rubber cover has a cut or a crack - Reinforcement layer is not corroded or not cut - No sign of oil

Hose is visually wet near the crimp fitting - Oil does not propagate There is a small surface of remaining oil which is visually wet but does not result in the formation of drop.

Dry dust collection which does not propagate

Immediately

Seriousdamage

If you find a serious damage:

Inform formally the responsible Maintenance Manager about the condition of the hose assembly.

Make sure that you have the correct replacement part in stock.

Examine the hose assembly. Monitor if the deterioration increases.

Daily

One of the next services, but not later than 250 hours

Ifthedeteriorationofthehoseassemblyincreasesinasmall numberofdays, refer to next section "Major damage" for the actions to do.

Replace the hose assembly.

Rubber cover has many cuts or cracks - Reinforcement layer is not corroded or not cut - No sign of oil

Rubber cover is rubbed - Reinforcement layer is uncovered but not corroded - No sign of oil

Hoses and fittings are visually wet - Oil propagates There is a surface of remaining oil which is visually wet and results in the formation of non-falling or falling drop.

Visual check of the hydraulic hoses

Majordamage

If you find a major damage:

Danger!

Inthiscase,thehoseassemblymustbereplacedimmediatelybecauseitcanburst at any time.

Obey all safety instructions given in the Operating Manual to avoid accidents and fires.

Stop the machine immediately (no exception).

Immediately

InformformallytheresponsibleMaintenanceManager,orhissuperior,thatthe machine is stopped and about the condition of the hose assembly.

Before restart the machine Replace the hose assembly.

Oil leakage

The frequency of the drops makes a measurable flow.

6.2Centralized lubrication system

1.MainScreensandControlButtons

Menu:UsedtoEnterintoMenuListandreturntoPreviousMenu.

Up:UsedtomoveupcursorintheMenuListsandtoincreaseaValue.

Down:UsedtomovedowncursorintheMenuListsandtodecreaseaValue.

Themainmenuisaccessedthroughthe"Menu"button;allthemenusaredisplayedontherightdisplay.

InagivenMenulist,youcanpressthe"Up"and"Down"buttonstoscrollthroughmenus.Pressingthe buttonwillthenscrollthroughmenusfromtopofscreentothelastmenuonscreen;butifthe buttonis pressed,selectionwillscrollfromtoptobottomofmenuslist.

Theactivelineis"inversevideo"(whitetext,blackhighlighted),usethe"Menu"keytogetinsidetheselected submenu.

Thelastlineofamenulistisalwaysdefinedas"Back",itisusedtomovetothepreviousmenubypressingthe "Menu"buttonwhenhighlighted.

WithinagivenMenuwherethevaluecanbechanged,thechangecanbemadebyusingthe"Up"buttonto increasethevalueandusingthe"Down"buttontodecreasethevalue.Changesareimmediatelyregisteredin controller.Pressingthe"Menu"buttonreturnsyoutothepreviousmenu.

StartCycle

Thethreekeys"StartCyclePX"canbeusedtostartanewlubricationcycleatthecorrespondingpump.Pushing thisbuttonsactslikesimulatinganEnablingsignalcomingtothegreasingcontroller, foreachpump independently.ThechosenpumpwillstartifthePilotpressureissufficient.

IfpumpPXisinsafetymode,athreesecondsactivationofthebutton makesthepumpPXreturnto thenormalmode.

Description of the software menus

2.StartScreens

LeftStartScreen: Grease Controller Startin g

RightStartScreen:

3.MainScreens

LeftMainScreen:

P1OFF

123bar 4 5 6 sec

P2ONSafet y bar0sec

P3ON 1 p ulse200sec

RightMainScreen:

LevelP1100%

P395%

PilotP 4 2bar

B150 12 p ulse

B150 21 p ulse

P2Safet y serv

4. ArchitectureofMenus

5. Menu

Infos y stem

Activeerrors

SetPausetime

Setmax p ress

Errorhistor y

Psafet y serv

SetPausetime

Setmax p ress

Errorhistor y

Psafet y serv

Check Back

Check:

UponenteringtheCheckmenu,thestatusesoftheanaloguesensorsareshown.

B 6 9OK

B71OK

B1 8 4 OK

B5 0 1OK

B5 0 2E R R

TorepresentSensorvaluesinmA,pressandholdboth"Up"and"Down"arrowbuttonsformorethanthree seconds.Thiswillonlyapplywhenaserviceorinspectordongleisplugged.

B6912mAB713 4mA

B18 4 1

6mAB5112mA

B5 0 _121mA A

B5 0 _219m

B15 0 19mA

B15 0 29mA

6.Appendix

ErrorList:

Operating Manual

Centralized Lubrication Systems

R9250

Productidentification

Manufacturer: SKF Lubrication SystemsGermany GmbH

Type: R9250, R9250E

Type no.: R9250: 437 and 1357, R9250E:1129

Address

Heinrich-Hertz-Str. 2-8

69190 Walldorf - Germany

1 Guidelines

As you read theseinstructions, you will notice a number of depictions and symbols which are to facilitate the navigation and understandingof these instructions.

For reasons of better legibility, in these instructions we mainly use the male form for general references.Of course, the femaleformis alsoalways intended.

Please read these instructions thoroughly and heed the warning and safety notes. Please observethewarning and safety notesand exerciseparticular caution in these cases.

Informalso other usersaccordingly.

Text representations

Bold print

Meaning

Highlighting ofparticularly important words or passages

List 1 Marks lists o List 2 Marks lists

(parenthesis)

Instructions

Itemnumbers

Instructions to personnel. These always appear in chronological order.

Explanation of symbols and signs

Activities which generate actual hazards (to life and limb or possible damage to the material) aremarked by warnings. Definitely observe the instructions given in the warnings. Youwillfindthesesymbols,whichwarnofspecificdangerstopersons,materialassets,orthe environment, next to all safetyinstructions intheseoperating instructions.

Please read these instructions thoroughly and heed the warning and safety notes. Please observethewarning and safety notesand exerciseparticular caution in these cases.

Informalso other usersaccordingly.

Thefollowing warningsare possible.

Symbol Meaning

Generalwarning

Activities which generateactual hazards (to life and limb or possible damage to thematerial)

Warning of suspended load

Risk ofexplosion

Carry out work on electricalparts only ifthe atmosphereis not potentially explosive. Workhas to be carried out by aspecialistfor maintenanceand repairs inpotentially explosive atmospheres.

