Liebherr Mining Crawler R 996B 1281 Hydraulic Excavator Operating Manual SN 26049 - PDF DOWNLOAD

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Machine and construction equipment

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Uppercarriage

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Vibration emissions

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Sample EC Declaration of Conformity

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Working technical data

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MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 2-1

Uppercarriage signs

MJFCIFSS

Fig. 2-2

PowerPack signs

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 3-1

Control cab

MJFCIFSS

Fig. 3-2

Joystick, right (3) and left (4)

MJFCIFSS

Fig. 3-3

Excavator keyboard

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 3-4

Control board

MJFCIFSS

MJFCIFSS

Fig. 3-5

Monitoring display

MJFCIFSS

Fig. 3-6

Screen menu control

MJFCIFSS

Fig. 3-7

Main screen

MJFCIFSS

Fig. 3-8

Service interval announcement on display initialization

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 3-9

Main screen

Fig. 3-10

Menu selection in the operator’s menu.

MJFCIFSS

Tab. 3-1 Tab. 3-2

Overview of menu options

Fig. 3-11

Examples of "i-machine" menu display

MJFCIFSS

Fig. 3-12

"i-hours" menu

Fig. 3-13

"i-errors" menu

MJFCIFSS

Fig. 3-14

Examples for "list sensor" submenu display

Fig. 3-15

"list elect." submenu

MJFCIFSS

Fig. 3-16

"print error" submenu

Fig. 3-17

Examples for "set option" menu display

MJFCIFSS

Fig. 3-18

Examples for "set service" menu display

MJFCIFSS

Fig. 3-19

Display for monitoring cameras

MJFCIFSS

Fig. 3-20

Full screen display

MJFCIFSS

MJFCIFSS

Fig. 3-21

Access ladder

MJFCIFSS

Fig. 3-22

Access ladder control box E1013

MJFCIFSS

Fig. 3-23

Control board

MJFCIFSS

Fig. 3-24

Safety lever

Fig. 3-25

Standard operator’ seat

MJFCIFSS

Fig. 3-26

Setting the armrests

MJFCIFSS

Fig. 3-27

Setting the seat and backrest

Fig. 3-28

Setting the horizontal

MJFCIFSS

Fig. 3-29

Switch bar on the air-cushioned operator’s seat

Fig. 3-30

Safety belt

MJFCIFSS

Fig. 3-31

Auxiliary seat

MJFCIFSS

Fig. 3-32

Windscreen and side windows sunshade

MJFCIFSS

Fig. 3-33

Emergency handle on the rear emergency exit

MJFCIFSS

Fig. 3-34

Emergency hammer for the lateral emergency exit

MJFCIFSS

Fig. 3-35

Interior lightings

MJFCIFSS

Fig. 3-36

Fire extinguisher fixing location

MJFCIFSS

Fig. 3-37

Windscreen washing fluid container

MJFCIFSS

Fig. 3-38

Field of view

MJFCIFSS

Fig. 3-39

Floodlights arrangement

MJFCIFSS

Fig. 3-40

Control board

MJFCIFSS

Fig. 3-41

Front panel of the heating/air conditioning control unit

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 3-42

Dual air conditioning switch 77 on control board

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 3-43

Ignition key

Fig. 3-44

Batteries switches

MJFCIFSS

Fig. 3-45

Service interval request

MJFCIFSS

MJFCIFSS

Fig. 3-46

Speed adjustment on control keyboard

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 3-47

H103 and H104 preheating additional indicators on control board

Fig. 3-48

Socket for power supply and switch S176

MJFCIFSS

Fig. 3-49

Snow protection for air filters

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 3-50

Backhoe (left) and shovel (right) attachments position during preheating

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 3-51

Control board

Fig. 3-52

Tank pressure release valve

MJFCIFSS

MJFCIFSS

Fig. 3-53

Driving straight ahead

MJFCIFSS

Fig. 3-54

Turning on the spot

Fig. 3-55

Turning with a crawler

MJFCIFSS

Fig. 3-56

Machine position for turning in tight conditions

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 3-57

Rotating the uppercarriage

MJFCIFSS

MJFCIFSS

Fig. 3-58

Working position – machine

MJFCIFSS

Fig. 3-59

Operating the stick cylinder

Fig. 3-60

Stick in over dead center

MJFCIFSS

Fig. 3-61

Operating the boom cylinder

MJFCIFSS

Fig. 3-62

Float position

MJFCIFSS

Fig. 3-63

Operating the bucket cylinder

Fig. 3-64

Operating the bottom dump shovel bucket

MJFCIFSS

Fig. 3-65

Lowering the equipment when engine is not running

MJFCIFSS

Fig. 3-66

Working position – machine

MJFCIFSS

Fig. 3-67

Hazard area

MJFCIFSS

Fig. 3-68

Recommended digging

Fig. 3-69

Optimal angle for digging

MJFCIFSS

Fig. 3-70

30° forward to the vertical.

