Liebherr R 317 Litronic Industrie 1043 Machine for Industrial Applications Operating Manual SN 56335

en

Operating manual Machine for Industrial Applications R 317 Litronic Industrie from serial number 56335

Document identification ORIGINAL OPERATING MANUAL Id. number:

11140224

Edition:

09 / 2013

Valid for:

R 317 Litronic Industrie from serial number 56335

Author:

LHB - Technical documentation department

Product identification Manufacturer:

LIEBHERR Hydraulikbagger GmbH

Type:

R 317 Litronic Industrie

Type no.:

1043

Conformity:

CE

Address Liebherr Hydraulikbagger GmbH Liebherr-Straße 12 D - 88457 Kirchdorf / Iller

Operating manual

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

This will also be helpful when ordering spare parts.

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

Year of manufacture: . . . .

Delivery date: . . / . . / . .

MJFCIFSS

R 317 Litronic Industrie / 11140224

Introduction

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

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

The operating manual is an integral part of the scope of delivery of the machine. Ensure that a copy is at all times available in the storage compartment in the operator's cab.

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

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

– Maintenance including inspection, servicing and repair.

– Transport or loading of the machine.

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

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

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

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

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

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

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

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Operating manual

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

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

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

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

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

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Operating manual

Table of contents 1

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

1.2 1.3 1.4 1.5 2

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

2.4

3

Design and overview ............................................................................................................................. 1-1 1.1.1 Machine with industrial attachment .......................................................................................... 1-1 1.1.2 Uppercarriage........................................................................................................................... 1-2 1.1.3 Undercarriage........................................................................................................................... 1-3 Vibration emissions................................................................................................................................ 1-3 Sound emission ..................................................................................................................................... 1-4 EC Declaration of Conformity ................................................................................................................ 1-5 Technical data ....................................................................................................................................... 1-6

Symbols used in this operating manual ................................................................................................. 2-1 Proper use ............................................................................................................................................. 2-2 Safety instructions ................................................................................................................................. 2-2 2.3.1 General safety instructions ....................................................................................................... 2-2 2.3.2 Crushing and burn prevention .................................................................................................. 2-3 2.3.3 Fire and explosion prevention .................................................................................................. 2-4 Signs on the machine ............................................................................................................................ 2-4 2.4.1 Introduction............................................................................................................................... 2-4 2.4.2 Safety and information signs .................................................................................................... 2-5 2.4.3 ID tag...................................................................................................................................... 2-10

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

3.2

3.3

Operating and control elements............................................................................................................. 3-1 3.1.1 Overview of operator's platform................................................................................................ 3-1 3.1.2 Indicating elements .................................................................................................................. 3-2 3.1.3 Control consoles....................................................................................................................... 3-3 3.1.4 Control unit ............................................................................................................................... 3-7 3.1.5 Display and operator's menu.................................................................................................. 3-10 Control ................................................................................................................................................. 3-21 3.2.1 Entering and exiting the operator's cab .................................................................................. 3-21 3.2.2 Adjusting vertical position of the operator's cab (special equipment)..................................... 3-23 3.2.3 Safety lever ............................................................................................................................ 3-24 3.2.4 Operator seat ......................................................................................................................... 3-25 3.2.5 Operator seat ......................................................................................................................... 3-33 3.2.6 Windscreen ............................................................................................................................ 3-36 3.2.7 Sun blind ................................................................................................................................ 3-37 3.2.8 Emergency exit through rear window ..................................................................................... 3-38 3.2.9 Inside lighting ......................................................................................................................... 3-38 3.2.10 Fire extinguisher (optional equipment)*.................................................................................. 3-39 3.2.11 Windshield wiper .................................................................................................................... 3-39 3.2.12 Lighting................................................................................................................................... 3-41 3.2.13 Heating system....................................................................................................................... 3-42 3.2.14 A/c system (optional equipment) ............................................................................................ 3-43 Operation ............................................................................................................................................. 3-44 3.3.1 Safety instructions .................................................................................................................. 3-44 3.3.2 To see and to be seen............................................................................................................ 3-45 3.3.3 Camera system (optional equipment) .................................................................................... 3-46 3.3.4 Starting machine .................................................................................................................... 3-47 3.3.5 Adjusting engine speed .......................................................................................................... 3-51 3.3.6 Switching off the diesel engine............................................................................................... 3-53 3.3.7 Starting aid (Optional extra) ................................................................................................... 3-53 3.3.8 Jump start procedure ............................................................................................................. 3-53 3.3.9 Travel operation ..................................................................................................................... 3-54

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Operating manual

3.4

3.5

3.6

3.7 3.8

4

3.3.10 Travel alarm system (optional equipment).............................................................................. 3-57 Working with the machine.................................................................................................................... 3-58 3.4.1 Safety Instructions .................................................................................................................. 3-58 3.4.2 Low idle automatic .................................................................................................................. 3-61 3.4.3 Swivelling uppercarriage ........................................................................................................ 3-62 3.4.4 Halting uppercarriage ............................................................................................................. 3-62 3.4.5 Working position ..................................................................................................................... 3-64 3.4.6 Operating the working attachment.......................................................................................... 3-64 3.4.7 Lowering the working attachment when diesel engine is shut off........................................... 3-66 3.4.8 Swivelling uppercarriage ........................................................................................................ 3-66 3.4.9 Halting uppercarriage ............................................................................................................. 3-67 3.4.10 Adjustment of tool attachment ................................................................................................ 3-68 3.4.11 Operation of attachment (optional equipment) ....................................................................... 3-69 3.4.12 Changeover of the control system (optional equipment) ........................................................ 3-71 3.4.13 Operating attachment tool (mini joystick control, optional equipment) ................................... 3-72 3.4.14 Changeover of joystick control (optional equipment).............................................................. 3-74 3.4.15 Super Finish (optional equipment).......................................................................................... 3-74 3.4.16 Attachments in continuous operation (optional equipment).................................................... 3-75 3.4.17 Stroke limitation (optional equipment) .................................................................................... 3-76 3.4.18 Stick cylinder shut-off function (optional equipment) .............................................................. 3-78 Installation and removal of attachment parts ....................................................................................... 3-81 3.5.1 Safety Instructions .................................................................................................................. 3-81 3.5.2 Installation and removal of digging tool .................................................................................. 3-82 3.5.3 Attachment of grapple to bucket stick..................................................................................... 3-84 3.5.4 Installation and removal of grapple on industrial stick ............................................................ 3-87 3.5.5 Multi-coupling system (optional equipment) ........................................................................... 3-88 3.5.6 Mechanical quick-change adapter (optional equipment) ........................................................ 3-91 3.5.7 Hydraulic quick-change adapter (optional equipment) ........................................................... 3-95 3.5.8 Hydraulic quick-change adapter with LIKUFIX (optional equipment) ................................... 3-100 General working methods .................................................................................................................. 3-102 3.6.1 Tips for the proper operation of the machine preventing damage and wear ........................ 3-102 3.6.2 Preparation ........................................................................................................................... 3-103 3.6.3 Working with grapples .......................................................................................................... 3-104 3.6.4 Excavating and moving material with grapples..................................................................... 3-105 3.6.5 Loading operation ................................................................................................................. 3-106 3.6.6 Load lifting operation ............................................................................................................ 3-107 3.6.7 Use of quick-change adapter for load lifting operation ......................................................... 3-108 3.6.8 Overload warning system (optional equipment) ................................................................... 3-109 Parking and exiting machine.............................................................................................................. 3-110 Transport............................................................................................................................................ 3-110 3.8.1 Safety instructions ................................................................................................................ 3-110 3.8.2 Transportation on low-loader ................................................................................................ 3-111 3.8.3 Loading with crane ............................................................................................................... 3-112

Malfunctions ................................................................................................................................................... 4-1 4.1 4.2

4.3

Error code list......................................................................................................................................... 4-1 Troubleshooting ..................................................................................................................................... 4-6 4.2.1 Diesel engine and fuel system.................................................................................................. 4-6 4.2.2 Hydraulic system ...................................................................................................................... 4-7 4.2.3 Travel gearbox.......................................................................................................................... 4-8 4.2.4 Electrical system....................................................................................................................... 4-8 4.2.5 Heating and air-conditioning system ........................................................................................ 4-9 4.2.6 Working attachment.................................................................................................................. 4-9 Fuses and relays.................................................................................................................................. 4-10 4.3.1 Fuse box E50 ......................................................................................................................... 4-10 4.3.2 Control console C ................................................................................................................... 4-11 4.3.3 Control console....................................................................................................................... 4-12 4.3.4 Battery box ............................................................................................................................. 4-13

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Operating manual

4.4

5

Emergency mode................................................................................................................................. 4-14 4.4.1 Purpose .................................................................................................................................. 4-14 4.4.2 Emergency lowering of the operator's cab ............................................................................. 4-14 4.4.3 Towing the machine ............................................................................................................... 4-15

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

Safety instructions ................................................................................................................................. 5-1 5.1.1 General safety instructions ....................................................................................................... 5-1 5.1.2 Checking for cracks.................................................................................................................. 5-1 5.1.3 Welding .................................................................................................................................... 5-2 5.1.4 Fuels, lubricants and process chemicals.................................................................................. 5-2 5.1.5 Repair ....................................................................................................................................... 5-2 5.1.6 Electrical system ...................................................................................................................... 5-3 5.1.7 Pressure accumulator .............................................................................................................. 5-3 5.1.8 Hydraulic hoses and lines ........................................................................................................ 5-4 5.1.9 Cab protection (FOPS)............................................................................................................. 5-5 5.2 Maintenance access doors .................................................................................................................... 5-5 5.2.1 Overview of access doors ........................................................................................................ 5-5 5.2.2 Door lock .................................................................................................................................. 5-6 5.2.3 Engine hood release ................................................................................................................ 5-7 5.3 Cleaning machine .................................................................................................................................. 5-7 5.4 Care for rubber components.................................................................................................................. 5-8 5.5 Fuels, lubricants and process chemicals ............................................................................................... 5-8 5.5.1 General information .................................................................................................................. 5-8 5.5.2 Lubricating chart ..................................................................................................................... 5-10 5.5.3 Lubricant table........................................................................................................................ 5-11 5.5.4 Fuels, lubricants and process chemicals................................................................................ 5-12 5.6 Specifications for fuels, lubricants and process chemicals.................................................................. 5-12 5.6.1 Fuels and lubricant for the diesel engine................................................................................ 5-12 5.6.2 Hydraulic oil ............................................................................................................................ 5-12 5.6.3 Lubricants for axles and gearboxes ....................................................................................... 5-18 5.6.4 Lubricating oil for transmission............................................................................................... 5-19 5.6.5 Grease.................................................................................................................................... 5-20 5.6.6 Lubricants and care products for electrical and mechanical components .............................. 5-20 5.6.7 Grease and other process chemicals ..................................................................................... 5-21 5.7 Diesel engine ....................................................................................................................................... 5-21 5.7.1 Check oil level ........................................................................................................................ 5-21 5.7.2 Changing the oil ..................................................................................................................... 5-22 5.8 Cooling system .................................................................................................................................... 5-22 5.8.1 Checking and cleaning the cooling system ............................................................................ 5-22 5.8.2 Checking coolant level ........................................................................................................... 5-23 5.8.3 Corrosion inhibitor and antifreeze agent ................................................................................ 5-24 5.8.4 Changing coolant ................................................................................................................... 5-24 5.9 Fuel system ......................................................................................................................................... 5-25 5.9.1 Refuelling ............................................................................................................................... 5-26 5.9.2 Draining the water from the fuel tank ..................................................................................... 5-27 5.9.3 Emptying and cleaning the fuel tank ...................................................................................... 5-27 5.9.4 Fuel pre-filter .......................................................................................................................... 5-28 5.9.5 Replacement of fuel filter cartridge (fine filter)........................................................................ 5-29 5.10 Dry air filter .......................................................................................................................................... 5-30 5.10.1 Cleaning the dust removal valve ............................................................................................ 5-30 5.10.2 Replacing filter elements ........................................................................................................ 5-30 5.10.3 Checking the clean air line ..................................................................................................... 5-32 5.11 Hydraulic system ................................................................................................................................. 5-32 5.11.1 Checking the oil level in the hydraulic tank ............................................................................ 5-33 5.11.2 Releasing the pressure from the hydraulic system................................................................. 5-34 5.11.3 Releasing tank pressure......................................................................................................... 5-34 5.11.4 Emptying and refilling hydraulic tank ...................................................................................... 5-35