Electrical component hazard, electrical shock hazard

Make sure to disconnect the system or component from the power supply before carrying out works on electrical parts.

Do not use steam jet or high pressure cleaners for cleaning. Otherwise electrical components may be damaged. Do not touch cables or electrical components with wet or damphands.

Cleaning work on energized components may be carried out by electrical specialists only.

Risk offire

Risk of fireand explosion when using inflammablecleaning agents.

Health hazard

Hazarddue to spouting lubricant / pressureinjection due to a leakage (defectivefitting, too high systempressure orother damages).

Crushing hazard

Slipping hazard

Hot surfaces

Symbol Meaning

Disposal

Environmentally sound disposal and recycling

Disposal

Environmentally sound disposal of waste electricaland electronic equipment

Illustrations

The illustrations used refer to a specific product. In the case of other products or product versions they may have a schematic character only. The basic function, however, does not change.

Abbreviations

The followingabbreviations may beused within these instructions:. max. maximum min. minimum min minutes s seconds etc. and so on poss. possibly e.g. for example ml millilitre ccm cubic cm mm millimetre

°C degrees Celsius

°F degrees Fahrenheit

K Kelvin inch inch etc. et cetera kg kilogram l litre mbar millibar no. Number

Nm Newtonmeter incl. including i.e. this means rh relativehumidity approx.approximately

Ø diameter

® registered trademark

© Copyright

TM Trademark

% per cent dB (A) sound pressure level

> greater than < less than ± plus minus

SW width across flats

ESD Electrostatic Discharge

N/A not applicable

Manufacturer and Service addresses

Manufacturer

SKF Lubrication Systems Germany

GmbH

Heinrich-Hertz-Str. 2-8

DE - 69190 Walldorf

Customer Service

SKF Lubrication Systems Germany GmbH

Heinrich Hertz Straße 2-8

DE - 69183 Walldorf

+49 (0)6227-330

SKF Lubrication Systems Germany GmbH

2. Industriestraße 4

DE - 68766 Hockenheim

+49 (0)620527101

SKF Lubrication Systems Germany GmbH

Motzener Straße 35-37

DE - 12277 Berlin

+49 (0)30-720020

Warranty

Theinstallationinstructionsdonotcontainanyinformationonthewarranty.Thiscanbefound in our general terms and conditions.

Copyright

© Copyright SKF Lubrication Systems Germany GmbH. These installation instructions are copyright-protected. All rights reserved.

The integration of the content into the manufacturer's installation instructions of the machine, into which the pump shall be integrated, is expressly allowed.

Thisalsoincludesthecreationoftrainingmaterial for internal,non-commercial purposes.Any other use without the written consent of the copyright holder - of whatever kind - is prohibited and is regarded as aviolation of copyright.

2 Safetyinformation

Safety information is to be read and observed by any persons entrusted with works on the centralized lubrication system or by those persons who supervise or instruct the beforementioned group of persons.

It is prohibited to commission or operate the machine, the centralized lubrication system or single components prior to reading the installation instructions. The installation instructions must be keptat an accessible location for further use.

Disclaimer

Observation of these installation instructions is the prerequisite for safe operation and the achievement of productcharacteristics and performance levels.

The manufacturer shallnot be held responsible for damages causedby: o nonappropriateuse,faultyassembly,operation,setting,maintenance,repairoraccidents o improper or late response tomalfunctions o unauthorized modifications of the product o intent or negligence o Use of non-original SKF spareparts.

Liability for loss or damage resulting from the use of our products is limited to the maximum purchase price. Liability for consequential damages ofwhateverkind is excluded.

Emergency stopping of the centralized lubrication system

Incase of anemergencystop thecentralized lubrication systemby: switching off the machine, system or vehicle, into which the SKF centralized lubrication system or its componentshavebeenintegrated. separating the supply of power, compressed airor hydraulic pressure (dependingon the system) to thecentralized lubrication system or the corresponding components. actuatingthe emergency-offswitch, if any, of the machine, system or vehicle.

Intended use

ATTENTION

Allproductsmay be used onlyfor theirintendedpurposeand inaccordancewith the instructions.

Intendeduseistheuseoftheproducts to lubricatebearings andfrictionpointswith lubricants within the physical limits that can be found in the relevant product documentation, e. g. operating instructions and product descriptions, e. g. technical drawings and catalogues.

Operation of the lubrication system or single components of it

Operation ispermitted only, if in compliance with:

Allinformation given inthese installation instructions or stated in the referenced documents.

All laws andregulationsto be complied with by the user.

Properly andappropriately conducted installationof the system.

Foreseeable misuse

Any other use and purpose of the centralized lubrication system or its components than the ones described before arestrictly prohibited.

Use isexpresslyforbidden:

in a potentially explosive atmosphere, unless the centralized lubrication system or its components are expressly suitable for itand have been approved accordingly.

in a working environment or condition that corresponds to the required protection types IP (International Protection) and Nema (National Electrical Manufacturers Association) only inparts or not at all.

to use the CLS to feed, forward, or store hazardous substances and mixtures in accordance with annex I part 2-5 of the CLP regulation (EC1272/2008).

Forthesupply,transport,stockpilingofgases,liquefiedgases,dissolvedgases,vapours, andfluidswhosevapourpressureexceedsnormalatmosphericpressure(1013 mbar)by more than 0.5 bar at the maximumadmissible operating temperature. to use the CLSto feed, forward, or store glycol- or polyglycol based oils and greases. to use inadmissible components or components expressly not suitable for the purpose.

Unauthorised activities

The following activities may be carried out by SKF manufacturer specialists or authorized persons only due to potential sources of faults that may not be visible for the user, or due to legal regulations:

Removal, replacement or changes to the centralized lubrication system or components integrated or connected to it.

Changes to the control printed circuit board or the power supply board exceeding the adjustment of lubrication and pause times or thereplacement in caseof defects.

Dismantling of individualcomponents of the centralized lubrication system. Changesto the power supply or to the admissibleinput voltage.

Changes to the admissible or specifically required operating pressure for the supplied centralized lubrication system.

Conversions or modifications

Unauthorizedconversionsormodificationsmayresultinunforeseeableimpactsonsafetyand functionality. Therefore, any unauthorized reconstructions or changes are expressly prohibited.