Fig. 3-71

Taking up grab material

MJFCIFSS

Fig. 3-72

45° backward to the vertical

MJFCIFSS

Fig. 3-73

Emptying grab material

MJFCIFSS

Fig. 3-74

Digging

MJFCIFSS

Fig. 3-75

Unloading of the bucket

MJFCIFSS

Fig. 3-76

Hazard area r

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 3-77

Sticker for lifting and lashing operations

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 4-1

LIEBHERR service

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 4-2

PowerPack connection box E1001 / E1002

MJFCIFSS

Fig. 4-3

Cabin electrical cabinet E1005

MJFCIFSS

Fig. 4-4

Heating / air-conditioning electrical box E1006

MJFCIFSS

Fig. 4-5

Common connection box E1007/E1008/E1011/E1017

MJFCIFSS

Fig. 4-6

Access ladder electrical box E1009

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 5-1

Access doors

MJFCIFSS

MJFCIFSS

Fig. 5-2

Horizontal middle bar on handrail (example)

MJFCIFSS

Fig. 5-3

Welded anchor point (example)

MJFCIFSS

Fig. 5-4

Drilled anchor point (example)

MJFCIFSS

MJFCIFSS

Fig. 5-5

Lubricating chart

MJFCIFSS

Tab. 5-1

Lubricating chart key

MJFCIFSS

Tab. 5-2

Service trap couplings

Fig. 5-6

Service trap

MJFCIFSS

MJFCIFSS

Tab. 5-3

Lubricant chart

Tab. 5-4

Operating material chart

MJFCIFSS

Fig. 5-7

Service trap control box E1014 and lock disable button 73

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 5-8

LIEBHERR oils for hydraulic system

Fig. 5-9

Engine oils for hydraulic system

MJFCIFSS

(ISO VG68)

(ISO VG100) (ISO VG46)