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5.12

5.13

5.14

5.15

5.16 5.17

5.18

5.19 5.20

5.21

5.11.5 Changing return filter .............................................................................................................. 5-36 5.11.6 Changing control oil filter ........................................................................................................ 5-38 5.11.7 Checking the control circuit .................................................................................................... 5-39 5.11.8 Bleeding hydraulic pump ........................................................................................................ 5-39 5.11.9 Maintenance of hydraulic cylinders ........................................................................................ 5-40 5.11.10 Replacing hydraulic hoses...................................................................................................... 5-40 Changing the oil on components ......................................................................................................... 5-41 5.12.1 General notes ......................................................................................................................... 5-41 5.12.2 Swin gear - oil change ............................................................................................................ 5-42 5.12.3 Travel gear - oil change .......................................................................................................... 5-43 Drive..................................................................................................................................................... 5-43 5.13.1 Cleaning drive......................................................................................................................... 5-43 5.13.2 Checking fixtures of drive components................................................................................... 5-44 5.13.3 Checking chain tension .......................................................................................................... 5-45 5.13.4 Tensioning chain .................................................................................................................... 5-45 5.13.5 Releasing chain ...................................................................................................................... 5-46 5.13.6 Changing lubrication nipple .................................................................................................... 5-47 Electrical system .................................................................................................................................. 5-47 5.14.1 Notes regarding the electrical system .................................................................................... 5-47 5.14.2 Battery main switch ................................................................................................................ 5-48 5.14.3 Battery care ............................................................................................................................ 5-49 5.14.4 Slip ring body (optional equipment) ........................................................................................ 5-50 Heating system .................................................................................................................................... 5-51 5.15.1 Ambient air filter...................................................................................................................... 5-51 5.15.2 Heating system ....................................................................................................................... 5-52 5.15.3 Air-conditioning system (optional equipment)......................................................................... 5-53 Automatic lubrication of the machine ................................................................................................... 5-53 5.16.1 Central lubrication system ...................................................................................................... 5-53 Manual lubrication of the machine ....................................................................................................... 5-55 5.17.1 Digging buckets / bucket tilting device.................................................................................... 5-56 5.17.2 Attachments (optional equipment) .......................................................................................... 5-57 5.17.3 Hydraulic quick change adapter ............................................................................................. 5-57 5.17.4 Mechanical quick-change adapter .......................................................................................... 5-58 Couplings of the quick-change adapter systems (optional equipment) ............................................... 5-59 5.18.1 Hydraulic coupling .................................................................................................................. 5-59 5.18.2 LIKUFIX electric coupling ....................................................................................................... 5-60 Travel and swing brakes ...................................................................................................................... 5-61 General maintenance tasks ................................................................................................................. 5-61 5.20.1 Replacing wear parts .............................................................................................................. 5-61 5.20.2 Replacing teeth on digging tool .............................................................................................. 5-61 5.20.3 Welded parts on the machine ................................................................................................. 5-63 Maintenance and inspection schedule................................................................................................. 5-64

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1 Product description 1.1 Design and overview This section contains an overview of the machine and the displayed component parts.

1.1.1

Machine with industrial attachment

Fig. 1-1

Machine with industrial attachment

1

Uppercarriage

2

Undercarriage

3

Grapple

4

Stick

5

Gooseneck boom

6

Stick cylinder

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Product description

Operating manual

Design and overview

1.1.2

Uppercarriage

Fig. 1-2

Uppercarriage

1

Diesel engine

2

Dry air cleaner

3 5

Hydraulic tank Operator's platform

4 6

Slewing gear mechanism Operator's cab

7 9

Fuel tank Radiator

8 10

Control valve Fan

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Operating manual

Product description Vibration emissions

1.1.3

Undercarriage

Fig. 1-3

Undercarriage

1 3

Travel drive Chain

5

Chain tensioner

2 4

Idler Rotary connection

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

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

Whole-body vibration If the machine is operated according to the manufacturer instructions, the weighted (frequency-rated) effective vibration shown for specific machine applications in the table below apply. These values conform to the specifications in the technical report ISO/TR 25398:2006 "Earth-moving machinery – Guidelines for assessment of exposure to whole-body vibration of ride-on machines – Use of harmonized data measured by international institutes, organizations and manufacturers". The method

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Product description

Operating manual

Sound emission

of assessment conforms to ISO 2631-1:1997. The effective values in the table for representable machines are shown with the applicable standard deviations. These deviations are classified according to the operating conditions in the classes "lightduty", "normal" and "heavy-duty". It is the responsibility of the machine owner to assess the operating conditions according to the classes, taking into account the terrain, site conditions, site organisation, material, machine equipment, working procedure and training of the operator.

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

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

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

Crawler excavator

Mobile excavator

Typical working cycles

x-axis

y-axis

z-axis

1

2

3

1

2

3

1

2

3

Excavator

0.14

0.31

0.49

0.08

0.19

0.31

0.13

0.30

0.47

with hydraulic hammer

0.16

0.38

0.59

0.09

0.22

0.35

0.27

0.55

0.83

Use for mining

0.31

0.46

0.61

0.19

0.30

0.41

0.29

0.61

0.93

Transfer travel

0.21

0.34

0.48

0.09

0.23

0.37

0.56

0.79

1.02

Excavator

0.19

0.37

0.56

0.09

0.25

0.41

0.16

0.29

0.42

Transfer travel

0.21

0.29

0.38

0.24

0.38

0.52

0.42

0.61

0.80

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

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

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

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

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Operating manual

Product description EC Declaration of Conformity

1.4 EC Declaration of Conformity

Fig. 1-4

Sample EC Declaration of Conformity (from year of manufacture 2010)

Only for customers in member states of the European Union: a EC Declaration of Conformity has been shipped together with your machine. You will find this document in the machine documentation.

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Product description

Operating manual

Technical data

1.5 Technical data See technical description on the following pages.

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2 Safety notes, signs There are certain risks associated with the operation of the machine. These risks might concern you as the owner, operator or maintenance technician of the machine.

Read the safety notes and instructions in this operating manual carefully and on a regular basis. Strictly adhere to the safety notes and instructions in order to prevent dangerous situations and accidents. This applies especially to persons who only rarely work on or with the machine, e.g. in the context of maintenance work.

In addition to the safety instructions in this manual, always adhere to all safety regulations applicable at the place of operation. Such regulations might include statutory regulations or instructions issued by trade associations.

For operation in EU member states, the minimum safety requirements to be met by the machine owner are laid down in Directive 2009/104/EC.

2.1 Symbols used in this operating manual Potential dangers in connection with work on or with the machine are labelled with safety notes and signs as follows: Danger, Caution and Note.

These terms have the following meaning: Danger!

Warning referring to a danger where there is a high probability of death or serious injury to operators, unless the prescribed safety measures are taken.

Caution!

Warning relating to dangers that might lead to injury and/or damage to the machine, unless the prescribed safety measures are taken.

Note!

This symbol accompanies instructions and tips regarding the operation and maintenance of the equipment. If adhered to, the service life of the machine can be extended and/or procedures are made easier.

The following symbols are used to guide you through the prescribed procedures: Identifies a precondition or prerequisite that must be met before the subsequent procedures can be carried out.

Identifies a procedure or activity.

Identifies the result of a procedure or activity.

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2-1

Safety notes, signs

Operating manual

Proper use

2.2 Proper use – The hydraulic excavator is a machine equipped with an attachment (e.g. backhoe bucket, grapple, front shovel) designed to loosen, lift, transport and disperse soil, stones and other material, whereby the load is normally transported with the machine being stationary during the process. If the machine is to travel with a load, special safety measures must be taken (see section "Instructions for safe work").

– Machines used to lift loads are subject to special safety requirements and must be equipped with specific safety devices (see section "Load lifting operation").

– Machines used underground (deep mining and tunnel construction) must be equipped with exhaust gas reducing equipment (e.g. diesel particle filter). Always comply with the statutory regulations applicable at the location of operation.

– Special tasks such as demolition work and goods handling require special attachments and possibly also special safety devices. This equipment (e.g. tree grapple, demolition hammer, concrete shear, etc.) may only be attached to the machine and used with the explicit consent of and according to the instructions of the manufacturer of the basic machine.

– Any other use, in particular transportation of persons or working in explosive atmospheres or contaminated environments is deemed improper. The manufacturer shall not be liable for any damage arising from such use. The operator shall be solely responsible for any damage caused by improper use of the equipment.

– Compliance with the instructions in the operating manual and the inspection and maintenance schedules is an integral part of proper use.

2.3 Safety instructions 2.3.1

General safety instructions – Please familiarize yourself with the operating instructions before starting the machine.

– Please verify that you have read and understood supplemental instructions (this may concern special options for the machine).

– Only explicitly authorized personnel may operate, maintain or repair the machine.

The legal minimum age must be observed.

– Use only trained or instructed personnel. Clearly define who is responsible for the operation or set up, maintenance and repair. Reject unsafe instructions by third parties and/or allow your personnel to reject these. This also applies in regards to traffic regulations.

– Any person still in training should only operate or work on the machine under the constant supervision and guidance of an experienced person.

– Check and observe all persons working or operating the machine at least periodically to ensure that they observe safety instructions and guidelines given in the operating manual.

– Wear proper work clothing when operating or working on the machine. Avoid wearing rings, watches, ties, scarves, open jackets or loose clothing. There is a danger of injury, as these items could get caught or be pulled in.

Wear task-appropriate personal protective equipment at all times.

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Safety notes, signs Safety instructions

– Consult the supervisor for any special safety procedures applicable to your job site.

– Always raise the safety lever before leaving the operator’s seat.

– Keep steps, ladders and handholds (handles) in proper condition. Make especially sure that they are free of dirt, oil, ice and snow.

NOTE: To ensure that the doors open in all weather conditions, lubricate the weather strips at least every two months, or more often, if necessary, with talcum powder or silicon. Lubricate the door hinges and locks regularly.

– When entering or leaving the cab, do not use the steering column, the control panel or the joysticks as handholds.

– Never jump off the machine, always use the steps, ladders, rails and handles provided to climb off or on the machine.

– Always face towards the machine when climbing on and off it, and always use the three points of contact with the machine (all times either two hands and one foot, or two feet and one hand are in contact with the access system).

– Familiarize yourself with the emergency exit.

– Proceed as described in the operating manual, if no other instructions are available for maintenance and repairs: • Place the machine on a solid and level ground and lower the working attachment to the ground.

• Depressurize the hydraulic system.

• Move all control levers to the neutral position.

• Move the safety levers up prior to leaving the machine.

• Remove the ignition key.

– Before servicing the hydraulic system you must reduce the pressure in the hydraulic system and tank, as described in this operating manual.

– Secure all loose parts on the machine.

– Never start a machine before completing a thorough walkaround inspection.

Insure that all required safety signs are in place and legible.

– Do not modify, alter or otherwise change any safety-related systems of components without the specific approval of LIEBHERR. – Do not stand near the running diesel engine. Persons with a pacemaker must keep clear of the vicinity of the running diesel engine (minimum distance 50 cm).

– While the diesel engine is running, do not touch the powered components at the electrical connection of the solenoid valve-controlled injection pumps.

2.3.2

Crushing and burn prevention – Never work underneath the attachment as long as it is not safely resting on the ground or properly supported.

– Insure that all load supporting systems are in good repair and rated for the required load.

– Always wear work gloves when handling wire ropes.

– When working on the attachment, never align bores with your fingers, always use a suitable alignment tool.

– Keep hands, tools and any other objects away from contact with the cooling fan.

The cooling fan can cause severe injury, objects can be catapulted away or destroyed, and the fan can be damaged by the objects.

– At or near operating temperature, the engine cooling system is hot and under pressure. Avoid contact with any components containing coolant. Danger of severe burns.

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MJFCIFSS

2-3

Safety notes, signs

Operating manual

Signs on the machine

– Check the coolant level only after the radiator cap on the expansion tank is cool enough to touch. Turn the cap carefully to relieve the pressure.