Inspections

Thefollowing inspections were carried out prior to delivery: Electrical inspections following EN 60204-1 (depending on the type of component supplied) Tests made in accordance with ATEX (depending on the type of component supplied)

Safety and functional tests (depending on the type of component supplied)

Warning labels on the centralized lubrication pump or system

Hand injurywarning

During operation of the centralized lubrication system,particularly of the pump, never remove the lid or the barrel andreach into the reservoiror the barrel. Risk of trapping or shearingoff hands and fingers!

Electric shock

Connection of 24 V DCcomponents mustbe provided by a safe galvanic isolation PELV (ProtectiveExtraLow Voltage) or SELV (Safety Extra LowVoltage) always.

Other applicable documents

Inaddition tothese installation instructions,the following documents mustbe observed by the respective target group:

Operational instructions andreleaseprovisions by theoperator.

Safety data sheet and operating instructions of thelubricant or material used. The operator must ensure adding them to these installation instructions.

Operating instructions and technical descriptions of the components used inthe centralized lubrication system.

Operating instructions and technicaldescriptions of purchased parts.

Where appropriate:

Projectplanning documents.

Other relevant documents for the integration of thecentralized lubrication systeminto the superiormachine or system.

The owner must supplement these documents by the respective valid national or regional regulations laiddown by the country inwhich the centralized lubricationsystemis to beused. Ifthecentralized lubrication systemissoldortransferred, anyassociateddocumentsmustbe passed on to the subsequent operator as well.

Sources of hazard

The centralized lubrication system and the components used have been designed, built and tested usingstate-of-the-art technology.

Depending on their version and necessity, they will have left our company only after having passedstringentsafetyandreliabilitytests.Likeforallcomplexmachines,alsoforthissystem there may stillbe involved potential sources of hazard.

Moving or rotating parts

Drive

Tooth wheels

Stirringpaddle

Shovelfoot

Piston Guides

Articulations etc.

Energies

Electricity

Temperature(hot orcoldsurfaces)

Position energy (raisedcomponents)

Parts subject topressure(operatingpressure, oilpressure, greasepressure, airpressure, etc.)

Bursting reservoir if filled by ahigh-performancepump

Parts subjectto spring tension

Lubricants

Greases

Oils

Transportlifecycle

Residual risks Remedy

Tilting or fallingof parts during transport, e.g. overinclines.

Secure parts against tilting or falling during transport (e.g. using tapes, belts, ropes,etc.).

Dropping of lifted parts or tools. No people may remain under suspended loads. Keep unauthorized persons away. Secure suspended loads using suitable hoisting equipment (e.g. tapes, belts, ropes, etc.).

Existing residual risks

Installation lifecycle

Residual risks Remedy

People slipping due to floor contamination with spilled or leaked lubricant

Take care when filling. Bind and remove leaked or spilled lubricant immediatelywith a suitable agent.

Follow the operational instructions for handling lubricants and contaminated parts.

Installation lifecycle

Residual risks

Deviating installation position.

- Foreign objects falling into the motor air intake or into other components.

- Borehole for drainage of condensation water is no longeratthelowestpointof the motor.

Tearing or damaging of lines when installed on moving machineparts(e.g.pivotarm).

Tearing or damaging of lines due to installation on chafing points or installation with too littlebending radius

Falling of parts dueto insufficient fixingto the machine.

Remedy

Installation of a suitable protective roof over the air intake.

Deviating installation position only, if the formation of condensation water has been completed. Remove condensation with suitable suction device.

If possible, do not mount onto movable parts. Should thisnot bepossible,use flexiblehoselinesofsufficient length.

Use protective pipes or spring coils.

Fix parts only to machine parts with sufficient load capacity. Observethe weight and the stated tightening torques.

If no tightening torques are stated, the tightening torques are to be applied to the screw size for 8.8 screws.

Literature, see screw manufacturer. Electric shock through reduced insulation resistance. Check the formation of condensation water inthe motor regularly.

If applicable, drain off condensationwater at the drain plug. Check the insulation resistanceregularly. Electric shock when connecting thepump. Prior to connection of electrical components (pump, switchcabinet,valves, etc.) de-energizeallaffected electrical components. If necessary, please observe discharge times.The electrical connection may be carried out by commissioned andqualified electricians only and inaccordancewith the connection diagram.

Lifecycle - commissioning

Residual risks

Electricalshock dueto defective connection cable

Remedy

Beforeinstallation andstart-up check allcables with regardto possibledamages.

Incase of damage, properly replace affectedcable. Immediately switch off the centralized lubrication system.

Lifecycle - commissioning

Residual risks

Lubricant spraying out due to incorrect screwconnectionof components or lines.

Remedy

Tighten allparts with appropriate tightening torques. Use suitable hydraulic screwconnections and lines for the stated pressures.

Check these prior to commissioningfor correct connection and damage.

Contactwith corrosive or toxic substances that maybe set free by a defective battery.

Wear protective clothes.

Ensuresufficient ventilation. Storage and disposalof defective batteries in accordancewith the corresponding safety data sheets for lithium.

People slipping due to floor contamination with spilled or leaked lubricant.

Take care when filling. Bind and remove leaked or spilled lubricant immediately with a suitableagent.

Observe the legal or company regulations on dealing with oils and greases and contaminatedparts.

Falling of parts dueto insufficient fixingto the machine.

Fix parts only to machine parts with sufficient load capacity. Observethe weight and the stated tightening torques.

If no tightening torques are stated, the tightening torques are to be applied to the screw size for 8.8 screws.

Literature, see screw manufacturer.

Bursting reservoir if filled by a high-performancepump

Monitor the filling procedure and stop it when reaching the maxmarking ofthe reservoir

Contact withstirring paddleor shovel foot during "test operation" without lubricant reservoiror barrel

Tearing or damaging of lines when installed on moving machineparts(e.g.pivotarm).

Alwaysoperatepumpwith lubricantreservoiror barrel. Do not reach into the stirring paddle, the drive or the supply piston.

If possible, do notmount on moveable parts.

Should this not be possible, use flexible hose lines of sufficient lengths.

Lifecycle - operation, maintenance, repair Residual risks Remedy

Contact to the shovel foot during change of barrel of a pneumatic, hydraulic or electric barrel pump.