MJFCIFSS

Fig. 5-10

Hydraulic oil for hydraulic system

MJFCIFSS

MJFCIFSS

Fig. 5-11

Oil changes at pre-set intervals

Fig. 5-12

Oil changes at optimized intervals

MJFCIFSS

Fig. 5-13

Swing gear and travel gear oils

MJFCIFSS

Tab. 5-5

Tab. 5-6

Tab. 5-7

Tab. 5-8

MJFCIFSS

Tab. 5-8

Fig. 5-14

Gear oils for use as splitterbox oil

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 5-15

Sampling pump

MJFCIFSS

MJFCIFSS

Fig. 5-16

Sampling valve 1 for splitterbox oil

MJFCIFSS

Fig. 5-17

Oil sampling points 1 for travel gear oil

MJFCIFSS

Fig. 5-18

Sampling valve 1 for hydraulic oil

Fig. 5-19

Sampling valve 1 for Diesel engine oil

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 5-20

Dipstick for engine oil level indication and oil filler neck

MJFCIFSS

Fig. 5-21

Couplings on service trap for diesel engine oil change

MJFCIFSS

Fig. 5-22

Oil filters

MJFCIFSS

Fig. 5-23

Oil reserve system

MJFCIFSS

Fig. 5-24

Control box quick-change couplings for oil reserve system

MJFCIFSS

MJFCIFSS

Fig. 5-25

Mounting screws

MJFCIFSS

Fig. 5-26

Elastic bedding

Fig. 5-27

Belt

MJFCIFSS

Fig. 5-28

Mounting screws

MJFCIFSS

Fig. 5-29

Mounting screws

Fig. 5-30

Elastic bedding

MJFCIFSS

Fig. 5-31

Breathers on splitterbox

MJFCIFSS

Fig. 5-32

Wear gauge 735 on Geislinger coupling

MJFCIFSS

Fig. 5-33

Coolant expansion tank

MJFCIFSS

Fig. 5-34

Coolant filters

Fig. 5-35

Coolant filters

MJFCIFSS

Fig. 5-36

Coolant drain plug

MJFCIFSS

Fig. 5-37

Service trap

Fig. 5-38

Fuel tank drain valve

MJFCIFSS

MJFCIFSS

Fig. 5-39

Fuel water separators

MJFCIFSS

Fig. 5-40

Pressure regulator 1 and compressor 2

MJFCIFSS

Fig. 5-41

Air dryer

MJFCIFSS

Fig. 5-42

Automatic drain valve on air tank

MJFCIFSS

Fig. 5-43

Air intake system

MJFCIFSS

Fig. 5-44

Primary filter element

MJFCIFSS

Fig. 5-45

Safety element

MJFCIFSS

Fig. 5-46

Air channels for the precleaner

Fig. 5-47

Rubber hoses

MJFCIFSS

Fig. 5-48

Machine check position for hydraulic oil level check or level adjustment

MJFCIFSS

Fig. 5-49

Level inspection window for hydraulic oil

MJFCIFSS

Fig. 5-50

Hydraulic tank pressure release valve

MJFCIFSS

Fig. 5-51

Hydraulic oil change coupling on service trap

Fig. 5-52

Hydraulic tank shut-off valve

Fig. 5-53

Return filters on hydraulic tank

MJFCIFSS

Fig. 5-54

Leak oil filters and return-line filters parts

MJFCIFSS

Fig. 5-55

Filter assembly

MJFCIFSS

Fig. 5-56

Filters on splitterbox and control oil unit

MJFCIFSS

Fig. 5-57

Oil filter assembly

MJFCIFSS

Fig. 5-58

High pressure filters on valve bank

MJFCIFSS

Fig. 5-59

Accumulators on valve bank

MJFCIFSS

Fig. 5-60

Leak oil connection on working pump

Fig. 5-61

Leak oil connections on swing pumps

MJFCIFSS

Fig. 5-62

Leak oil connection on optional engine cooling pump

MJFCIFSS

Fig. 5-63

Hydraulic oil suction pipe and shut-off valve

MJFCIFSS

Fig. 5-64

Protective soft shield covers installation

MJFCIFSS

Fig. 5-65

Dust filters for the safety relief valves

Fig. 5-66

Oil cooler protection filter

MJFCIFSS

Fig. 5-67

Piston rod mount

MJFCIFSS

Fig. 5-68

Machine with piston rods drawn in

MJFCIFSS

MJFCIFSS

Fig. 5-69

SAE flanges

MJFCIFSS

Tab. 5-9

Tightening torques for SAE flanges

Fig. 5-70

Sealing flange 1 and hydraulic block 2

MJFCIFSS

Fig. 5-71

Criss-cross tightening

MJFCIFSS

MJFCIFSS

Fig. 5-72

Oil change on the swing gear

MJFCIFSS

Fig. 5-73

Oil change on the travel gear

MJFCIFSS

Fig. 5-74

Travel motor plugs

MJFCIFSS

MJFCIFSS

Fig. 5-75

Oil change on the splitterbox

MJFCIFSS

MJFCIFSS

Fig. 5-76

Changing the oil in the coupling

MJFCIFSS

Fig. 5-77

Grease nipple on hydraulic rotary connection

MJFCIFSS

Fig. 5-78

Undercarriage components

MJFCIFSS

Fig. 5-79

Travel gear mounting screws

Fig. 5-80

Track components mounting screws

MJFCIFSS

Fig. 5-81

Monitoring the track tension

Fig. 5-82

Track correctly tensioned

MJFCIFSS

Fig. 5-83

Track tensioning levers

MJFCIFSS

MJFCIFSS

Fig. 5-84

Electrical boxes with battery switches

Fig. 5-85

OEM connectors on Diesel engine

MJFCIFSS

Fig. 5-86

Battery care

MJFCIFSS

Fig. 5-87

Electrical components location

MJFCIFSS

Fig. 5-88

Emergency switches arrangement

MJFCIFSS

Fig. 5-89

Aeration device

MJFCIFSS

Fig. 5-90

Coolant shut-off valves 1 on Diesel engine

Fig. 5-91

Heater

MJFCIFSS

Fig. 5-92

Evaporator filter

MJFCIFSS

Fig. 5-93

Condenser unit

MJFCIFSS

MJFCIFSS

Fig. 5-94

Counterweight bolts

MJFCIFSS

Fig. 5-95

Swing ring bolts

MJFCIFSS

Fig. 5-96

Fuel tank bolts

MJFCIFSS

Fig. 5-97

Hydraulic tank bolts

Fig. 5-98

PowerPack bolts

MJFCIFSS

Fig. 5-99

Swing gear and swing motor bolts

MJFCIFSS

Fig. 5-100 Hydraulic pumps assembly

MJFCIFSS

Fig. 5-101 Track tensioning pump’s bolts

Fig. 5-102 Side frames bolts

MJFCIFSS

Fig. 5-103 Driver’s cabin bolts

MJFCIFSS

Fig. 5-104 Driver’s cabin elevation bolts

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 5-105 How to use the check lists (in addition to the daily maintenance)

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

Tab. 5-10 Daily maintenance schedule - R 996B

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

Tab. 5-11 250 Hours maintenance schedule - R 996B

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

Tab. 5-12 500 Hours maintenance schedule - R 996B

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

Tab. 5-13 1000 hours maintenance schedule - R 996B

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

Tab. 5-14 2000 hours maintenance schedule - R 996B

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 6-1

Hydraulic tube and hose assembly

MJFCIFSS

Fig. 6-2

Marking of hose

Fig. 6-3

Marking of hose assembly

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS!

1. Main Screens and Control Buttons

Menu: Used to Enter into Menu List and return to Previous Menu.

Up: Used to move up cursor in the Menu Lists and to increase a Value.

Down: Used to move down cursor in the Menu Lists and to decrease a Value.

The main menu is accessed through the "Menu" button; all the menus are displayed on the right display.

In a given Menu list, you can press the "Up" and "Down" buttons to scroll through menus. Pressing the button will then scroll through menus from top of screen to the last menu on screen; but if the button is pressed, selection will scroll from top to bottom of menus list.

The active line is "inverse video" (white text, black highlighted), use the "Menu" key to get inside the selected submenu.

The last line of a menu list is always defined as "Back", it is used to move to the previous menu by pressing the "Menu" button when highlighted.

Within a given Menu where the value can be changed, the change can be made by using the "Up" button to increase the value and using the "Down" button to decrease the value. Changes are immediately registered in controller. Pressing the "Menu" button returns you to the previous menu.