– At or near operating temperature, the engine and the hydraulic oil are hot. Do not allow your skin to come into contact with hot oil or components containing hot oil.

– Always wear safety glasses and protective gloves when handling batteries. Avoid sparks and naked flames.

– Do not let any assisting personnel hold the attachment, bucket or grapple to assist in any operation.

– When working on the engine area, make sure that the side doors are properly secured to remain open during the service operation.

2.3.3

Fire and explosion prevention – Switch off the diesel engine prior to filling the tank.

– Have skilled personnel immediately repair all defects, such as loose connections, blown fuses and burned out light bulbs, burned or frayed cables.

– Do not smoke and avoid naked flames when filling the tank or loading the batteries.

– Always start the diesel engine according to the operating instructions.

– Never store flammable fluids on the machine except in appropriate storage tanks.

– Regularly inspect all lines, hoses and fittings for leaks and damage.

– Repair any leaks immediately and replace damaged components.

– Be certain that all clamps, guards and heat shields are properly installed to prevent vibration, rubbing and heat build up.

– Do not use cold start aids (ether) near heat sources or naked flames or in insufficiently ventilated areas.

– Do not use ether containing starting aids to start diesel engines with pre-heat system or flame glow systems.

– Familiarize yourself with the location and use of fire extinguishers on the machine as well as the local fire reporting procedures and fire fighting possibilities.

2.4 Signs on the machine 2.4.1

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

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

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

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Operating manual

Safety notes, signs Signs on the machine

Danger!

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

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

Replace missing or illegible safety and information plates immediately.

2.4.2

Safety and information signs The signs refer to specific hazards and accident prevention measures. They contain information for the operation, maintenance and transportation of the machine as well as details of machine properties.

Danger!

Non-compliance with safety and other information provided on the signs can result in serious or even fatal injury and damage to the machine.

Ensure that all required safety signs are in place and legible.

Always replace missing and illegible signs without delay.

Fig. 2-1

Position of the signs on the machine

The signs indicate the following:

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Safety notes, signs

Operating manual

Signs on the machine

15: Lubricating chart Provides information on work to be carried out in connection with lubricants and specifies the test, lubrication and change intervals.

20: Prohibition sign It is prohibited to access the marked area.

22: Operating symbols Describe the functions of the operating devices that are not individually labelled.

25: Emergency lowering of operator's cab Indicates the location of the emergency discharge valve of the height-adjustable operator's cab.

30: Lubrication chart of engine Indicates the maintenance intervals of the diesel engine.

35: Loading and tie-down points Indicates the position of the loading and tie-down points and the respective weight of the machine.

The values are maximum values. The actual values might deviate from those indicated on the signs.

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Operating manual

Safety notes, signs Signs on the machine

40: Tie-down point Indicates tie-down points.

45: Attachment point for lifting Indicates attachment points for lifting.

47: Jump-starting When jump-starting the machine, strictly adhere to the instructions in the operating manual.

50,51: Point of danger Risk of injury!

Do not stand inside the danger area of the machine while it is in operation.

52: Engine shut-down Before opening the bonnet, shut down the engine.

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Safety notes, signs

Operating manual

Signs on the machine

60: Information sign re. Lwa noise level Indicates the sound power level of the machine in dB(A). *XX = the value that applies to the machine is indicated on the operator's cab.

65: Load lift chart Indicates the maximum permissible loads depending on the reach.

66, part 1: Accident prevention When operating the machine, always strictly adhere to the accident prevention instructions included in the operating manual.

66, part 2: Safety lever Before leaving the operator's seat, pull the safety lever up to the stop.

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Operating manual

Safety notes, signs Signs on the machine

66, part 3: Attachment The working attachment can reach the operator's cab! Proceed with extreme caution when retracting the attachment.

80: Seat belt Before starting the machine, put on the safety belt.

85: Bonnet release Indicates the external release of the bonnet.

90: Engine cleaning The engine compartment may only be cleaned when the diesel engine is off.

Before cleaning the engine compartment with water or steam, cover all openings that must be protected for safety-functional reasons from penetrating steam, water or detergent.

250: Emergency exit through rear window Pull the handle on the inside of the rear window to remove the rubber insert. The rear window can then be pushed out.

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Safety notes, signs

Operating manual

Signs on the machine

2.4.3

ID tag The machine and its components (e.g. diesel engine, gearbox, pumps) are equipped with ID tags. The ID tags indicate the ID numbers of the components.

The ID tag of the machine is located at the front of the uppercarriage. It contains the following information: – Vehicle ID no.

– Type – Year of manufacture – Motor output – Max. speed – Permissible total weight – Permissible front axle load – Permissible rear axle load

Fig. 2-2

ID tag of the machine

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3 Control, operation 3.1 Operating and control elements 3.1.1

Overview of operator's platform

Fig. 3-1

Operator's platform

1

Safety lever of servo control

2

Operator seat

3

Right joystick

4

Left joystick

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Control, operation

Operating manual

Operating and control elements

5

Control lever for support system

6

Travel pedal, left

7

Travel pedal, right

8

Heating outlet

9 11

Operation of attachment* Control devices of various kits*

10 12

Positioning slewing brake* Indicating elements

13 Control unit with display S5/6 Push buttons for special functions*

S4 Horn S6M Horn

S382 Super Finish (SF) switch*

A-C

E8

Control console

Cigarette lighter, 24 V socket

* optional equipment

3.1.2

Indicating elements

Fig. 3-2

Control console A, indicating instruments

P5 - Operating hour meter Indicate the operating hours.

Used to schedule maintenance work according to he maintenance schedule.

P6 – Engine coolant temperature Indicates the temperature of the engine coolant.

P7 - Fuel level indicator Indicates the fuel level in the fuel tank.

To prevent condensation, keep the fuel level as high as possible.

P50 - Clock Indicates the time.

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Operating manual

Control, operation Operating and control elements

3.1.3

Control consoles

3.1.3.1

Control console A

Fig. 3-3

Overview of control console A

S18 - Overload warning system* The overload warning system warns the machine operator with a visual signal (indicator light 22) and an acoustic signal (buzzer sound) when the permissible maximum load is reached.

The warning signal should ensure that the permissible load is not inadvertently exceeded. In the event of a warning signal, reduce the extension of the attachment or lower the load to the ground without increasing the extension.

S17 - Slewing gear brake Applies/releases the mechanical slewing gear brake.

May only be used when the uppercarriage is not in motion.

S19 - Grapple rotator* The control console allows operators to activate the rotators of working tools (e.g. grapple) and similar functions.

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Control, operation

Operating manual

Operating and control elements

S21 – Fast run Switching of travel drive between normal travel and fast run mode.

Normal travel: maximum drawing pull at moderate speed.

Fast run: reduced drawing pull at maximum speed.

On slopes and uneven terrain, the machine shows improved traction when it is set to fast run mode.

S47 - Hydraulic quick-change adapter* Actuate this switch to activate the hydraulic quick-change adapter for the attachment and removal of working tools. The quick-change adapter can be locked and released.

S241 - Additional users* This switch determines whether the attachments (additional consumers) or the boom adjustment (if mounted) can be operated.

Depending on the switch position (see chapter "Tool Control"), the consumer is supplied with hydraulic oil at adjusted pressure and flow settings.

S360 - Acknowledgement of quick change adapter buzzer* Switches off the acoustic warning signal of the quick-change adapter.

A warning signal indicates that the quick-change adapter is not properly locked. If no working tool is to be mounted, it is useful to deactivate the warning signal. This is also recommended to ensure that other buzzer sounds (i.e. from the overload warning system) are actually audible.

S422 - Radio mute mode The radio mute mode allows you to reduce the volume of the radio to mute level without switching off the radio.

* optional equipment ** only in conjunction with overload warning system (optional equipment)

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Operating manual

Control, operation Operating and control elements

3.1.3.2

Control console B

Fig. 3-4

Control console B

S1 - Ignition switch The ignition switch is used to switch on the electrical equipment and to start the machine.

S92 - Air distribution in legroom This rotary switch is used to adjust the blower air distribution in the legroom.

When the switch is in the left position, the air flows from the exit nozzles at the windscreen. When it is in the right position, the air flows through the exit nozzles at the operator seat.

If the rotary switch is set to an intermediate position, the air is distributed between these two opening systems.

S93 - Heating This rotary switch is used to adjust the temperature of the blower air.

S284 - Blower output The blower has 4 output levels. The rotary switch is used to adjust the blower output.

S318 - A/c system* During a/c operation, the blower air is cooled. The cooling effect can be adjusted with the heating S93. The cooling effect is greatest when the heating is switched off (rotary switch S93).

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Control, operation

Operating manual

Operating and control elements

S398 - Switching of blower air output The switch determines whether the air flow of the blower exists at the rear panel of the cab or in the legroom. Within the legroom, the air distribution can be further adjusted (see S92).

* optional equipment

3.1.3.3

Control console C

Fig. 3-5

Control console C

S8 - Beacon* Activates the beacon.

S11 - Windscreen washer system Activates the windscreen automatic wiper/washer. Water is sprayed through the outlet nozzles onto the windscreen, while the wiper is operated for a set time in continuous mode.

S14 - Windscreen wipers Two switch positions for windscreen wiper: 1. continuous mode / 2. interval mode.

S22 - Front attachment light*, front roof light* (work light) Two switch positions for work lights: 1. A / 2. attachment light / 2. front roof light

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Operating manual

Control, operation Operating and control elements

S22-1 - Rear roof light*

S61 - Parking light, dipped light Two switch positions for light: 1. parking light / 2. dipped light This switch works even if the ignition key is in position 0 or P.

S218 - Cab roof window wiper Two switch positions for the cab roof window wiper: 1. continuous mode / 2. windscreen washer system (automatic wiper/washer).

* optional equipment

3.1.4

Control unit

Fig. 3-6

Overview of control unit

1 - Display The display – Indicates the nominal speed of the diesel engine in ten steps.

– Indicates the total operating hours and the daily operating hours.

– Indicates the error codes.

– Can be used to call up machine data.

– Can be used to adjust and manage functions (operator menu).

The display is automatically activated when the vehicle ignition is switched on, completes a self-test and then shows the start screen.

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Control, operation

Operating manual

Operating and control elements

2 - Speed Indicates the nominal speed of the diesel engine in ten steps.

3 - Speed minus (-) key Reduces the nominal speed of the diesel engine.

4 - Idle automatic key The idle automatic function automatically reduces the engine speed without actuation of the joystick or the travel pedal. This helps save fuel and reduces the noise level. By touching the joystick or the pedals, the engine speed returns to the initial level.

5 - Speed plus (+) key Increases the nominal speed of the diesel engine.

9 - Indicator light for engine fault The light is on, if a fault is detected in the diesel engine or its control system.

12 - Indicator light for Super Finish (SF) Is on if the SF mode is activated.

13 - Indicator light for pre-heating This light is on when the diesel engine is being pre-heated. After completion of the pre-heating process, the indicator light is off and the diesel engine can be started.

15 - Indicator light of engine oil pressure This light is on if, during operation, the engine oil pressure drops below a set limit value. This signal is accompanied by a warning sound.

When this light is on, immediately switch the engine to its lower idle speed and shut it down.

17 - Indicator light for air filter contamination This light is on if the air filter is contaminated.

Immediately switch the diesel engine to its lower idle speed and let it run idle for another approx. 30 seconds.

Switch off the diesel engine.

Replace the filter element, if required.

19 - Indicator light for coolant level This light is on, if the coolant level drops below a certain level.

When this light is on, immediately switch the engine to its lower idle speed and shut it down.

Check the system for leaks and repair them, if necessary. Add coolant.

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Operating manual

Control, operation Operating and control elements

Note!

The indicator light for coolant level is an additional indicating device preventing damage caused by excessive loss of coolant (e.g. due to hose break). The machine operator or maintenance personnel must however still regularly inspect the coolant level in the expansion tank.

20 - Indicator light of hydraulic oil temperature This light is on, if the hydraulic oil temperature in the tank exceeds 100 °C. When this light is on, immediately switch the engine to its lower idle speed and shut it down.

Identify the cause of the problem (e.g. dirty radiator) and eliminate it.

21 - Indicator light of fuel pre-filter This light indicates that there is excessive water in the fuel pre-filter.

Remove the water from the fuel pre-filter.