Contactwith the stirring paddlewhen filling a reservoir pumpfrom thetop during pumpoperation.

Change barrel only with the centralized lubrication system and pumpbeing de-pressurized.

Switch off the pump before changing the barrel and relieveexisting system pressure.

Fill preferablyvia the filling connection.

Filling fromthe top or changing ofbarrel in case of barrel pumps onlywhile thepumpis idle.

When filling, donot reach into the reservoir.

Electricalshock dueto defective connection cable

People slipping due to floor contamination with spilledor leaked lubricant

Switch off the centralized lubrication system and check connection cablefor damage.

Exercisecaution when connecting the system. Promptlyapply suitablebinding agents to remove the leaked orspilled lubricant.

Follow the operational instructions for handling lubricants and contaminated parts.

Tearing or damaging of lines

Switch of the centralized lubrication system, check the routing of the hose lines and optimize or replace defective hoseor line, if necessary.

Should this not be possible, use flexible hose lines of sufficient lengths.

Faultlifecycle

Too strong heating up of the motor or other electrical components.

Too strong heatingup of hydraulicallydriven components

Strong coolingdown and formation of ice onsound absorber and air leakage on pneumatically driven pumps or other components

Inadmissible lubricant leakage oncomponentsor lubricantlinesof the centralized lubrication system

Switch off the pump and system. Let parts cool down, eliminate cause. Replacedefective motoror other defective components.

Switch ofthe system or the affected component.

Ensureproperfunctioning ofthe oil cooler.

Check the compressor and the drier ofthe compressedairsupply. Reduce the operating speed of theaffectedpump.

Shortly switch off thesystem or heat it, if necessary.

Switch off the centralized lubrication system and determine cause. Replacedefective lines or components.

Faultlifecycle

Lubricant spraying out due to incorrect screwconnectionof components or lines.

Tighten allparts with appropriate tightening torques. Use suitable hydraulic screwconnections and lines for the stated pressures.

Check these prior to commissioningfor correct connection and damage.

Disposal lifecycle

Contamination ofthe environment withlubricant and wetted parts

People slipping due to floor contamination with spilledor leaked lubricant.

Dispose of theparts following the valid legal and company regulations.

Exercise caution when disconnecting the lines. Promptlyapply suitablebinding agents to remove the leaked orspilled lubricant.

Follow the operational instructions for handling lubricants and contaminated parts.

Contamination ofthe environment due to used batteries on control printed circuit boards

Dispose ofusedbatteries followingthe valid legal and company regulations.

Until disposal, store used battery, e.g.in a closed polyethylene bag , in order to avoidany damages.

Persons authorized to operate the pump

Only qualified technical personnel may install, operate, maintain, and repair the products described in this document. The core principles of these country-specific qualification requirements for technical personnel cannot be below those of the two standards mentioned above.

Operator

A person whois qualified bytraining and experienceto carry out the functions and activities related to normal operation.

This includes avoiding possiblehazards that may arise during pumpoperation.

Specialist for maintenance and repairs

Qualifiedtechnicalpersonnelarepersonswhohavebeentrained,assigned,andinstructedby the operatorof the final product. Such persons are familiar with the relevant standards, rules, accident prevention regulations, and assembly conditions as a result of their training, experience, and instruction.

They are qualifiedto carry out therequired activities and indoingso recognize and avoid any potential hazards.

Specialist in electrics

The definition of qualified personnel and the prohibition against employing non-qualified personnel are laid down in DIN VDE 0105 and IEC 364. Relevantcountry specificdefinitionsof qualifiedtechnicalpersonnelapplyforcountriesoutsidethescopeofDINVDE0105orIEC364.

Protection of special groups of persons

The respective legal employment restrictions do apply.

3 Safetyrecommendationstobecompliedwith

General behaviour when handling the system

The centralized lubrication system,pumpor single components may be used only in awareness ofthe potential dangers, in proper technical condition, and according tothe information inthese installationinstructions.

Familiarize yourself with the functionsand operation of the product. The specified assemblyand operating steps and theirsequences must be observed.

Any unclear pointsregarding proper condition or correctassembly/ operation must be clarified. Operation is prohibited untilissues have beenclarified.

Keep unauthorized personsaway from the centralizedlubrication system.

Precautionary operational measures and instructions for the respective work must be observed.

Responsibilities for different activitiesmust be clearly defined and observed. Uncertainty seriously endangerssafety.

Safety-related protective and emergency devices must not be removed, modified or affected otherwiseintheirfunction and areto be checked at regular intervals for completeness and function.

Remedy occurring faults inthe frameof responsibilities. Immediately inform your superior inthecase offaults beyond your competence.

Do not reachinto thesystem during operation.

Wear personal protectiveequipment always.

When handling lubricants observethe relevant safety data sheets and operating instructions bythe lubricant manufacturer or supplier.

Never use parts of the centralized lubrication system or of the machineas standingor climbing aids.

Explosion protection

Always behaveso that fireand explosion hazards are avoided.

A writtenwork approvalfromthe operator is required prior to working inpotentially explosive areas.

There must be no indications that parts of the explosion protection aremissing or are not working. Should such indications become apparent, switch off the machineand informa superior without delay. Keepunauthorized personsaway.

Measures forexplosion protection must never be deactivated, modifiedor bypassed.

It is forbidden to bring inignition sources such as sparks, open flames and hot surfaces in potentially explosive areas.

Check the machine at regular intervalsfor damage whichmay represent an ignition risk.

The ignition temperatureof the lubricant must lie at least50 K over the maximum admissiblesurface temperature of the components.

Only use tools andclothing which are permitted for usein potentially explosive areas (ESD).

Transport, installation, repairs and work on electrical components may only be carried out, if it has been ensured that the atmosphere is not potentially explosive.

Repairs or modifications to machines which are protected against explosions may be carried out onlyby themanufacturer or by a workshop recognized by a named institution and confirmed in writing.

If thework is not carriedout by themanufacturer,the repairs must be approved by a namedexpertand confirmed inwriting. The repairs are to bemarked by a repair sign on the machine, stating the following: o Date o Executing company o Type of repair o If applicable, expert'scode

Transport damages can result in the loss of the explosion protection. If transport damages canbe seen,do not assemblethe machine or put it into operation

All parts of the earthingconcept mustbe correctly availableand connected with the superordinate machine.