Start Cycle The three keys "Start Cycle PX" can be used to start a new lubrication cycle at the corresponding pump. Pushing this buttons acts like simulating an Enabling signal coming to the greasing controller, for each pump independently. The chosen pump will start if the Pilot pressure is sufficient.

If pump PX is in safety mode, a three seconds activation of the button the normal mode.

Description of the software menus

makes the pump PX return to

MJFCIFSS!

2. Start Screens Left Start Screen : G r e a s e C o n t r o l l e r S t a r t i n g

Right Start Screen : I n f o S y s t em F am 1 Mo d u l e

s y s t e m P1 P2 E xe c 2

P 3 EM E xe c 2

V1 . 03

3. Main Screens Left Main Screen : P 1 O F F 1 2 3 b a r P 2

4 5 6 s e c

O N b a r

S a f e t y 0 s e c

P 3 O N 1 p u l s e

2 0 0 s e c

Right Main Screen : L e v e l

P 1 P 3

1 0 0 % 9 5 % P i l o t P 4 2 b a r B 1 5 0 1 2 p u l s e B 1 5 0 2 1 p u l s e P 2 S a f e t y s e r v __________________________________________________________________________________

Description of the software menus

MJFCIFSS!

4. Architecture of Menus

Description of the software menus

MJFCIFSS!

5. Menu I n A c S e S e E r P

f t t t r s

o s y s t e m i v e e r r o r s P a u s e t i m e m a x p r e s s o r h i s t o r y a f e t y s e r v

S e t P a u s e t i m e S e t m a x p r e s s E r r o r h i s t o r y P s a f e t y s e r v C h e c k B a c k

Info System : I n f o S y s t em F am 1 Mo d u l e B a c k

s y s t e m P1 P2 E xe c 2

P 3 EM E xe c 2

V1 . 03

Config P1/P2

Config P3

Active Errors : A c t i v e

e r r o r s

G 1 : P r e s s P 1 s t a y l ow G3 : No f e e dba c k P3 l i ne G4 : No p r e s s d r op P1 B a c k

Description of the software menus

MJFCIFSS!

Set Pause Time : S e t P1 P2 P3

P a u s e

se t t i ng s se t t i ng s se t t i ng s

t i m e 600se c 600se c 600se c

B a c k

P a u s e

2 4 5

Set max Press : S e t

m a x

2 4 0

Description of the software menus

P r e s s

b a r

t i m e

s e c

P X

MJFCIFSS!

Error History : E r r o r

h i s t o r y

G 1 : P r e s s P 1 s t a y l ow G 2 : P r e s s P 2 s t a y l ow G3 : No f e e dba c k P3 l i ne G4 : No p r e s s d r op P 1 G5 : No p r e s s d r op P2

E r r o r

h i s t o r y

G14 : L e v s e n s o r G17 : L e v s e n s o r G28 : G r e a s e l e v G29 : G r ea s e l ev G33 : G r e a s e l e v

E r r o r

P1 P3 P1 P3 P1

NC NCe f ew f ew l ow

h i s t o r y

G 3 4 : G r e a s e l e v P 3 l ow G 3 6 : P i l o t p r e s s l ow n e G3 7 : No f e e dba c k B1 5 0 1 G3 8 : No f e e dba c k B1 5 0 2 B a c k

G34 : G r e a s e

l ev

P3

l ow

Nb r o f o c c u r e n c e s La s t hour 00003 La s t 10 hour s 00015 Tota l h i s tor i c 01224 B a c k

Safety Function : P

s a f e t y P 1 P 2 O F F

B a c k

Description of the software menus

s e r v

MJFCIFSS!

Check : Upon entering the Check menu, the statuses of the analogue sensors are shown.

B 6 9 O K B 7 1 O K B 1 8 4 O K B 5 0 1 O K B 5 0 2 E R R

To represent Sensor values in mA, press and hold both "Up" and "Down" arrow buttons for more than three seconds. This will only apply when a service or inspector dongle is plugged.

B69 1 2 mA B71 B184 1 6 mA B51 B50_1 2 1 mA B50_2 1 9 mA B150 1 9 mA B150 2 9 mA

3 4 mA 1 2 mA

__________________________________________________________________________________

6. Appendix Error List : G1 : P r e s s

P1

s tay

l ow

G2 : P r e s s

P2

s tay

l ow

G3 : No

f eedba ck

P3 l i ne

G4 : No

pres s

dr op

P1

G5 : No

pres s

dr op

P2

G14 : L e v

sensor

P1

NC

G17 : L e v

sensor

P3

NC

G28 : G r e a s e

l ev

P1

f ew

G29 : G r e a s e

l ev

P3

f ew

G33 : G r e a s e

l ev

P1

l ow

G34 : G r e a s e

l ev

P3

l ow

G36 : P i l o t

pres s

l ow

G3 7 : No

f eedba ckB150

1

G3 8 : No

f eedba ckB150

2

Description of the software menus

MJFCIFSS

Servicing Manual Centralized Lubrication System for LIEBHERR Hydraulic Excavator R 996B Manual

A. Description of the system as a whole 1

FUNCTION OF THE LUBRICATION SYSTEM...................................................................................................2