22 - Indicator light of overload warning indicator This light is on, if the overload warning system (S18) is activated and the maximum permissible load of the machine is reached. This signal is accompanied by a warning sound.

Avoid increasing the load.

Reduce the load of the machine.

23 - Indicator light of quick-change adapter This light is on during the release procedure or if the lock pins are retracted.

25 - Indicator light for battery charging This light is on when the ignition is started, and is off as soon as the diesel engine is running.

During engine operation, the indicator light is on, if the V-belt of the alternator or the electrical charging system is defective.

Set the engine to low idle gear.

Let engine run in low idle for about 30 seconds.

Switch off the diesel engine.

Repair the defect.

26 - ENTER key Press this key to confirm your entry (see chapter "Display").

27 - RIGHT key Moves the cursor in the display to the right (see chapter "Display"). Press this key to exit the menu.

28 - DOWN key Moves the cursor in the display down (see chapter "Display).

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Control, operation

Operating manual

Operating and control elements

29 - UP key Moves the cursor in the display up (see chapter "Display).

* optional equipment

3.1.5

Display and operator's menu

Fig. 3-7

Operator's menu The figures shows a model with all available options.

1

Display (start screen)

26

Key ENTER

27

Key RIGHT

28

Key DOWN

29

Key UP

A

Daily operating hours counter

B D

Operating hours counter Speed step

C

Error codes

Scrolling through the operator's menu: Press the UP or DOWN key to select the desired submenu (black bar).

Press the ENTER button.

The display shows the selected submenu.

Within the submenu, move the cursor (black bar) using the UP, DOWN and RIGHT keys.

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Operating manual

Control, operation Operating and control elements

Menu

Description

Menu

Start screen (shown when ignition is started)

tool option (1)

Selection of working tool settings

sf-flow (2)

Super Finish. Adjustment of flow reduction for Super Finish function

torque slew

Adjustment of slewing gear torque (sensitivity)

info-hours

Display of operating hours of individual machine components

info-IO

Status display of individual inputs and outputs

info-software

Display of software version

cyl. extern (3)

Activation of an attachment with hydraulic cylinder (e.g. mower rake)

hbg max point (4)

Electronic stroke limitation for the restriction of the moving range of the boom

Y268 on/off (5)

Use of foot pedals for the adjustment of the boom while the attachment is operated with the right joystick

stick limit (6)

Electronic stick shut-down for the restriction of the moving range of the stick

(1) only in conjunction with "Tool Control" or "Tool Control Plus" (optional equipment) (2) only in connection with "Tool Control Plus" (optional equipment) (3) only in connection with "Tool Control Plus" and "Tool Permanent" (optional equipment) (4) only in connection with "Stroke limitation" (optional equipment) (5) only in connection with "Control switchover" or "Tool Permanent" (optional equipment) (6) only in connection with "Stick cylinder shut-down" (optional equipment)

Tab. 3-1

Explanation of submenus

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Control, operation

Operating manual

Operating and control elements

3.1.5.1

Description of the submenus Tool Option

Fig. 3-8

Tool Option menu (figure shows menu with Tool Control Plus)

This menu is used to select pre-set pressure and flow reductions to the working tools (activation of foot pedals, e.g. for hydraulic hammer or grapple).

Prior to using the working tools, the correct option for the working tool must be selected at the display.

Caution!

Incorrect pressure or flow reduction settings may result in damage to the working tool (e.g. hydraulic hammer) or impair its functions (e.g. mill).

Select the correct option before using the working tools.

Menu navigation: Move the cursor down with the DOWN key, until the desired working tool is selected (options 1 to 10) and then press the ENTER key.

The working tool is selected.

Note!

On request, LIEBHERR and the customer service department will pre--set the desired options and label them with the names of the associated tools, e.g. "hammer" or "grapple".

Contact us to have the menu for each working tool set up.

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Operating manual

Control, operation Operating and control elements

SF-Flow

Fig. 3-9

SF-Flow menu

This menu allows you to adjust the flow reduction (SF-Flow) for the Super Finish function. With the Super Finish function, the movement of the attachment can be slowed down, so that tasks can be carried out with greater precision.

Adjustment range: 0 % (max. flow reduction) to 100 % (no reduction).

Menu navigation: Use the UP and DOWN keys to select the desired reduction.

Press the RIGHT key to confirm your selection.

The SF-Flow settings are selected.

Actuate the SF switch on the A console. The respective menu is shown on the display.

Torque Slew

Fig. 3-10

Torque Slew menu

In this menu, you can adjust the sensitivity of the slewing gear. These settings determine the accuracy with which the uppercarriage can be positioned.

The acceleration of the uppercarriage is determined by the distance by which the joystick handle is moved and the set sensitivity of the drive. The swivelling movement can be set to slow or fast (direct propulsion).

The set sensitivity remains active when the menu is closed and cannot be deactivated or activated without accessing the menu again.

Adjustment range: 0 (very slow) to 100 (fast).

Menu navigation: Use the UP and DOWN keys to select the desired movement speed.

Press the RIGHT key to confirm your selection.

The desired torque slew is now set.

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Control, operation

Operating manual

Operating and control elements

Info hours

Fig. 3-11

Info hours menu

The menu shows the operating hours of individual machine components. hours-day: Daily operating hours counter (can be reset with ENTER key). hours-rpm: Operating hours of three speed ranges (low, medium, high) hours-sensor: Operating hours with "automatic speed adjustment" during which the respective pilot control units were used. hours-drive: Operating hours in travel mode sensor control: Adjustment of time after (in seconds) which the diesel engine is automatically slowed to idle speed, if no pilot control unit has been actuated.

Menu navigation: Use the UP and DOWN keys to select the desired submenu (black bar).

Press the ENTER key to confirm your selection.

The display shows the selected submenu.

Press the RIGHT key.

The display shows the subordinate menu.

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Operating manual

Control, operation Operating and control elements

Info I / O

Fig. 3-12

Info I / O menu

The menu shows the status of individual inputs and outputs of the control system.

IO-Master: control system (master); values of inputs and outputs IO-Slave: control system (slave); values of inputs and outputs var-master: control system (master); variables and operating data Menu navigation: Use the UP and DOWN keys to select the desired submenu (black bar).

Press the ENTER key to confirm your selection.

The display shows the selected submenu.

Press the RIGHT key.

Info Software

Fig. 3-13

Info Software menu

The menu shows the software versions used.

M: Master control version/ S: Slave control version/ D: Display control version.

Menu navigation: Press the RIGHT key.

The display shows the subordinate menu.

Cyl. extern (optional equipment)

Fig. 3-14

Cyl. extern menu

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Control, operation

Operating manual

Operating and control elements

This menu is used to activate the application of an attachment with hydraulic cylinder (e.g. mower rake).

Menu navigation: Use the UP and DOWN keys to select the "cylinder extern" line.

Press the RIGHT key.

The cursor changes to the right section where you can change the parameter value.

Use the UP and DOWN key to select the desired setting.

1 = Use of attachment possible.

0 = Use of attachment not possible.

Press the ENTER button.

Move the cursor to the >back line and press the RIGHT button.

The display shows the superordinate menu.

Hbg max point (optional equipment) In situations where the machine's working space is limited in the vertical direction (e.g. by power transmission lines), it may be helpful to use stroke limitation to predefine a max. working height.

Danger!

Risk of injury and damage to equipment!

During the adjustment of the stroke limitation, there is a risk of serious damage and injury, as the equipment might collide with another object.

When adjusting the limitation function, operate the machine with exceptional care.

Setting stroke limitation:

Fig. 3-15

Attachment at max. working height - example:

1

Obstacle (e.g. tunnel roof, overhead power line)

2

Safety margin, as prescribed

m Max. working height (shut-off point)

The maximum permissible working height m must be at a sufficient distance to the object 1 that limits the vertical movement of the machine.

For the adjustment of the shut-off point, the machine must be properly supported.

The settings are shown at the display in the hbg max point submenu:

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Operating manual

Control, operation Operating and control elements

Fig. 3-16 *

hbg max point* menu

Values in cm

There are two methods to set stroke limitation: Menu option

Description

teach point

Saves the current position of the working attachment as the maximum permissible working height.

Move the stick upwards and fully tilt the digging bucket (if attached).

Move the attachment to the desired maximum working height.

Move the cursor to the teach point line and press the RIGHT key to change to the right field.

Press the UP button to enter the value "1" and confirm with ENTER. The current working height (act. max. point) is saves as the maximum permissible working height (hbg max point).

Move the cursor to the >back line and press the RIGHT button.

The display shows the subordinate menu.

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Control, operation

Operating manual

Operating and control elements

Menu option

Description

hbg max point

Enter the maximum permissible working height at the display.

Position the attachment below the planned maximum working height.

Move the cursor to the hbg max point line and press the RIGHT button to change to the right field.

Press the UP or DOWN button to select the new value (in cm) and confirm with ENTER. The maximum working height (hbg max point) is staved.

Move the cursor to the >back line and press the RIGHT button.

The display shows the subordinate menu.

*)

Special equipment: The movement range of the stick can also be restricted when it is extended.

Checking stroke limitation Turn key switch S249 to position 0.

The stroke limitation function is activated.

Prop up the machine, position the uppercarriage in longitudinal direction and lower the boom.

Using the boom cylinders, carefully move the attachment upwards to test the stroke limitation function.

When the maximum permissible working height is reached, the upward movement of the attachment must be stopped.

If required, readjust the stroke limitation.

Y268 on/off (optional equipment)

Fig. 3-17

Y268 on/off menu

Use this menu to activate the pedals for boom adjustment while an attachment (e.g. mower rake) is operated with the right joystick.

Menu navigation: Use the UP and DOWN keys to select the "Y268 on/off" line.

Press the RIGHT key.

The cursor changes to the right section where you can change the parameter value.

Use the UP and DOWN key to select the desired setting.

1 = Use of pedals possible.

0 = Use of pedals not possible.

Press the ENTER button.

Move the cursor to the >back line and press the RIGHT button.

The display shows the superordinate menu.

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Operating manual

Control, operation Operating and control elements

Stick limit (optional equipment) This means that the stick can only be moved within a preset angle range (defined by a minimum and a maximum angle). The reach of the attachment thus depends on the stick cylinder shut-down point and the angle of the boom.

Danger!

Risk of injury and damage to equipment!

During the adjustment of stick cylinder shut-down, there is a risk that the attachment might collide with the operator's cab.

When adjusting the limitation function, operate the machine with extreme caution.

Fig. 3-18

Menu stick limit

Settings in menus "stl max point" and "stl min point":

Fig. 3-19

Value

Stick position

0 (min)

Stick fully extended

500

Stick in centre position

1000 (max)

Stick fully retracted

Settings

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Control, operation

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Operating and control elements

The stick cylinder shut-down can be adjusted in various ways, depending on the equipment of the machine: Menu option

Description

teach max

Saving of current stick position as the maximum permissible stock position for retraction of the stick.

Move the attachment to its highest position.

Carefully retract the stick with the respective attachment (e.g. grapple) to the desired position.

Move the cursor to the teach max line and press the RIGHT key to change to the right field.

Press the UP button to enter the value "1" and confirm with ENTER. The current stick position (act. position) is stored as the maximum permissible stick position (stl max point).

Move the cursor to the >back line and press the RIGHT button.

The display shows the subordinate menu.

stl max point

Enter the maximum permissible stock position for retraction of the stick.

Position the stick within the planned range of movement.

Move the cursor to the stl max point line and press the RIGHT button to change to the right field.

Press the UP or DOWN button to select the new value and confirm with ENTER. The maximum permissible stick position for retraction is saved.

Move the cursor to the >back line and press the RIGHT button.

The display shows the subordinate menu.

teach min

Saving of current stick position as the maximum permissible stock position for extension of the stick *).

Carefully retract the stick with the respective attachment (e.g. grapple) to the desired position.

Move the cursor to the teach min line and press the RIGHT key to change to the right field.

Press the UP button to enter the value "1" and confirm with ENTER. The current stick position (act. position) is stored as the maximum permissible stick position (stl min point).

Move the cursor to the >back line and press the RIGHT button.

The display shows the subordinate menu.

copyright by

3 - 20

MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Control, operation Control

Menu option

Description

stl min point

Enter the maximum permissible stock position for extension of the stick *) Position the stick within the planned range of movement.