If transport lugsare dismantled after set-up, the threaded bores mustbe permanently sealed in accordancewith the protectionclass. Handle the materials so that no sparksare generatedby tilting,falling,sliding, rubbing, impacting,etc. If needed, cover materials with suitable means.

Never disconnect plug-in connections when energized. Secureplug-in connections against inadvertent manualdisconnection with the safetyclips included inthedelivery.

The operator must check critically whether operationwithout a low-level signalmight lead toa new risk potential(e.g. throughheat-up of bearing points on themachine in the area of ignition temperature, poor lubrication or bearing damage). If this cannot be ascertained,provide a low-level signal or suitableorganisational measures for monitoring of thebearing point temperature.

Avoiddust accumulation and removedust immediately. Dust accumulations havea thermally insulating effectand, ifwhirled up, generatethe formationof a potentially explosiveatmosphere.

The pumpshould be integratedinto the operator's lightningprotection concept.

All parts are to bechecked regularly for corrosion. Replace the affected parts.

Terminalboxesmust befirmly closedand the cablebreakthroughs correctly sealed.

Additional electrical monitoring devices must be firmly connected and correctly adjusted.

Protect the motor with a motor circuit breaker against inadmissible heating up. When reachingtheirnominallife,themotorbearingshavetobereplacedorinspectedtoensure their suitability for further utilisation.

Transport / installation / maintenance / repairs / servicing

All relevant persons (e.g., operating personnel, supervisors) must be informed of the respective activity prior to starting any work. Observe the precautionary operational measures and work instructions.

If protective and safety equipment has to be dismantled, it must be reassembled immediatelyafter finishingthe work,and then checked for correct function.

Ensurethroughsuitablemeasuresthatmovableordetachedpartsareimmobilizedduring the work and that no limbscan be caught in betweenby inadvertentmovements. Carry out transportusingonly suitablehoisting equipment.

If transported separately(e. g. repair)lift themotor bymeans of the transportlugs or eye bolts. Ensure that transport lugs or eye bolts are firmly seated. Do not carry any further load onthe transportlugsor eyebolts. Do not transport motors on the fancover.

Assemblethepumpsandothercomponentsonlyoutsideoftheoperatingrangeofmoving parts,at an adequatedistancefrom sources of heat or cold.

Dry wet, slipperysurfaces.

Cover hot or coldsurfaces accordingly.

Prior to performing work, de-energize and depressurize the pump and secure it against unauthorized switch-on. Work on electrical components must be carried out by electrical specialists only. Observe anywaiting periods for discharging, if necessary.

Carry out electrical connections only according to the information in the valid wiring diagram and takinginto account the relevant regulations, thelocal connection conditions andlegalprescriptions(e.g.DIN,VDE).Electricalconnectionsmustbedoneinsuchway that no forces are transferred to the product (tension-free connection).

Do not touchcables or electrical componentswith wet or damphands.

Maintenance and repair work can be subject to restrictions at low or high temperatures (e.g. changedflowpropertiesof the lubricant). Therefore, wherepossible, trytocarryout maintenanceand repairworkat room temperature.

Carry out all works on electrical components using adequate, voltage insulated and technically proper tools only.

Fuses must never be bridged but have to be replaced by the same type of fuse always. Determine the causeof thefailure of the fuse.

Ensurecorrect earthingof the electrical system.

Undertake drilling at non-critical, non-load bearing parts only.Use any available boreholes. Donot damagelines and cables when drilling. It is essentialto observe the machine manufacturer's installation instructions and to consult themachine designer in case of doubts.

Observe possibleabrasion points. Protect the parts accordingly.

Other units of themachine or vehicle must not be damaged or impaired in their function by the installation of the centralized lubrication system.

All components used must be designedfor: o maximumoperating pressure o lubricant to be supplied o maximum/ minimumtemperature o corresponding supply voltage availableon site o operating and ambient conditions at the locationof use o requiredlubricant volume

Parts of the centralized lubrication system must never be subjected to torsion, shearing or bending.

Check all parts prior to use for contamination and clean, if necessary. Lubricant lines shouldbeprimedwithlubricantpriortoinstallation.Thismakesthesubsequentventilation and commissioning of the system easier.

Observe the specified tightening torques. When tightening, use a calibrated torque wrench.

When working with heavy parts usesuitableliftingtools. Ifneed be,consultthe responsiblesafety officer.

Avoidmixing up or wrongassembly ofdismantled parts. Mark these parts accordingly.

Laying of the lubrication lines

Whenlayingthelubricationlines,observethefollowinginformationinordertowarranttroublefree function of the entire centralized lubrication system.

Caution

Environmentalpollution

Lubrication lines must be absolutely leakproof. Lubricants maypollute ground andwaters.Lubricantshavetobehandledanddisposedofproperly.Observeall applicableprescriptionsandlawsregardingdisposaloflubricantsaswellasthe relevantsafetydatasheets.

Slippinghazard

Centralizedlubricationsystemsmustbeabsolutelyleakproof.Leakinglubricant ishazardousduetotheriskofslippingandinjury.Duringassembly,operation, maintenanceandrepairofcentralizedlubricationsystemswatchoutforleaking lubricant.Leaksmustbesealedimmediately.

Dimensionthelubricationlineaccordingtothemaximumpressureandtheoutputvolume of thepumpunit used.

Starting from the pump unit the main lubrication line should be laid preferably rising with a possibility to vent it at the highestpoint of thelubricationline system.

Mount the lubricant metering devices at the end of the main lubrication line in such way that the outlets of the lubricant metering devices show upwards. If lubricant metering deviceshavetobemountedbelowthemainlubricationline,thenthisshouldnotbedone at theend of the main lubrication line.

Thetubelines,hoses,shut-offandwayvalves, fittings,etc.haveto be laidoutaccording to the maximum operating pressure of the pump unit, the admissible temperatures and the lubricants to be supplied. Furthermore, the lubrication line system must be protected against inadmissibly high pressure.

Before the assembly thoroughly clean all components of the lubrication line system like tube lines, hoses, shut-off and way valves, fittings, etc. In the lubrication line system no seals should protrude towards the inside, as the lubricant flow could be impeded and contaminations could enterthe lubricationline system.

Lubrication lines shall generally be laid in such way that there can never be created air pocketsatanypoint.Avoidchangingthecrosssectionsofthelubricationlinefromsmaller tolarger crosssectionsin thelubricant flowdirection.Designcrosssectiontransitionsas smooth as possible.