1.1

DESCRIPTION OF THE ENTIRE SYSTEM........................................................................................................2

Standard: 1 Pump variant ...........................................................................................................................2 Option: 2 Pumps variant .............................................................................................................................2 1.2 SEQUENCE OF A LUBRICATION CYCLE..........................................................................................................3 1.2.1 Systems 1 and 2: .......................................................................................................................................3 1.2.2 System 3 ...................................................................................................................................................3 1.3 LUBRICATION DIAGRAM .....................................................................................................................................4 1.3.1 Standard: 1 Pump variant ...........................................................................................................................4 1.3.1 Option: 2 Pump variant ...............................................................................................................................5 1.1.1 1.1.2

2

OPERATION .........................................................................................................................................................6

3

ELECTRONIC CONTROLLER.............................................................................................................................7 3.1 3.2 3.3 3.4

DESCRIPTION OF DISPLAY AND OPERATING ELEMENTS ........................................................................................7 FAULT SIGNALS...............................................................................................................................................10 ADJUSTED VALUES .........................................................................................................................................10 PAUSE-TIME ADJUSTMENT ...............................................................................................................................11

4

INSPECTION AND MAINTENANCE..................................................................................................................12

5

TOPPING UP GREASE RESERVOIRS .............................................................................................................13

5.1 6

P1 AND P2: FILLING OF THE CONTAINER ..................................................................................................13

MALFUNCTIONS AND THEIR REMEDY ..........................................................................................................14

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Servicing Manual Centralized Lubrication System for LIEBHERR Hydraulic Excavator R 996B Manual

1 1.1

Function of the lubrication system Description of the entire system

The lubrication points of the hydraulic excavator are supplied by two (two Pumps Option: three) mutually independent centralized lubrication systems:

1.1.1 Standard: 1 Pump variant System 1 – Equipment lubrication and slewing rim lubrication (P1) Single-line system Main components:

Hydraulic pump (600L) Injectors

"P1" 609-77116-1 LM5

System 2 – Gear rim lubrication (P3) Main components:

Hydraulic pump (80L) Progressive metering devices

"P3" 609-29966-1 SSV 8

1.1.2 Option: 2 Pumps variant System 1 – Equipment lubrication (P1) Single-line system Main components:

Hydraulic pump (600L) Injectors

"P1" LM5

609-77117-1

System 2 – Slewing rim lubrication (P2) Main components:

Hydraulic pump (600L) Injectors Progressive metering devices

"P2" 609-77117-1 LM5 SSV 8

System 3 – Gear rim lubrication (P3) Main components:

Hydraulic pump (80L) Progressive metering devices

"P3" 609-29966-1 SSV 8

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Servicing Manual Centralized Lubrication System for LIEBHERR Hydraulic Excavator R 996B Manual

1.2

Sequence of a lubrication cycle

1.2.1 Systems 1 and 2: Upon expiration of the pause time the pump begins operating and supplies the lubricant to the injectors LM5 via the main line.

The pistons in the injectors are actuated by the lubricant under pressure and discharge a pre-dosed quantity of lubricant to the connected lubrication points.

The pressure continues to rise in the main line until the value (220 bar) set at the pressure switches (B69 or B71) is reached.

The control unit stops the pump and, at the same time, the main line is discharged via the solenoid valves (Y79 or Y81). The relieved lubricant reaches the pump reservoir via a bypass.

The pistons in the injectors LM5 return to their initial position by spring force.

The pause time begins. The system is ready to carry out a new lubrication cycle.

Only for the 2 pumps variant: The solenoid valves Y80, Y82 and Y83 allow – after they have been switched accordingly – the systems 1 and 2 to be both supplied together by pump 1 or pump 2 in the case that either pump fails to operate owing to a fault.

1.2.2 System 3 After the pause time has elapsed, the pump supplies the lubricant to the connected progressive metering devices.

A progressive metering device SSV 8 is equipped with a proximity switch for control and monitoring.

A lubrication cycle is completed after the SSV 8 has supplied three times, and the pump is switched off again.

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Servicing Manual Centralized Lubrication System for LIEBHERR Hydraulic Excavator R 996B Manual

1.3 Lubrication diagram 1.3.1 Standard: 1 Pump variant

Zur Ausrüstung KDV

Attachment

P1

Lubrication pump –attachment and swing ring race

B69

Pressure switch / end of lube cycle for P1

P3

Lubrication pump -swing ring teeth

B51

Limit switch on progressive distributor for P3

Y79 Solenoid valve / pressure release

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Servicing Manual Centralized Lubrication System for LIEBHERR Hydraulic Excavator R 996B Manual 1.3.1 Option: 2 Pump variant

Ausrüstung Attachment

KDV

P1

Lubrication pump -attachment

B69

Pressure switch / end of lube cycle for P1

P2

Lubrication pump -swing ring race

B71

Pressure switch / end of lube cycle for P2

P3

Lubrication pump -swing ring teeth

B51

Limit switch on progressive distributor for P3

Y79 Solenoid valve / pressure release (attachment) Y81 Solenoid valve / pressure release (swing ring race) Y80 Solenoid valve / shut off P1 Y82 Solenoid valve / shut off P2 Y83 Solenoid valve / lube in parallel Subject to change LINCOLN GmbH

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Servicing Manual Centralized Lubrication System for LIEBHERR Hydraulic Excavator R 996B Manual

2 Operation CAUTION Only allow operation by properly instructed personnel Do not exceed permissible system pressures Top up lubricant in good time When the machine is started all centralized lubrication systems are automatically pressurized.