Move the cursor to the stl min point line and press the RIGHT button to change to the right field.

Press the UP or DOWN button to select the new value and confirm with ENTER. The maximum permissible stick position for extension is saved.

Move the cursor to the >back line and press the RIGHT button.

The display shows the subordinate menu.

*)

Special equipment: The movement range of the stick can also be restricted when it is extended.

Checking stick cylinder shut-down: Carefully extend and retract the stick to check the stick shut-down function.

When the set shut-down positions are reached, the stick movement must be automatically stopped.

If required, readjust the stick cylinder shut-down.

3.2 Control 3.2.1

Entering and exiting the operator's cab Caution!

Risk of injury when operator's cab is entered or exited without due regard to the safety instructions!

When entering and exiting the operator's cab, ensure that the safety lever is in its top position.

Always access and exit the machine using the provided climbing aids.

When climbing or descending, face the machine.

For safe climbing and descending, use the 3-point method: Always hold on the climbing aid with at least 1 foot + 2 hands or 2 feet + 1 hand.

Do not use operating elements as handles.

Never jump from the machine.

copyright by R 317 Litronic Industrie / 11140224

MJFCIFSS

3 - 21

Control, operation

Operating manual

Control

3.2.1.1

Mounting and dismounting from the machine

Fig. 3-20

Ascending using climbing aids

Swivel the uppercarriage by approx. 10° to the right.

Access and exit the machine using the steps and the chain.

3.2.1.2

Entering and exiting operator's cab

Fig. 3-21

Operator’s cab

1

Door handle

3

Inside door handle

2

Locking mechanism

4

Lever of locking mechanism

Accessing cab: Press the door lock on the door handle 1 and open the door.

If you wish to leave the door open, open it fully (swivel by 180° backwards) and secure it with the locking mechanism 2.

Always enter the cab facing the machine, and sit down on the operator seat.

If necessary, adjust the operator seat and steering column.

Exiting cab: Shut down the machine and push the safety lever upwards.

Push down the door handle 3 at the door lock.

Open the door fully and secure it with the locking mechanism 2.

Face the machine when descending from it.

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MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Control, operation Control

Releasing door locking mechanism: The door is secured with the locking mechanism 2.

Move the lever 4 beside the operator's cab frame outwards.

The door is now released.

Close the door.

3.2.2

Adjusting vertical position of the operator's cab (special equipment) The height of the operator's cab can be adjusted steplessly.

Danger!

Risk of collision of elevated operator's cab with obstacles!

There is a risk of injury, if the elevating cab's paths of travel are obstructed or inclined. The stability of the machine might be compromised when the operator's cab is lifted.

Do not move the machine while the operator's cab is elevated, and if the paths of travel are obstructed or inclined.

Adjust the cab height only when the machine is stationary.

During the adjusting procedure, ensure that no persons are standing in the danger area of the machine.

Danger!

If the operator's cab is inadvertently lowered, there is a serious risk of injury or even death.

Familiarise yourself with the emergency operating devices of the cab so that you can take appropriate measures, if the need arises.

Ensure that no persons are standing in the danger area of the cab (i.e. under it).

Keep a safe distance to moving parts while the operator's cab is being lowered.

Danger!

There is an increased risk of injury when repair and maintenance work is to be carried out while the operator's cab is elevated.

If at all possible, carry out such work when the operator's cab is lowered.

If it is necessary to carry out work on the elevated cab, prop it up with suitable supports.

copyright by R 317 Litronic Industrie / 11140224

MJFCIFSS

3 - 23

Control, operation

Operating manual

Control

Fig. 3-22

Height adjustment of the operator's cab

The machine is in ready mode.

The engine is running.

The safety lever is moved down.

Operate the control lever 1 to lift a or lower b the operator's cab.

3.2.3

Safety lever

Fig. 3-23

Safety lever

To prevent inadvertent movements of the machine, the left control console is equipped with a safety lever.

Caution!

When entering or exiting the operator's cab, always ensure that the safety lever is in its top position (arrow).

When the safety lever is tilted up, a number of machine functions are disabled or otherwise modified: – Actuation of the pilot control units (e.g. joysticks or pedals) does not result in movement of the machine.

– The slewing gear brake is applied.

– It is now not possible to release the slewing gear brake.

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MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Control, operation Control

By moving the safety lever to its bottom position, the initial switching statuses are reestablished, and the pilot control units are enabled.

Before commencing work with the machine, take place on the operator's seat and move the safety lever to its bottom position.

3.2.4

Operator seat Danger!

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

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

Therefore do not adjust the seat while the engine is running.

Before adjusting the operator seat, fold the safety lever upwards.

Fig. 3-24

Operator seat with mechanical spring mechanism (left) or pneumatic suspension (right)

1 4

Operator seat heating 2 Hand wheel for the 5 adjustment of the armrest angle

Lumbar support 3 Horizontal adjustment 6

Backrest adjustment Horizontal suspension (optional equipment)

7

Horizontal adjustment 8 with control console

Weight adjustment

Height adjustment

10 Shock absorber 13 Safety belt sign

9

11 Seat depth adjustment 12 Seat angle adjustment

copyright by R 317 Litronic Industrie / 11140224

MJFCIFSS

3 - 25

Control, operation

Operating manual

Control

3.2.4.1

Adjusting the seat suspension

Fig. 3-25

Adjustment of seat suspension for seats with mechanical spring mechanism (left) or pneumatic suspension (right)

Seats with mechanical spring mechanism: Adjust the seat to the body weight, turning the handle 1.

The indicator beside the handle indicates the set body weight.

Seats with pneumatic suspension: Before adjusting the height, set the shock absorber to "soft".

Sit down on the seat.

Pull the lever 1 briefly upwards.

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

3.2.4.2

Adjusting seat height

Fig. 3-26

Adjustment of seat height for seats with mechanical spring mechanism (left) or pneumatic suspension (right)

Seats with mechanical spring mechanism: The seat can be adjusted at various height levels.

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MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Control, operation Control

Caution!

To adjust the seat height, pull it up with both hands.

Danger! The hands could become squeezed between the seat and the control consoles. Do not reach below the seat surface from the side to move it from its top to its bottom position.

To lift the seat, place both hands under the front part of the seat. When pushing the seat down, hold it firmly.

Lift the seat to the desired height and ensure that it engages properly in this position.

If the seat is lifted to a position above the last step (stop), it is lowered automatically to its lowest position.

Seats with pneumatic suspension: The seat height can be adjusted steplessly by means of compressed air and a compressor. If the upper or lower stops are reached, the height is automatically adjusted near that position to provide minimum suspension travel. To prevent damage to the equipment, do not let the compressor run for longer than 1 minute.

Before adjusting the height, set the shock absorber to "soft".

Adjust the seat height by pulling or pushing the lever 1 to the respective stop.

3.2.4.3

Adjusting horizontal seat position

Fig. 3-27

Adjustment of horizontal seat position for seats with mechanical spring mechanism (left) or pneumatic suspension (right)

Pull the lever 1 and move the seat into a horizontal position.

Pull the lever 2 and move the seat together with the control consoles horizontally.

copyright by R 317 Litronic Industrie / 11140224

MJFCIFSS

3 - 27

Control, operation

Operating manual

Control

3.2.4.4

Adjusting seat angle

Fig. 3-28

Adjustment of seat angle

Lift the button 1.

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

3.2.4.5

Adjusting seat depth

Fig. 3-29

Adjustment of seat depth

Lift the button 1.

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

3.2.4.6

Adjusting backrest

Fig. 3-30

Adjustment of backrest

Pull up the locking lever 1.

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MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Control, operation Control

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

Release the locking lever. Ensure that the locking lever engages in the desired position and that the backrest cannot be moved to another position.

3.2.4.7

Adjusting lumbar support

Fig. 3-31

Adjustment of lumbar support

Only for seats with pneumatic suspension: Adjust the shape of the lumbar support by pressing the button 1 at the rear side of the seat.

3.2.4.8

Adjusting shock absorption

Fig. 3-32

Adjustment of shock absorption

Only for seats with pneumatic suspension: The shock absorption level can be adjusted to suit the road or terrain conditions.

Turn the handle 1 to the desired position and release it.

Position 1 = hard Position 2 = medium Position 3 = soft

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MJFCIFSS

3 - 29

Control, operation

Operating manual

Control

3.2.4.9

Adjusting horizontal shock absorption mechanism (optional equipment)

Fig. 3-33

Adjustment of horizontal shock absorption mechanism

Only for seats with pneumatic suspension: Under certain operating conditions (e.g. travelling with trailer), operator comfort can be increased by actuating the horizontal shock absorption.

Move the handle 1 to the desired position.

Position 1 = horizontal shock absorption OFF Position 2 = horizontal shock absorption ON

3.2.4.10

Adjusting armrests

Fig. 3-34

Adjustment of armrest angle

Adjusting the armrest angle: Turn the hand wheel 1 until the armrests are in the desired position.

Adjusting armrest height: The armrests can be folded back and adjusted individually in height.

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MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Control, operation Control

Fig. 3-35

Adjustment of armrest height:

Remove the cover cap 1 from the seat covering.

Loosen the hex nut 2 (wrench size 13 mm).

Set the armrest to the desired position.

Tighten the hex nut.

Replace the cover cap on the hex nut.

3.2.4.11

Adjusting headrest (optional equipment)

Fig. 3-36

Adjustment of head rest

Adjusting head rest: Adjust the head rest by pulling it from the engaging mechanism.

Adjust the headrest angle by pushing it forward or back.

Removing headrest: Move the headrest to the upper stop and then pull it sharply from the seat.

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MJFCIFSS

3 - 31

Control, operation

Operating manual

Control

3.2.4.12

Seat heating (optional equipment)

Fig. 3-37

Seat heating

Actuate the switch 1 to switch on the seat heating.

3.2.4.13

Wearing/taking off safety belt

Fig. 3-38

Seat belt

The safety belt is an inertia seat belt. It is thus not necessary to adjust the belt length.

Pull the belt 1 from the reeling mechanism 2.

When the belt is pulled with a jerk, it might lock.

Push the locking piece into the buckle 3 so that it engages.

Danger!

The seat belt is designed to protect the machine operator.

Prior to starting the machine, put on the seat belt.

Ensure that the seat belt is not twisted.

To ensure proper safety, regularly check the seat belt and replace it without delay if you detect any damage to parts.

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

The reeling mechanism 1 automatically pulls in the belt.

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MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Control, operation Control

3.2.5

Operator seat Danger!

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

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

Do not adjust the operator seat while driving the machine.

Park the machine and apply the parking brake.

Move the safety lever up.

Fig. 3-39

Operator seat

1

Operator seat heating

2

3

Backrest adjustment

4

Mechanical / pneumatic lumbar support* Armrest height adjustment

5 7

Armrest adjusting wheel Horizontal adjustment with control consoles

6 8

Horizontal suspension* Display for weight settings*

9

Manual/automatic adjustment for body weight and seat height*

10 Shock absorber*

11 Horizontal adjustment 13 Seat inclination

12 Seat depth 14 Safety belt

15 Armrests

16 Headrest

* Model variant

copyright by R 317 Litronic Industrie / 11140224

MJFCIFSS

3 - 33

Control, operation

Operating manual

Control

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

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

Check the display 8.

• green = settings correct • yellow = correction required If necessary: Adjust the settings by pulling or pushing the lever 9 to the stop.

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

Sit down on the seat.

Pull the lever 9 briefly upwards.

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

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

Caution!

Risk of damage to compressor.

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

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

Adjusting seat depth: Lift the button 12.

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

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

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

Horizontal adjustment: Pull up the lever 11.

Adjust the operator seat in horizontal direction.

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

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

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

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

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

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

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MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Control, operation Control

Adjusting backrest: Pull up the lever 3.

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

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

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

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

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

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

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

• Position 1 = hard • Position 2 = medium • Position 3 = soft Adjusting horizontal cushioning*: Under certain operating conditions, you can improve the operator comfort by adjusting the horizontal cushioning mechanism. This helps reduce impact stress in travel direction on the operator as these impacts are better cushioned by the seat.

Move the handle 6 to the desired position.