The lubricant flow in the lubrication lines should not be impeded by the installation of sharpelbows, anglevalvesandcheck valves. Provide unavoidablechangesof the cross sections in the lubrication lines with as smooth transitions as possible. Avoid sudden changes of direction, if possible.

Initial commissioning / daily start-up

Ensurethat:

The machine manufacturer's instructionsregarding the lubricants tobe used are observed.

Allsafety devices arecompletely availableand functional. All connections are correctly connected. Allparts arecorrectly installed.

All warning labels on thecentralized lubrication systemarecompletely available, highly visibleand undamaged.

Illegible or missing warning labels areto be replaced without delay.

The system pressurespecifiedfor proper operation is adheredto and neither exceeding nor falling belowspecification.

Cleaning

Risk of fire and explosion when using inflammablecleaning agents. Only use nonflammablecleaningagents suitablefor the purpose.

Do not use any aggressive cleaningagents.

Donotusesteamjetorhighpressurecleaners.Otherwiseelectricalcomponentsmaybe damaged. Observe the protection classes, e.g. IP (International Protection) and NEMA (National Electrical Manufacturers Association), required for proper operation.

Cleaning work on energizedcomponents may be carried out by electrical specialists only.

Do not touchcables or electrical componentswithwet or damphands. Mark damp areas accordingly.

4 Operatorobligations

Determination of hazards

The operator must determine all hazards resulting from the integration of the pumpinto the superordinate machine and the hazards at the location ofoperation of the machine, and carry out the measures necessary to ensure safety and health protection.

Provision of necessaryinformation

The operatormust make the installationinstructions required for the respectiveactivity accessible to allpeoplecommissionedwithoperation,maintenance and repairs.

Hemustensurethat these people have read and understood the necessaryinstallation instructions.

The sameappliesfor allrelevant safetydata sheets,company instructions, accident prevention regulations, instructions fromsuppliers of purchaseparts and utilities. Depending onthe business organization, the relevant installationinstructions may have to be made accessible to other people and departments.

Inspection for correct use

The operatormust check atregular intervalsthrough suitable measures that thecentralized lubrication system is being used according toits intended purpose,that no conversions or manipulations have been made to the centralizedlubrication systemor to singlecomponents and that all parts arefully functional.

Briefing of external technicians

Prior to commencing theactivities, external technicians must be informed by the operator of the company safety provisions,the applicable accident preventionregulations to be maintained, and the functionsof the centralized lubricationsystem and protective devices.

Provision of personal protective equipment

The operatormust provide suitable personal protective equipment for the respective location of operation andthe purpose of operation.

Training courses

Inorder to provide a maximum of safetyand economic viability, SKF carries out detailed producttraining courses. It is recommendedthat the trainingcoursesare attended. Please contact SKF Customer Service for information.

Inspection of the delivery / returns

The delivery must be inspectedfor completeness based on the delivery papers.Transport damages mustbe reportedto the forwarder immediately.Keep the packaging material until any discrepancies are resolved.

Returns

Clean all parts and pack them properly, i.e. following the regulations of the recipient country, before returning them.Mark returns on the packaging as follows;

Donot burden / this side up!

Protect against moisture!

Handle with care! Fragile, do not throw!

Disposal

At the end of their service life, the centralized lubrication system and its components must be dismantled and disposed of according to the respective valid provisions in an environmentally friendly manner. It is forbidden to use parts of a centralizedlubricationsystemthatistobedisposed ofortoassemblethesepartstobuildanewsystem.

In case of a final shutdown follow the applicable rules and regulations on the disposal of contaminatedpartsormeansofoperation.TheproductcanalsobereturnedtoSKFforproper disposal, in which case the customer is responsible for reimbursing the costs incurred. The parts arerecyclable.

Caution

Lubricants may pollute ground and waters. Lubricants have to be handled and disposed of properly.

Observe the instructions by the machinemanufacturer regarding the lubricants to be used.

5 Lubricant

For lubricant information, refer to chapter 5.3 “Lubricants and operating fluids” ofthe Liebherr Operating Manual

Filling of the reservoir

Warning

Riskof hand injuries caused bythe stirring paddle or shovel foot

Fill lubricant via the lid only when pumpis idle. Never reach into the reservoir or grease barrel while the pump is running.

Observe extremecleanlinesswhen topping up the grease reservoirs. Contaminated lubricant causes malfunctions and premature wear of the greasepump and other componentsof the system. Clean surroundings beforeexchanging or topping up Switch off centralized lubrication system

Filling ofthe container through service-plate

Remove dust protective cap at the filling coupling and the dust protective cap at the filling nipple

Couplethe filling hose for P1 resp. P2 and switchon the filling pump

When the reservoir is full,the sensor transmits an electric signalto the controlunit. Visual control is possible by using the dipstick

When the filling pump is switched off Disconnect the filling couplingand reinstall the dustprotective caps

Inadvertent filling with incorrect lubricant

Should incorrect lubricant have been filled, pleaseproceedas follows: Switch off the pump orcentralized lubrication systemand secure itagainst being switched on.

Remove lubricant.

Clean the entirecentralized lubricationsystem (lubricant reservoir, pump housing, metering devices and line systems).

Fill inlubricantof correct specification. Switch thesystem or pumpon. Vent lubrication system.

Inform yoursuperior to ensure that the error won't occur again.

Inspections prior to initial start-up

Attention

Risk of damageto the machine

Fill the feed lines and bearing housingswith lubricant to specification and lubricate the lubrication points by hand. Otherwise thebearing points may becomedamaged due to a lack of lubricant.

Check the entire system for accordance with the intendedpurposeand theplanning documentation. Ensure that all parameters, characteristic values and means of operation arepresent andhave beencorrectly adjusted. If deviations aredetected, they must be remedied without delay.

Inordertowarrantsafetyandfunction,apersonassignedbytheoperatormustinspectcertain areas of the central lubrication system prior to initial commissioning. Report any detected deficienciesimmediatelytoyoursuperiorandremedythem.Deficienciesmayberemediedby an authorized and qualifiedspecialist only.

Check the following points prior to initial commissioning.

Electrics:

Electrical connectionscarried out correctly. Cable entriessealedcorrectly.