Each pump triggers one lubrication cycle, stops only for the preadjusted pause time, ... etc.

Standard: 1 Pump When the excavator is delivered from the factory the time period between two lubrication cycles is six minutes for pump P1 and four minutes for pump P3. This corresponds to a grease consumption of approx. 2000 g/h for P1 and 60 g/h for P3.

Option: 2 Pump variant When the excavator is delivered from the factory the time period between two lubrication cycles is six minutes for pump P1 and P2 and four minutes for pump P3. This corresponds to a grease consumption of approx. 1700 g/h for P1, 300 g/h for P2 and 60 g/h for P3.

The time intervals for P1, (or P2 and P3 respectively) can be readjusted at the lubrication system monitor.

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Servicing Manual Centralized Lubrication System for LIEBHERR Hydraulic Excavator R 996B Manual

3 Electronic Controller 1

20

2

21

3

22

4

23 24 25

5 6 7

26

8

27 28

9

29

10

30

11

31

12

32 33

13 14 15

34

16 17

35

18 36

19

3.1 Description of display and operating elements

1 ON: Pilot pressure > 45 bar 2 ON: Pump 1 operates 3 ON: Pressure > 220 bar OFF: Pressure < 40 bar 4 Display: Pressure (bar) or remaining pause time (sec) in system 1.

If the pause time is displayed, the point in the first 7-segment display is lit.

In the setup mode the display flashes every second and shows the adjusted pause time.

5 Actuation of a key is detected when releasing the key.

If the key is pressed < 5 sec, the controller will change between the remaining pause time display and the pressure display.

If the key is pressed > 5 sec, the controller will change into the setup mode and the adjusted pause time will be indicated by a flashing mode.

Pressing the key in the setup mode < 5 sec increases the pause time by one second.

Pressing the key in the setup mode > 5 sec increases the pause time in increments of 5 sec continuously as long as the key is being pressed.

If in the setup mode no key is pressed during 20 sec, the former pause time setting will be taken and the setup mode will be quit.

When pressing the Enter key (36) the newly adjusted pause time will be adopted and the setup mode will be quit.

Pressing key 5 and key 16 simultaneously, the display of P1 (item 4) will show the software version.

6 Display of the filling level in the grease reservoir P1 in 10 steps from 0 to 100 % 7 ON: Filling level in the grease reservoir P1 < 30 % and > 15 % 8 Flashing: Filling level in the grease reservoir P1 < 15 % 9 ON: Pump 2 operates *) 10 ON: Pressure > 220 bar *) OFF: Pressure < 40 bar *) 11 Display: Pressure (bar) or remaining pause time (sec) in system 2.

If the pause time is displayed, the point in the first 7-segment display is lit.

In the setup mode the display flashes every second and shows the adjusted pause time. *) 12 Actuation of a key is detected when releasing the key.

If the key is pressed < 5 sec, the controller will change between the remaining pause time display and the pressure display.

If the key is pressed > 5 sec, the controller will change into the setup mode and the adjusted pause time will be indicated by a flashing mode.

Pressing the key in the setup mode < 5 sec increases the pause time by one second.

Pressing the key in the setup mode > 5 sec increases the pause time in increments of 5 sec continuously as long as the key is being pressed.

If in the setup mode no key is pressed during 20 sec, the former pause time setting will be taken and the setup mode will be quitted.

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Servicing Manual Centralized Lubrication System for LIEBHERR Hydraulic Excavator R 996B Manual

1

20

2 3

21

13 14 15

16

22

4

23 24 25

5 6 7

26

8

27 28

9

29

10

30

11

31

12

17

32 33

18 19 20

34

21 22 23 24 25

13 14 15 16 17

35

18 19

36

26 27 28

When pressing the Enter key (36) the newly adjusted pause time will be adopted and the setup mode will be quit. *) ON: Pump 3 operates.

ON: Girth gear is lubricated (signal from sensor B51) Display: Remaining pause (sec) in system 3.

In the setup mode the display flashes every second and shows the adjusted pause time.

Actuation of a key is detected when releasing the key.

If the key is pressed < 5 sec, the controller will change between the remaining pause time display and the pressure display.

If the key is pressed > 5 sec, the controller will change into the setup mode and the adjusted pause time will be indicated by a flashing mode.

Pressing the key in the setup mode < 5 sec increases the pause time by one second.

Pressing the key in the setup mode > 5 sec increases the pause time in increments of 5 sec continuously as long as the key is being pressed.

If in the setup mode no key is pressed during 20 sec, the former pause time setting will be taken and the setup mode will be quit.

When pressing the Enter key (36) the newly adjusted pause time will be adopted and the setup mode will be quit.