• Position 1 = horizontal cushioning OFF • Position 2 = horizontal cushioning ON After the handle has been moved to position 1, ensure that is engages properly in this position: push the seat back until you hear an audible click.

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

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

Loosen the hex (wrench size 13 mm).

Set the armrest to the desired position.

Tighten the hex nut (25 Nm).

Replace the cover cap on the hex nut.

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

Adjust the headrest angle by pushing it forward or back.

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

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MJFCIFSS

3 - 35

Control, operation

Operating manual

Control

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

• Position 0 = seat heating OFF • Position 1 = seat heating ON * Model variant

3.2.6

Windscreen

Fig. 3-40 1

Windscreen

Locking lever

2

Handle bracket

The windscreen can be placed to 2 positions.

– Position a: Windscreen closed.

– Position b: Windscreen is fully opened (attached to the roof of the operator's cab).

Caution!

The windscreen is very heavy.

There is a risk of injury to fingers, if they become caught between the panel and the frame when closing the windscreen.

Hold the windscreen with both hands by the handle brackets 2.

Caution!

Risk of glass break.

The windscreen might break, if it is allowed to drop without support.

Hold the windscreen with both hands by the handle brackets 2.

Opening windscreen: Pull the latch 1 inwards and down.

The windscreen is released.

Hold the windscreen by the two brackets and slide it upwards until it engages.

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MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Control, operation Control

Lock the windscreen in its position by engaging the latch 1.

Closing windscreen: Pull the latch 1 inwards and forward.

The windscreen is released.

Hold the windscreen by the two handle brackets and slide it carefully down until it engages.

Lock the windscreen in its position by engaging the latch 1.

3.2.7

Sun blind

Fig. 3-41

Sun blinds for windscreen and cab roof

The operator's cab is equipped with two sun blinds, one for the windscreen and one for the glass panel in the cab roof.

Windscreen Pull the sun blind down, holding it by the cross bar 1.

The sun blind can be individually adjusted.

Press the switch 2 (red).

The sun blind is automatically rolled up.

Cab roof Pull out the sun blind and engage it in the holders provided.

To open the sun blind, remove it from the holders and let it roll up slowly.

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3 - 37

Control, operation

Operating manual

Control

3.2.8

Emergency exit through rear window

Fig. 3-42

Emergency exit through rear window

Pull the latch 1 at the inside of the rear window to remove the rubber seal 2.

In the event of an emergency, pull out the rubber seal 2 along the entire circumference of the rear window panel and push out the window.

3.2.9

Inside lighting

Fig. 3-43

Inside lighting

The inside lighting is switched on/off by a rocker switch.

Set the rocker switch to position 1.

The light is switched on.

Set the rocker switch to position 0.

The light is switched off.

Switch position 2 is not assigned a function.

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MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Control, operation Control

3.2.10

Fire extinguisher (optional equipment)*

Fig. 3-44

Fire extinguisher / first aid kit

The hook for the fire extinguisher is located in a recess in the bottom right corner of the operator's cab. *Operator instructions

3.2.11

Windshield wiper

3.2.11.1

Windshield wiper With the ignition turned on, press switch S14 on control panel C to activate the windshield wiper operation.

This switch has two settings: Push the switch in position 1 down (center position).

Continuous operation is activated.

Push the switch in position 2 down (final position).

Intermittent control is activated.

3.2.11.2

Window washer system With the ignition turned on, press switch S11 on control panel C fo activate the windshield washer system.

Press the button down and hold.

Water will be sprayed onto the front windshield through nozzles.

The windshield wiper runs continuously.

Release the button.

The water flow stops.

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

copyright by R 317 Litronic Industrie / 11140224

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3 - 39

Control, operation

Operating manual

Control

3.2.11.3

Windshield washing fluid container

Fig. 3-45

Windshield washing fluid container

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

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

Quantity: see Lubrication Chart

3.2.11.4

Window wiper on cab roof

Fig. 3-46

Window wiper on cab roof

With the ignition turned on, press switch S14 on control panel C to activate the windshield wiper operation.

This switch has two settings: Push the switch in position 1 down (center position).

Continuous operation is activated.

Push the switch down to position 2 and hold (final position).

Water will be sprayed on the windshield.

The windshield wiper runs continuously.

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MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Control, operation Control

3.2.12

Lighting

Fig. 3-47 1 3

Arrangement of the lighting devices

Parking and travel light Roof light (optional equipment)

2 4

Attachment headlight Beacon (optional equipment)

The switches for the lighting devices are located on the control console C.

Parking and lower beam headlight When the ignition is on or off, the parking and lower beam headlight can be switched on with the switch S61.

– 1. (centre position): parking light on.

– 2. (limit position): travel light on.

Front attachment headlight, front roof light (optional equipment) When the ignition is on, the roof light and the attachment headlight can be switched on with the switch S22.

– 1. (centre position): Attachment light on.

– 2. (limit position): attachment headlight and roof light on.

Rear headlight (optional equipment) When the ignition is on, the rear work light can be switched on with the switch S22-1.

– 1. (centre position): no function (standard equipment).

– 2. (limit position): rear roof light and the rear work light on.

Beacon (optional equipment) When the ignition is on, the beacon can be switched on with the switch S41.

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Control, operation

Operating manual

Control

3.2.13

Heating system The operator's cab is equipped with a heating system as standard. The heating system can be used to heat or ventilate the operator's cab. The switch of the heating system is located on the control console B.

Fig. 3-48

Operation of the air-conditioning system

S92

Air distribution in legroom

S318 A/c system*

S93

Heating output

S398 Switching of blower air output

S284 Blower output * optional equipment

Fig. 3-49

Overview of air outlets in the operator's cab

A Legroom, front windscreen B Legroom, operator's seat

C Rear of cab

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R 317 Litronic Industrie / 11140224

Operating manual

Control, operation Control

Adjusting blower output: The output of the blower is adjusted by means of the rotary switch S284.

Position 0: The blower is switched off.

Positions 1 to 4: The blower motor can be run at 4 different speeds.

Changing air outlet: Use the switch S398 to choose whether the air is to be let out in the legroom (A and B) or at the rear of the cab C. Press the switch down.

The air flow from the blower is fed through the ventilation openings in the legroom (A and B).

The indicator light in the switch is on.

Press the switch up.

The air flow from the blower is fed through the ventilation openings in the rear panel of the cab C. The indicator light in the switch is off.

Adjusting air distribution in the legroom: This rotary switch S92 is used to adjust the air distribution in the legroom.

The air is fed to the legroom (reverse switch light is on).

Turn the rotary switch to the left.

The air is blown through the openings 1 (windscreen).

Turn the rotary switch S92 to the right.

The air is blown through the openings 2 (operator's seat).

If the rotary switch is set to an intermediate position, the air is distributed between the two openings 1 and 2.

Adjusting heating output: Turn the rotary switch S93 to adjust the heating output.

The diesel engine must be on.

Turn the rotary switch S93 to the left.

The heating output is reduced.

When the switch is in position "0" (left stop), the heating is switched off.

Turn the rotary switch S93 to the right.

The heating output is increased.

Note!

In order to achieve optimum comfort in the cab, we recommend feeding the air through the openings in the legroom (A and B).

3.2.14

A/c system (optional equipment) On request, the machine can be equipped with an a/c system.

The a/c system is activated by means of the switch S318.

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Control, operation

Operating manual

Operation

The diesel engine must be on.

Press the switch S318 down.

The a/c system is active.

The indicator light in the switch is on.

Press the switch S18 up.

The a/c system is off.

The indicator light in the switch is off.

If the rotary switch S284 (blower output) is in position 0 when the a/c system is switched on, the blower speed is automatically set to 1.

During a/c operation, the blower air is cooled. Use the rotary switch S93 (heating) to adjust the room temperature. The blower air is coolest when the rotary switch S93 is in position 0 (left stop).

In order to dehumidify the cab, switch on the a/c system while the system is in heating mode. Switch off the a/c system when all windows are completely defogged.

Note!

In order to achieve optimum comfort in the cab with a/c operation, we recommend feeding the air through the openings at the rear of the cab ( C).

3.3 Operation 3.3.1 3.3.1.1

Safety instructions Bringing the machine into service – Before starting the machine, perform a thorough walkaround inspection.

– Visually check the machine for loose bolts, cracks, wear, leaks and damage.

– Never start or operate a damaged machine.

– Make sure to correct any problems immediately.

– Verify that all hoods, covers and doors are closed, however, the locks should remain unlocked.

– Verify that all safety signs are in place.

– Make sure that all windows, as well as the inside and outside mirrors are clean.

Secure all doors and windows to prevent unintentional movement.

– Before operating the machine, adjust the operator’s seat, the mirror, the armrests and the other items to ensure comfortable and safe working conditions.

– The noise protection devices on the machine must be in working order.

– Never operate the machine without the cab.

3.3.1.2

Starting the machine – Before start up, check all indicator lights and instruments for proper function, bring all controls into neutral position and insure that the safety lever is in the raised position.

– Blow the horn briefly prior to starting the diesel engine, in order to warn persons located near the machine.

– Only start the machine from the driver’s seat.

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Operating manual

Control, operation Operation

– Start the diesel engine according to the regulations in the operating instructions, if you have not received any other instructions.

– Lower the safety lever and check all indicators, gauges, warning devices and controls for their proper indication.

– Only operate the diesel engine in a well-ventilated area, if the area is enclosed. If necessary, open doors and windows in the building to provide ample fresh air.

– Bring the engine and hydraulic oil to operating temperature. Low oil temperatures cause a slow reaction of the controls.

– Check that all attachment functions are operating properly.

– Carefully take the machine to an open area and check all control functions.

3.3.1.3

Shutting down the machine – Park the machine on level and stable ground whenever possible. Otherwise, chock or block wheels when parking on a slope.

– Lower the attachment so that it rests on the ground.

– Move all control elements into the neutral position. Set the parking and slewing gear brake.

– Switch off the diesel engine according to the operating instructions and move the safety lever up, prior to leaving the driver’s seat.

– Lock the machine, as well as all hoods, covers and doors; remove all keys and secure the machine against any unauthorized use.

3.3.1.4

Towing the machine – Always observe the correct procedure: See chapter “Towing the machine” in this operating manual.

– The machine may only be towed in exceptional circumstances, such as moving a disabled machine from a hazardous location.

– Before pulling or towing the machine, check all cables, hooks and couplers for safety and stability.

– Towing equipment must have sufficient tensile strength and must be attached to the undercarriage at the designated tiedown attachment points.

– Never allow anyone to remain in the area of the towing devices.

– During the towing procedure, keep within the required transport position, the permissible speed and distance.

– Proceed as outlined in the operating manual when putting the machine back into service.

3.3.2 3.3.2.1

To see and to be seen Field of vision As a machine operator, most information you need for safe working is acquired through vision. Good sight and a large field of vision help effectively minimise risks to you and others when driving the machine and working with it.

As not all areas around the machine can be seen directly from the operator's cab, the machine is equipped with a number of visual aids (e.g. mirrors and cameras). These aids are used to monitor areas around the machine that are not directly visible to the operator.

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Caution!

Certain attachments and tools can restrict the view of the machine operator. Risk of accident!

Be aware of these restrictions to your view and the existence of dead angles.

If required, avail of a signaller to guide you.

Observe the applicable statutory regulations for visibility from the operator's cab. For member states of the European Economic Area, ISO 5006:2006 specifies a static test method for determining and evaluating the machine operator's visibility. The field of vision is thereby assessed with the standard equipment of the machine. In principle, changes to machine, such as the attachment or removal of components, must not affect the field of vision. If such changes however do affect visibility, a test according to ISO 5006:2006 or according to the regulations applicable at the site of operation must e carried out. Depending on the result of the test, certain measures might need to be taken. The machine operator must always be informed of any such changes to the machine.

3.3.2.2

Measures to be taken prior to and during operation Ensure that all persons establish contact with the machine operator before approaching the machine.

Regularly check all visual aids for dirt, correct adjustment and proper functioning.

Adjust visual aids so that they provide the largest possible field of vision around the machine.

Keep visual aids and the windows of the operator's cab clean at all times.

Repair or replace defective visual aids without delay.

Do not use visors, if they obstruct your view.

Always keep an eye on the area around the machine so that you can spot potential dangers in advance.

Avoid reversing wherever possible.