The voltage and frequency of the power network correspond tothe information on the type identification plate of the motor.

Monitoring devices and additional equipment (e.g. motor circuitbreaker)are correctly connected and adjusted.

All parts suchas lines, cables, metering devices, etc.havebeencorrectly installed and areundamaged.

Mechanics:

No loose or missing parts remaining (e.g. pressurerelief valves,feed lines).

No damages, deformations,cracks, burnt and smoky points. No discolorations, contaminations and/or corrosion.

No unusual humidity accumulations, odours, vibrations, orsounds.

No leakages of lubricant at connectionsand fromlines.

Activation of the pump

Depending onthe version the centralized lubrication system or pumpis activated:

Byinstalling itintoa machine

By switchingon the machine contact

By acontrol provided by the customer

Bymanual activation

6 Standardoperation

Daily start-up

Below find the activities to be carriedout in case of standardoperation.

Inspections

With regard to the actions listed below "Inspections prior to commissioning" the operator has todetermineadequatecontrolintervalsdependingontherespectiveoperatingsituationofthe pumpor centralized lubricationsystem.

Filling of the reservoir during operation

Fill the reservoir as described in chapter "Installation and commissioning".

Cleaning

Execution, required protective clothes, cleaning agents and devices following the valid operationalregulations of the operator.

Danger

Danger tolife

Risk of fireand explosion when using inflammablecleaning agents. Donot usesteam jet or high pressurecleaners. Electrical components may bedamaged. Donot touch cables or electrical componentswith wet or damphands.Cleaningwork on energizedcomponents may be carried out by electrical specialists only. Wear personal protective equipment always.

Exterior cleaning

Thorough cleaning of allsurfaces. Mark and secure wet areas.

Interior cleaning

Normally, interior cleaning is not required.

Attention

Risk of damageto the machine

Ifusingsolventsforcleaning,ensurecompatibilitywithplasticpartsandpainting.Donot usepolar organic solvents such as alcohol, methanol or acetone.

7 Maintenanceandrepairs

Safetyinstructions for maintenance and repairs

WARNING

Electric shock

Make sureto disconnect the pump from the power supply before carrying out works on electrical parts.

Risk of injury

Beforecarrying out any maintenanceor repair work, takeat leastthe followingsafety measures: o Keep unauthorized persons away. o Mark and secure work area. o Depressurize the product. o Disconnect the productfrom the power supply andsecure it against being switched on. o Verify that no power is being applied. o Earthand short-circuit the product. o Whereneeded, cover neighbouring units that arelive.

Maintenance of the system

Dependingontheversionourcentralizedlubricationsystemsrequirevirtuallynomaintenance. However, the following parts should be inspectedand, if necessary, replaced by newparts at regular intervals:

Pressure relief valves

Check valves

Pumpelements

Pressurerelief valvetolerance +5 %/ -10 % If this toleranceis exceeded, thepressurerelief valves must be replaced.

8 Technicaldataandoperatinginstructions

Operating pressure / operating temperature

Allsystem components must be designedfor themaximumoperatingpressureand mustbe secured by an adequate pressurerelief valve against too high system pressures. For details see operatingor installation instructions and data sheets of the respectiveproduct.

Installation position, sound pressure level, weight, dimensions

For details see operating or installationinstructions and data sheets of the respective product.

Tightening torques

For details see operating or installationinstructions and data sheets of the respective product.

Output / connections

Fordetailsseeoperatingorinstallationinstructionsanddatasheetsoftherespectiveproduct. Deviating conditions such as NLGI class, temperature and counter pressure may lead to a deviation in the flow rate. This should be taken into account when designing the lubrication points.

Filling possibilities

For details see operating or installationinstructions and data sheets of the respective product.

Electrical connection (electricallydriven products)

Following the respective applicable installationprescriptions for electrical systems. For detailssee operating orinstallation instructions and datasheets of the respective product.

IP type of protection

Motorandsystem:

For IP or NEMA protective class see type identification plate of motor or system respectively the Technical Data chapter of the individual components. For details see operating or installation instructions and datasheets of the respectiveproduct.

Air pressure and air quality(air-operated products)

Filtered and oiled airaccordingto DIN ISO8573-1 not higher thanclass 5

Inlet airpressure 5.5 – 7 bar

Maximum particledensity 10 mg/ m3

Water content (pressure dewpoint) + 7 °C

Oil content (maximum oilconcentration) 25 mg / m3

Please follow theinstructions of the respectiveproduct.

9 LubricationSystem:Description

General design

9.1.1 Systems

The lubrication system of the R9250 excavator which provide lubricant to the lubrication points are supplied by two independent centralized lubrication systems:

System P1, to lubricate the swing gear bearing and the attachment bushes (and options)

System P3, to lubricate the swing ring teeth and the swing gear centering seat

9.1.2 Allocation of the lubrication points

The lubrication points of theR9250 excavator described beloware dispatched as follows:

Backhoeattachment:

Fig.1 Positionoflubricationpoints

Shovel attachment:

9.1.3Characteristicsof lubrication points on the excavator

Allthe necessary information regarding the greasing points and quantities areavailable inchapter 21 of theLiebherr Service Manual.

System P1: Automatic lubrication

Intheautomaticsystem,acentrallubricationpumpprovideslubricanttoeachlubricationpointthrough a single line via injectors modelLM5and subsequent metering devices model SSV.

9.2.1 Configuration

InjectormodelLM5supplieslubricanttotheprogressivemeteringdevicesmodelSSVwhichdistributes thelubricanttoeachlubricationpointevenly.Acontrolunitcommandsandmonitorstheentiresystem.

Legend: Equipment: Uppercarriage:

Fig.3 Automaticallyoperatedsingle-linesystemwithLM5andsubsequentprogressivedivider valveforbackhoeattachment

Legend:

Fig.4

Equipment:

Uppercarriage:

Automaticallyoperatedsingle-linesystemwithLM5andsubsequentprogressivedivider valveforshovelattachment

9.2.2Greasing cycle

When the pause time has lapsed, the pump starts operating and supplies the lubricant via the main line to the LM5 injectors. The pistons inside the injectors are operated via lubricant pressure. A premetered amount of lubricantis dispensed to the connected SSV.