Pressing key 5 and key 16 simultaneously, the display of P1 (item 4) will show the software version.

Display of the filling level in the grease reservoir P1 in 10 steps from 0 to 100 % ON: Filling level in the grease reservoir P1 < 30 % and > 15 % Flashing: Filling level in the grease reservoir P1 < 15 % The error is shown in the 7-segment display. In case of several errors arising simultaneously, these will be switched through in intervals of 2 seconds. If the same error arises one after another several times, it is displayed only once.

Reserved for lubrication monitoring – presently without function Reserved for lubrication monitoring – presently without function ON: Slewing ring is lubricated (signal from sensor B150_1) ON: Slewing ring is lubricated (signal from sensor B150_2) Actuation of a key is detected when releasing the key.

When pressing the key, in the corresponding lubrication circuit a lubrication cycle is triggered in the normal mode. However, this is effected only if the pressure in the respective lubrication circuit has dropped below 40 bar and the circuit is in pause time. If during a lubrication cycle triggered such way the pressure in the lubrication circuit P1 rises up to 220 bar, the respective lubrication circuit continues operating in the normal mode, even though it had been in the emergency mode before.

This means, the CYCLE start will be seen as confirmation in the case of emergency operation.

ON: Pump 1 operates in the safety mode for lubrication circuits 1 and 2. *) ON: Pump 2 operates in the safety mode for lubrication circuits 1 and 2. *) Actuation of a key is detected when releasing the key.

This key is active only if the excavator is equipped with a pump station with 2 pumps (P1 and P2) and at least one sensor or actuator is defective.

If the key is pressed once, lubrication is effected via P1.

Thereby, solenoid valves Y83 and Y82 are activated and pump 2 is switched off. The numerical display for P2 will also be switched off.

If the key is pressed twice, lubrication is effected via P2.

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Servicing Manual Centralized Lubrication System for LIEBHERR Hydraulic Excavator R 996B Manual

1

20

2

29 21

3

30

22

4

23 24 25

5

31 32

6 7

26

8

27

33

28

9

29

10

30

11

31

12

32 34 33

13

35

14 15

34

16 17

35

18

36

19

36

Thereby, solenoid valves Y80 and Y83 are activated and pump 1 is switched off. The numerical display for P1 will also be switched off.

If the key is pressed three times, pumps 1 and 2 return to normal operation.*) ON: The pressure line of pump 1 is shut off (solenoid valve Y80 is active) *) ON: The pressure line of pump 2 is shut off (solenoid valve Y82 is active) *) ON: Lubricant circuits 1 and 2 are connected to each other (solenoid valve Y83 is active) *) The error is shown in the 7-segment display. In case of several errors arising simultaneously, these are switched through in intervals of 2 seconds. If the same error arises one after another several times, it is displayed only once. *) Actuation of a key is detected when releasing the key.

When pressing the key, in the corresponding lubrication circuit a lubrication cycle is triggered in the normal mode. However, this is effected only if the pressure in the respective lubrication circuit has dropped below 40 bar and the circuit is in pause time. If during a lubrication cycle triggered such way the pressure in the lubrication circuit P2 rises up to 220 bar, the respective lubrication circuit continues operating in the normal mode, even though it had been in the emergency mode before.

This means, the CYCLE start is seen as confirmation in the case of emergency operation. *) The error is shown in the 7-segment display. In case of several errors arising simultaneously, these are switched through in intervals of 2 seconds. If the same error arises one after another several times, it is displayed only once.

Actuation of a key is detected when releasing the key.

When pressing the key, in the corresponding lubrication circuit a lubrication cycle is triggered in the normal mode. If during a lubrication cycle triggered via CYCLE start in the lubrication circuit P3 a lubrication pulse is detected by the sensor B51, this lubrication circuit continues in the normal mode, even though it had been in the emergency mode before. This means, the CYCLE start is seen as confirmation in the case of emergency operation.

Pressing the ENTER key confirms minor errors and switches off the buzzer as well. Pressing the key in the setup mode (pause time setting) adopts and saves the adjusted pause time and quits the setup mode.

*): For pump stations with 2 pumps only!

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Servicing Manual Centralized Lubrication System for LIEBHERR Hydraulic Excavator R 996B Manual 3.2 Fault signals

Each time a fault arises, an acoustic signal will be given by the controller (buzzer) and the two flashing lights on the pump stations will be activated. Buzzer and flashing lights can be deactivated by pressing the ENTER key.

In two cases this will not be possible: - very low grease level in the barrel (LL) - both sensors for monitoring the lubrication of the slewing rim are defective In these cases, buzzer and flashing lights will be deactivated when switching off the motor, however, will be activated again when starting the motor.

3.3 Adjusted values

For service personnel with PC, corresponding software and authorization:

adjustable max. value adjustable min. value

adjusted value

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Servicing Manual Centralized Lubrication System for LIEBHERR Hydraulic Excavator R 996B Manual 3.4 Pause-time adjustment

The operator may also use the control unit in the driver’s cab to adjust the lubricant volume following the adjusting range given in chapter 3.2 in order to quickly react to poor or excessive lubrication.