Direct vision is always safest: plan your work so that you can properly see the working area without any obstructions to your view.

When working with restricted visibility or if visual aids are defective, always work with a signaller. Agree hand signs. For especially difficult tasks, establish voice contact (e.g. via radio).

When visibility is poor, use the lights according to the applicable statutory regulations.

3.3.3

Camera system (optional equipment) Due to the machine design and dimensions, the field of vision from the operator's cab might be somewhat restricted. The camera system is designed to increase the field of vision of the operator and is installed in addition to the mirrors. The machine operator can thus see areas that are not directly visible from the cab. The monitor in the operator's cab shows the image captured by the camera.

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Danger!

The camera system is only an aid and might not capture certain obstacles. In addition, the image might be slightly distorted. It does not warn the operator if there are persons or obstacles in the danger area.

Please note: – It is the responsibility of the machine operator to monitor the working area and the path of travel of the machine.

– In the event of a failure of the camera system, the machine must be moved and operated with the aid of a signaller.

For detailed information, refer to the operating manual of the camera manufacturer.

3.3.4 3.3.4.1

Starting machine General instructions Note!

When using the machine above a certain height above sea level and at low ambient temperatures, the performance and the service life of the diesel engine with turbo charger is considerably reduced.

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

To prevent damage to the diesel engine, the output of the engine is automatically in line with the elevation above sea level and the ambient temperature.

Simultaneously observe the coolant circuit and the hydraulic oil cooling system.

3.3.4.2

Tasks to be completed prior to machine start Caution!

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

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

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

Position of the locks: see chapter "Maintenance".

Caution!

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

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

Before starting the machine, carry out the following routine procedure: – Check oil level in engine*.

– Check coolant level of diesel engine*.

– Check oil level in hydraulic tank*.

– Remove water from fuel system*.

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– If necessary, remove ice and snow from the cooling air and combustion air intake openings. * For instructions on how to complete these tasks, refer to chapter "Maintenance".

3.3.4.3

Deactivating the electronic immobiliser (optional equipment) On request, the machine can be equipped with an electronic immobiliser.

Prior to start-up the electronic system checks whether the ignition key code is correct. If this is the case, the control system is enabled.

The machine is delivered with two sets of keys (blue and red):

Fig. 3-50 1

Keys in different colours

Programmed ignition key (blue)

2

Master key (red)

Note!

The red master key cannot be used to start the machine. It is only used for the programming and deprogramming of additional blue ignition keys.

It is very important that the red master key is kept in a safe place (e.g. machine owner's office) and only the blue key is handed over to the machine operator.

Start the machine with a blue programmed key.

Safety functions The electronic immobiliser is automatically activated after five seconds, provided that the diesel engine is shut down and the ignition key is removed.

If more than five keys with different codes are inserted into the ignition within a period of one minute, the immobiliser remains activated for 15 minutes. During this period, it is not possible to start the machine with any other key.

Manipulation protection The electronic immobiliser cannot be deactivated by manual manipulation to the machine.

Deprogramming keys If a programmed key is lost, the remaining programmed keys must be deprogrammed and reprogrammed.

For detailed information (functions, deletion of program, programming of keys, troubleshooting), see the user manual of the manufacturer.

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3.3.4.4

Switching on the electrical system Switch on the main battery switch:

Fig. 3-51

Battery main switch

Turn battery main switch to position 1 (ON).

Switching on the ignition:

Fig. 3-52 0 1

Ignition switch

Neutral position Contact position

2 P

Ignition position Parking position

Turn the ignition key to contact position 1.

The ignition is switched on.

As soon as the system is switched on, it completes a self-test of the control panel keyboard and the indicating instruments: all indicator lights are on for a short period of time.

During the self-test, observe the indicating instruments.

Note!

If the system fails to complete a self-test of the control panel keyboard and the indicating instruments, check whether the battery main switch is in the "ON" position.

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3.3.4.5

Starting the diesel engine Note!

Incorrect starting can damage the diesel engine!

Only operate the starter, if the diesel engine is off.

Do not operate the starter for periods of more than 20 seconds.

If the machine fails to start after 20 seconds of starter operation: Wait at least 1 minute until the next start attempt.

Turn the ignition key to position 0 before starting the engine again.

After three unsuccessful start attempts: identify the cause of the failure and eliminate it.

Engine starting process: The ignition key must be in position 1.

Set the engine to speed step 3.

Turn ignition key to ignition position 2.

As soon as the engine is running, release the ignition key.

All indicator lamps must be off.

A buzzer signal is audible while the engine oil pressure is built up.

Starting engine at low ambient temperatures: Pre-heating improves the starting behaviour of the diesel engine at lower temperatures. Depending on the temperature, the diesel engine is automatically preheated.

Turn key switch to position 1.

If the diesel engine is pre-heated , the pre-heating symbol is displayed.

Set the engine to speed step 3.

Wait until the symbol disappears.

The pre-heating process is completed.

Turn ignition key to ignition position 2.

As soon as the engine is running, release the ignition key.

All indicator lamps must be off.

A buzzer signal is audible while the engine oil pressure is built up.

3.3.4.6

Warm-up phase for the diesel engine If the engine coolant is cold (temperature below 20 °C), the speed of the diesel engine is automatically set to step 3.

This process is continued until the engine coolant temperature reaches 20 °C, or for maximum 3 minutes.

You can then gradually increase the speed of the diesel engine to the desired value, using the key +.

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3.3.5

Adjusting engine speed

Fig. 3-53

Speed indicator

The speed range of the diesel engine is displayed on a scale from 1 to 10.

The display indicates the current actual speed (see circle), while the speed indicator shows the set nominal speed (see arrow).

If there is a discrepancy between the two displays, the control system has automatically reduced the speed (idle speed).

The following events result in an automatic reduction of the speed: – The safety lever is moved up.

– The set idle automatic function detects that the operator does not touch any of the pilot control units.

After the initial operating status is restored, the machine is again run at nominal speed.

In the example, the diesel engine is running at speed of 1, while the nominal speed is 7.

Adjust the speed with the + and - buttons.

Speed

Description

1

Speed step 1

2

Speed step 2

3

Speed step 3

4

Speed step 4

5

Speed step 5

6

Speed step 6

7

Speed step 7

E

Speed step 8 (Economy) For particularly economical and environmentally-friendly operation.

P

Speed step 9 (Power) For excellent digging performance at low fuel consumption.

PP

Speed step 10 (Power Plus) For highest digging performance and heavy-duty applications.

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3.3.5.1

To be observed after start-up Danger!

Risk of asphyxiation from exhaust gases.

In confined rooms, do not start the engine unless you have ensured sufficient ventilation.

Open doors and windows in the window to provide ample fresh air.

Caution!

Risk of injury, if function check is not carried out properly.

Bring the engine and hydraulic oil to operating temperature. At low oil temperature, the steering responds only slowly.

Move the machine to an open space to test the function of the travel and the slewing gear brake.

Check that all attachment functions are operating properly.

Note!

The engine is damaged if it is operated for a prolonged time at idle speed.

Shut down the diesel engine, if the machine is not operated.

3.3.5.2

Preventing overheating of engine If the engine is overheating, the coolant temperature indicator light is on and an audible alarm signal (buzzer) is issued.

Immediately switch the diesel engine to the lower idle speed and shut it down (see also operating and maintenance instructions of Deutz engine).

Fig. 3-54

Air intake system of the diesel engine

Note!

In order to ensure optimised conditions for the operation of the engine, remove any ice and snow from the bonnet of the engine and the intake openings for cooling and combustion air.

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3.3.6

Switching off the diesel engine Caution!

Risk of damage to the engine!

Do not suddenly shut down the engine from full-load operation.

Set the engine speed to the lower idle speed (step 1).

Let the diesel engine run for approx. 1 minute at lower idle speed to allow for temperature adjustment.

Turn the ignition key to position 0 to shut down the engine.

Remove the ignition key.

3.3.7

Starting aid (Optional extra) Starting may be assisted using a fuel heating device.

The fuel feed is electrically heated to prevent the fuel from gelling at low outdoor temperatures.

Fuel preheating should be switched on at least 5 minutes before starting in low outdoor temperatures.

Press switch S213 on the right control panel before starting and with the ignition switched on.

Fuel preheating is switched on.

Indicator light in the switch illuminates.

Starting the diesel engine.

Note!

Only switch off fuel preheating when the fuel tank has warmed up sufficiently. This may take up to 30 minutes at low outdoor temperatures.

Press switch S213 again.

Fuel preheating is switched off.

Indicator light in the switch goes out.

3.3.8

Jump start procedure Danger!

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

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

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3.3.8.1

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

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

Start the engine as described above.

Caution!

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

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

3.3.8.2

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

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

Check the electrical functions of the machine.

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

3.3.9 3.3.9.1

Travel operation Travelling straight ahead

Fig. 3-55

Travelling straight ahead

1

Idler

6a / 6b Left travel pedal

2

Tumbler wheel

7a / 7b Right travel pedal

Caution!

Risk of injury!

Before setting the machine to travel mode, ensure that the idler 1 is at the front and the tumbler wheel 2 is at the rear of the machine.

Before travelling backwards, ensure that no persons or obstacles are in the path of the machine.

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Travelling forward: Press both pedals forward (6a and 7a).

Travelling backwards: Press both pedals down (6b and 7b).

3.3.9.2

Turning at standstill

Fig. 3-56

Turning at standstill

Turning left (1): Press the left pedal down (6b).

Simultaneously press the right pedal forward (7a).

Turning right (2): Press the right pedal down (7b).

Simultaneously press the left pedal forward (6a).

Note!

In order to protect the drives against excessive wear, turning at standstill should be avoided, if possible.

3.3.9.3

Turning machine with one chain

Fig. 3-57

Turning machine with one chain

Turning left (1): Press the right pedal forward (7a).

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Turning right (2): Press the left pedal forward (6a).

During travel, applying different forces to the two pedals results in a change of direction.

3.3.9.4

Manually steering chassis

Fig. 3-58

Manual steering system of chassis

For particularly accurate manoeuvring, the chassis must be steered manually.

Attach the supplied manual levers (1 and 2) to the chassis pedals.

The chassis can now be steered by hand.

Note!

For safety reasons, the chassis must be steered manually when the machine is loaded on or unloaded from a low-loader.

3.3.9.5

Adjusting speed The achievable travel speed is determined with the switch S21. The machine features two speed levels: – Normal travel (position 1): Maximum drawing pull at moderate speed.

– Fast travel (position 2): Reduced drawing pull at maximum speed.

Press the switch S21 down.

The switchover from normal to fast travel is activated.

The indicator light in the switch is on.

During travel, the system automatically switches from normal to fast travel, provided that the ground conditions permit this. On difficult terrain, the system switches back to normal travel.

Press the switch S21 up.

The switchover is deactivated.

The indicator light in the switch is off.

When the switchover is deactivated, the machine can only be operated in normal travel mode.

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3.3.9.6

Braking Caution!

Quick release of the pedals causes the machine to come to an abrupt halt. The operator might find it difficult to remain seated in the cab.

Prior to starting the machine, put on the safety belt.

If possible, avoid quick braking manoeuvres.

The hydrostatic travel drive acts as a working brake.

Release travel pedals.

The pedals automatically return to their neutral positions.

The travel operation is stopped, and the machine is slowed down.

When the travel pedals are in neutral position, the machine is secured and cannot roll away. Approximately five seconds after the pedals have been released, the parking brake is applied automatically. The working attachment can still be moved.

3.3.10

Travel alarm system (optional equipment)

Fig. 3-59

Travel alarm system

Actuate the travel pedal 1 or 2.

The travel alarm system is automatically switched on.

An acoustic signal (warning signal) is generated.

Deactivating the travel alarm system: Depending on the machine equipment, the switch to deactivate the travel alarm system is mounted on the left or right joystick.

Actuate the push button S6L on the right joystick or the switch S382 on the left joystick.

The travel alarm system is switched off.

Note!

The travel alarm system can be switched off earliest 10 seconds after travel start.

If a travel pedal is actuated again, the travel alarm system is reactivated.

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3.4 Working with the machine 3.4.1 3.4.1.1

Safety Instructions Working with the machine – Before starting to work, familiarize yourself with the specific conditions of the job site and any local regulations. These include: the obstacles in the working or movement area, the load carrying capacity of the ground and required safeguards for the job site to protect machines and personnel from public highway traffic.