After all injectors have operated, the pressure in the main line rises until the preset pressure on the pump is reached 240 bar. The control unit stops the pump via the pressure switch B69. The pump stops running and the relief valve is deactivated at the same time. The compressed lubricant in the mainline canflowbackintothe reservoir,the pressuredrops. When the pressure hasfallen below80 bar the pistons inside the LM5 injectors return to their initial positions by means of spring force and reload the adjustableamountof lubricant by this action.

The pause time canstartand thesystem is now ready for another lubrication cycle.

Level I

P1 with pressure control

Legend: T:running time

Pause time: 6min

A: pressurecontrol device

P1 safety mode, without pressure control

Legend: T:runningtime10sec –250 sec

Pause time: 4min-10min

A: timecontrol device, pressure switchoff

Legend:

D Pause time 5min – 15 min

T Runningtimefor one lubricationcycle

Y95 Pump

Y79 Dumpvalve

Y114 Valve

B69 GreasePressure

A Cycleends with maxpressureafter hold time

B Winter operation on

C Winteroperation off

E Max pressure– 40 bar

F Max pressure

G Tempo

H Holdtime

I Continous pumping (only with winter operation buttonon)

Fig.5

Cycle:Equipmentanduppercarriage

9.2.3 Single-linesystem

The single-line system consists of a pump to supply lubricant under pressure to the injector metering devices via the supplyline. Theinjector metering devices deliver lubricant to a secondary (progressive)metering device or to the bearing through feed lines.

The lubrication cycle is initiated by anautomated pump. The injectors have indicator stems, which move inandout to indicate that they have been cycled.

A controller will control theautomatedsystem.

The timebetween on cycles and the length of off cycles is adjustable. The controller includes the timer function above witha monitor function and alarmcapability.A pressure switchisused to indicate when system pressurehas been reached to turn off the pump and verifythat a lubecycle has been completed. If the pressure switch does notdetect fullpressure withina preset period of time, the controllergoes into alarmstate.

Forinformationanddescriptionsofthecomponents,refertochapter13.

* refer tothe user manual9.3EN-98002-xx(page 19)

9.3.5 Electronic Controller

Formore details:

Operating elements Functions

Refer to Manual 93EN-98002-A11_OpInst_LIEBHERR-LFR_Mining_664-36957-7_...

Faultsignals

Each timea fault arises, anacoustic signal will be given by the controller (buzzer)and thetwo flashing lights on thepumpstations willbe activated. Buzzer and flashing lightscan be deactivated by pressing the ENTERkey.

Intwocasesthis willnot be possible:

- very lowgrease level in the barrel (LL)

- both sensorsformonitoring the lubrication of the slewing rimaredefective

In these cases, buzzer and flashing lights will be deactivated when switching off the motor, however, will be activated again when startingthe motor.

Adjustedvalues

For service personnel withPC,correspondingsoftware and authorization: adjustable max. value adjustable min. value adjustedvalue

System P3: Swing ring and swing gear lubrication

IntheautomaticsystemP3,thecentrallubricationpumpprovideslubricanttotheProgressiveMetering Device (Progressive System) which distributes the lubricant to each lubrication point evenly (swing ring teeth andthe swinggear centering seat).

Grease cycle

When the pause time has lapsed, the pump P3 supplies lubricant to the connected progressive metering device. A progressivemetering device type SSV 6 is provided with the proximity switch B51 for control and monitoring purposes. After two cycles of the SSV 6, which correspond to a full lubrication cycle, the pump P3 is switched off thanks to the proximity switch B51.

1 Reservoir 15 liters

2 Level sensor

3 High level sensor “Full”

4 Overflow pipe

5 Pump housingwith integrated motor

The pump is a compact multiline pumpconsisting of the following components:

· Reservoir with stirring paddle

· Printed circuit board

· Pump element

· Pressurerelief valve

· Filling nipple

· Electrical connection parts

· Operates according to lubrication cycles (pauseand operatingtimes)

· Designed forthe deliveryof greases up to NLGI 2

· Can be used at lowtemperatures downto -40 °C.

· During the operating time the pump dispenses lubricant to the connected lubrication points via onedevice.

Numberof outlets: 1

Piston diameter: 7 mm

Lubricant output: approx.4 cm³/min

Reservoircapacity: 15 liters

Formore details:

Description

Modeof operation

Maintenance

Troubleshooting

Technical data

Refer to Technical Description: 21EN-30001-xxx; 20EN-20003-xxx; 26A-20003-xxx

Forinformation and descriptions ofthecomponents, refer to chapter 13.

10 Operation

Greasing system – Cabin Location

Formore details:

Information regarding the operation of thecontrol unit are availablein the respective manual.

Refer to Data Sheet 93EN-98002-xxx for the Electronic Controller

System P1: Automatic lubrication

CAUTION!

Operation by authorized andinstructed personnel only! Never exceed the admissible system pressures! Refillcleanlubricant on time!

CAUTION!

Donot interrupt the power supply(mainswitchof battery) while thepumpis operating.

When starting the excavator, the centralized lubrication systems are connected to the power supply automatically.Eachlubricationpumpthenstartsafulllubricationcycleandisstoppedduringthepreset pause timeonly, etc.

The pump P1delivers lubricant viaa single-line systemto the lubrication points according to Chapter 9.2 Configuration.

Regarding the control and monitoring of the system refer to: Chapter 9.2. Cabingreasing module U41 or ElectronicController

If required, the operatorcan force the greasing cycle: for detailsrefer to therespective data sheets.

Seethecharacteristicsofeachlubricationpoints:Characteristicsoflubricationpointsontheexcavator.

Formore details:

Chapter 9.2 Greasing cycle

Pump P3 CAUTION!

Operation by authorized andinstructed personnel only! Never exceed the admissible system pressures! Refillcleanlubricant on time!

CAUTION!

Donot interrupt the power supply(mainswitchof battery) while thepumpis operating.

When starting the excavator, the centralized lubrication systems are connected to the power supply automatically. The lubrication pump starts a full lubrication cycle and stops during the preset pause time only, etc.

The pausetime is factory-set to6 minutes.

In normalworking condition,no actions are required from the operator.

The only useful informationis thelowlevel quantity ofthe pump P3 reservoir.

If required, the operator can force the greasing cycle:for detailsrefer to therespectivedata sheets.

NOTE!

DAILY:DOA VISUAL CHECKOF THE RESERVOIR FORGREASE LEVEL

Formore details:

Chapter 9.3 Greasing cycle