4

5

36

If key 5 is pressed > 5 sec, the controller will change into the setup mode and the adjusted pause time will be indicated by a flashing mode in display 4.

Pressing the key in the setup mode < 5 sec increases the pause time by one second.

Pressing the key in the setup mode > 5 sec increases the pause time in increments of 5 sec continuously as long as the key is being pressed.

If in the setup mode no key is pressed during 20 sec, the former pause time setting will be taken and the setup mode will be quit.

When pressing the Enter key (36) the newly adjusted pause time will be adopted and the setup mode will be quit.

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Servicing Manual Centralized Lubrication System for LIEBHERR Hydraulic Excavator R 996B Manual

4 Inspection and maintenance * * *

Do not perform any repairs while system is pressurized.

To relieve pressure open a threaded connection carefully Caution: Lubricant may escape while pressurized

Regular inspection and maintenance are the prerequisites for proper operation of the centralized lubrication system over a prolonged period of time. The warranty on our product can only be valid if the prescribed maintenance intervals are adhered to.

The regular inspections and maintenance procedures are described below: 1. System as a whole Daily:

Visual check of the lubrication points for escaping lubricant Visual check of the hose connections for leaks or wearing

Weekly:

Visual check of the screwed pipe connections for leakage Determining the time for one operating cycle. If the time determined differs from the usual operating time, the individual components (pump station, injectors, pipes) must be checked.

Functional check of the pressure switch

2. Pump station Weekly:

Check that threaded connections and hoses are firm and tight.

Visual check of pump tube gland seal Check function of the solenoid valve Check electrical cable connections Clean outside of pump station

1000 hours:

Clean filter element of grease filter

7500 hours:

Hydraulic pump: Change gland seal

3. Injectors Daily:

Check movement of control pins: During the work cycle the pins must be retracted depending on the metering quantity; in the resting phase all the pins must be extended.

Weekly:

Visual check for leaks

4. Progressive Plunger Metering Device Weekly:

Visual check for leaks

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Servicing Manual Centralized Lubrication System for LIEBHERR Hydraulic Excavator R 996B Manual

5 Topping up grease reservoirs CAUTION

5.1

Lines are pressurized. Be careful when decoupling.

Observe extreme cleanliness when topping up the grease reservoirs.

Contaminated lubricant causes malfunctions and premature wear of the grease pump and other components of the system.

Clean surroundings before topping up Switch off centralized lubrication system (turn off engine)

P1 and P2: Filling of the container

Filling of the container through service-plate Remove dust protective cap at the filling coupling and the dust protective cap at the filling nipple Couple the filling hose at item 10 and switch on the filling pump When the reservoir is full, the ultrasonic sensor transmits an electric signal to the control unit. Visual control is possible through the sight-glass on the 600 L rectangle reservoir the filling pump is switched off Disconnect the filling coupling and reinstall the dust protective caps

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Servicing Manual Centralized Lubrication System for LIEBHERR Hydraulic Excavator R 996B Manual

6 Malfunctions and their remedy In the following, only malfunctions of the system as a whole are described. You will find detailed remedies for malfunctions of the individual units in the respective User’s Information.

Malfunction: No pressure build-up in the system Cause:

Remedy:

Malfunctions of the pump

See Troubleshooting: Pump

Leakage in the main line

Check main lines, eliminate leaks, tighten threaded connections, replace defective hoses

Air trapped in the main line

De-aerate the line

Injectors leaky or worn

See Troubleshooting: Injectors

Malfunction: No pressure relief or too slow pressure relief in the main line Cause:

Remedy:

Pressure control device faulty

Replace pressure control device, check electric cable

Solenoid valve faulty

Replace solenoid valve, check voltage supply

Grease too hard or not suitable for low temperatures

Change lubricant

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User Manual

Error Codes 664-36957-7

EC

Error Codes G

Fault

Cause

Display E__

Display G__ to:

Signalisation

01

02

03

04

05

06

07

08

09

10

11

12

13

IMPORTANT NOTE

Lubrication

User Manual EC

Error Codes 664-36957-7

Error Codes, continuation G

Fault

14

15

16

17

18

19

20

21

22

23

24

25

26

27

IMPORTANT NOTE

Cause

Display E__

Display G__ to:

Signalisation

Lubrication

User Manual

Error Codes 664-36957-7

EC

Error Codes, continuation G

Fault

28

29

30

31

32

33

34

35

36

37

38

39 40 41 42 43 44 45

IMPORTANT NOTE

Caus e

Display Display E_ _ G__ to:

Signal isation

Lubrication

User Manual EC

Error Codes 664-36957-7

Error Codes, continuation G

Fault

46

47

48

49

50

51

52 53 54

55

56

57 58 59 60

61

81

82

IMPORTANT NOTE

Cause

Display E__

Display G__ to:

Signalisations

Lubrication

User Manual

Error Codes 664-36957-7

Error Codes, continuation G

Fault

83

84

85

86

87

88

89

90

IMPORTANT NOTE

Cause

Display E__

Display G__ to:

Signalisation

Lubrication

Conversion factors Pressure:

Length:

Volume:

Torque:

Weight:

Temperature:

MJFCIFSS