– Always keep an adequate safety distance to overhangs, edges, embankments and an unsecured substrate.

– Be particularly cautious in conditions of reduced visibility and changing ground conditions.

– Always locate any underground utilities before you dig. Observe the required clearance distances to any underground utilities.

– Familiarize yourself with the location of power lines and use caution when working near them. Observe the required clearance distances to any power lines.

– In the case of contact with a power line: • do not move the machine or its attachment, • do not leave the operator’s platform, • warn people in the vicinity not to approach or touch the machine, • have the power turned off.

– Before moving the machine, always ensure that the attachments are safely secured.

– When traveling on public roads, observe all traffic regulations, insure that your equipment has all required lighting and marking, and observe any applicable load limitations.

– Always turn on the lights in conditions of poor visibility or darkness.

– Do not permit any passengers on the machine (except on two way excavators).

– Operate the machine only when seated and with the seat belt fastened.

– Report any problems or needed repairs and make sure that all required repairs are carried out immediately.

– Insure that the intended work area is clear of all personnel before beginning work.

– Before starting to work, always check the brake system as outlined in the operating manual.

– Never leave the operator’s seat as long as the machine is still moving.

– Never leave the machine unattended while the diesel engine is running.

– Know the loads to be handled and be aware of any stability limitations these loads may create.

– The maximum approved passable incline / traverse slope of the machine depends on the attached equipment as well as the substrate.

– For travel, move the uppercarriage parallel to the undercarriage and hold the load as close as possible to the ground.

EXCEPTION: see WHEN LOADING AND UNLOADING – Adjust the travel speed to suit local conditions.

– Avoid working movements which could cause the machine to tip over.

– If possible, always work downhill or uphill, never sideways on a slope.

– Travel downhill at the permitted speed or you could lose control over the machine.

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– Travel down grades at the appropriate speed to maintain control of the machine.

Shift to a lower gear to allow the engine to control the maximum speed of the machine.

– When loading a truck, make sure that the truck driver leaves the cab, even if a rock protection is present.

– Always use the safety devices intended for their specific use for demolition work, clearings, hoisting operations, etc.

– For terrain which is difficult to gain an overview of and whenever necessary, ask for assistance of a guide. Have only one person signal you.

– Only permit experienced personnel to secure loads and signal the machine operator. The guide must position himself within view of the operator or be in voice contact with him.

– Depending on the attachment combination, there can be a danger of collision between the working tool and the operator’s cab, the cab protection or the boom cylinders. To avoid damage, utmost attention is required when the bucket teeth enter this range.

3.4.1.2

Use in material handling applications, specifically when travelling with raised loads and attachments – Material handling applications, especially using a grapple, may require travel with suspended loads. Doing this will shift the machine centre of gravity and reduce stability.

The following practices and precautions should be observed: • Match your travel behaviour to the changed machine characteristics and surrounding conditions.

• Reduce the travel speed to avoid sudden braking or steering manoeuvres.

• Avoid sudden speed changes, such as braking, acceleration, changes in travel direction.

• Turn the uppercarriage only if the undercarriage is not travelling.

• Turn the uppercarriage only after taking on the load.

• Move the machine only after you have taken on the load, lifted it and turned the uppercarriage in travel position.

• If so required to the job site conditions, ensure, that you have appropriate windscreen protection.

The protective screen (FOPS) must be installed if there is a danger of falling objects from overhead.

• Do not exceed the grapple rated load. Know the density and weight of materials being handled.

– The working sequences when working with machines with grapples require a properly instructed and trained operator.

– The work application is only permitted after the machine operator has received sufficient training and practical experience.

3.4.1.3

Application of machines with tower elevation – Due to the tower elevation, the centre of gravity of the machine will shift upward in vertical direction. The travel and work behaviour of the machine will thereby be strongly influenced, for example reduction of dynamic stability.

– Due to the elevated centre of gravity, the machine must be aligned in horizontal direction before starting to work. In horizontal direction, the centre of gravity of the uppercarriage is above the centre of the undercarriage, which improves stability.

– The machine can rock despite levelling and tip over!

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

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• Driving with loads is not permitted.

• Swing the uppercarriage parallel to the undercarriage (transport position).

• Pull the attachment as close as possible to the machine.

• Only then may the outriggers be retracted and the machine be driven.

• Check the roadway to ensure that the ground is solid and even! Potholes and uneven road surfaces endanger the stability of the machine.

• Match your travel behaviour to the changed machine characteristics (higher centre of gravity) and surrounding conditions.

• Reduce the travel speed to avoid sudden braking or steering manoeuvres.

• Avoid sudden speed changes, such as braking, acceleration, changes in travel direction.

• Travel up or down grades perpendicular (at right angles) to the slope.

• Special care must be taken when driving through narrow passages - drive slowly!

In material handling operation: • Wheel model: Before moving (turning) the uppercarriage from transport position, the machine must be supported on outriggers and horizontally aligned.

• Make sure to check the placement surface of the outriggers (load carrying capacity of ground). Sinking of an outrigger below ground level would result in devastating consequences!

• Carry out all movements with increased caution.

• When swinging a load, first bring the attachment as low and close to the machine as practical. Note: be aware of the hazard of grapple swing when moving a load toward the operator cab.

• Avoid abrupt slow down or acceleration of the attachment or uppercarriage.

• Never lift a heavier load than stated in the load chart.

3.4.1.4

Additional notes for machines with fixed cab raiser – To enter and exit the machine, park the machine on level ground. Position the uppercarriage to the undercarriage in such a way that the steps and ladders are aligned.

– When entering or leaving the machine, always face the machine and use the three points of contact with the machine.

– When you can reach the door handle with your free hand, open the door first before climbing higher. Note that factors such as wind, can make it more difficult to open the door. For that reason, always guide the door by hand when opening the door. Make sure that the door is properly latched open.

– Continue to climb up and immediately sit on the operator’s seat in the cab. Then close the door and fasten the safety belt.

– Proceed with the same care when exiting and climbing down as when entering and climbing up the machine.

– Park the machine only on firm and level ground. Position the uppercarriage to the undercarriage in such a way that the steps and ladders are aligned.

– Release the safety belt. When exiting, face the machine and use the three-point support. Climb down until you can close the door safely. Always guide the door by hand when closing the door.

– Finally climb down to the ground.

3.4.1.5

Protection from vibrations – The vibration impact on mobile construction machinery is usually the result of the manner of utilization. Especially the following parameters have a significant influence: • Terrain conditions: Unevenness and potholes; • Operating techniques: Speed, steering, braking, control of operating elements

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of the machine during travel as well as working.

– The machine operator determines the vibration impact to a great part, since he himself selects the speed, the gear ratio, the working manner and the travel route.

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

The full body vibration impact for the machine operator can be reduced if the following recommendations are observed: – Select the appropriate machine, equipment parts and auxiliary devices for the corresponding tasks.

– Keep the seat in good order and adjust it as follows: • The seat adjustment and the suspension should be made according to the weight and the size of the operator.

• Check the suspension and the adjustment mechanism regularly and make sure that the characteristics of the seat remain as specified by the seat manufacturer.

– Check the maintenance condition of the machine, especially regarding: Tire pressure, brakes, steering, mechanical connections, etc.

– Do not steer, brake, accelerate and shift or move and load the attachment of the machine in a jerky manner.

– Match the machine speed to the travel route to avoid vibration impacts.

• Decrease the speed when driving on pathless terrain; • Drive around obstacles and avoid very impassable terrain.

– Keep the quality of the terrain where the machine is working and travelling in good order: • Remove large rocks and obstacles; • Fill furrows and holes; • To establish and retain suitable terrain conditions, keep machines available and allow for sufficient time.

– Travel longer distances (i.e. on public roads) with suitable (medium) speed.

– For machines, which are frequently used for travel, consider use of auxiliary ride control systems, and also monitor speed to minimize buildup of "pitching" vehicle movement.

3.4.2

Low idle automatic The idle automatic function automatically reduces the engine speed without actuation of the joystick or the travel pedal. This helps save fuel and reduces the noise level. By touching the joystick or the pedals, the engine speed returns to the initial level.

This function is activated with the low idle automatic button: Press the button.

The idle automatic is activated.

The indicator light in the switch flashes.

Press the button again.

The idle automatic is deactivated.

The indicator light in the switch is off.

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3.4.3

Swivelling uppercarriage Caution!

All machines are equipped with the PCSA control as standard.

On special request, the machine can be fitted with a different control system (e.g.

LIEBHERR control). For such machines, observe the instructions in the respective separate operating manual.

The joystick functions described here apply only to the PCSA control.

The uppercarriage is swivelled by means of the left joystick.

Fig. 3-60

Swivelling uppercarriage

Move the joystick to the left c.

The uppercarriage is swivelled to the left.

Move the joystick to the right d.

The uppercarriage is swivelled to the right.

If required, also adjust the sensitivity of the slewing gear (see chapter "Display", Torque Slew menu):

Fig. 3-61

3.4.4

Torque Slew menu

Halting uppercarriage The uppercarriage can be hydraulically slowed down in its movement and halted.

The mechanical slewing gear brake allows the operator to secure the uppercarriage in any desired position.

Applying hydraulic brake: Move the left joystick 4 to its neutral position.

The uppercarriage is slowed down hydraulically.

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Move the left joystick 4 in the opposite direction.

The uppercarriage is stopped with the maximum hydraulic force.

Mechanical slewing gear brake: Caution!

The mechanical slewing gear brake might be damaged, if it is applied while the uppercarriage is moving.

Therefore apply the slewing gear brake only when the uppercarriage is standing still.

Press the switch S17.

Slewing gear brake is applied.

The LED in the switch is on.

Press the switch S17 again.

Slewing gear brake is released.

The LED indicator in the switch is off.

Checking of the mechanical slewing gear brake: Ensure that the uppercarriage is standing still.

Press the switch S17.

Slewing gear brake is applied.

The LED in the switch is on.

Move the left joystick 4 to the right and then to the left stop.

The uppercarriage must not move.

The slewing gear brake is working properly.

Positioning slewing brake (optional equipment): The positioning slewing brake is used for the progressive and precise slowing down of the uppercarriage.

Fig. 3-62

positioning slewing brake

Note!

Increased wear.

Do not use the positing slewing brake as a working brake, but only for special halting and parking manoeuvres of the slewing gear.

The uppercarriage should normally be stopped with the hydraulic brake.

Actuate the pedal 10; if required, carefully slow down the uppercarriage.

The uppercarriage is held in the desired position.

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Control, operation

Operating manual

Working with the machine

3.4.5

Working position

Fig. 3-63

Working position of the machine

If possible, all work with the machine should be carried out through the idler.

3.4.6

Operating the working attachment

Fig. 3-64

Operating the working attachment

Caution!

The machine is equipped with PCSA controls as standard.

On request, the machine can be fitted with a different control system (e.g.

LIEBHERR control). For such machines, observe the instructions in the respective separate operating manual.

The left joystick (1) controls the stick and swivelling movements: – Movement in direction a and b: Stick is extended or retracted.

– Movement in direction c and d: Uppercarriage is swivelled to the left or right.

The right joystick (2) controls the boom and grapple movements: – Movement in direction e and f: Grapple is closed or opened.

– Movement in direction g and h: Boom is lifted or lowered.

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MJFCIFSS

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Operating manual

Control, operation Working with the machine

Moving the stick: The stick is moved by operating the left joystick 1.

Push the joystick back a: Stick moves in direction a.

Push the joystick forward b.

Stick moves in direction b.

Moving the boom: The boom is moved by operating the right joystick 2.

Push the joystick back g: Boom is lifted.

Push the joystick forward h: Boom is lowered.

Operating the grapple: Danger Risk of accident!

It is strictly forbidden to guide the tool attachment by hand.

Move the joystick to the left e: Grapple is closed.

Move the joystick to the right f: Grapple is opened.

Operating tilting system (optional equipment)

Fig. 3-65

Operating tilting system

The tilting system of the industrial stick is operated with the right joystick 2.

Move the joystick to the left e: The working tool is tilted inwards.

Move the joystick to the right f: The working tool is tilted outwards.

Combined movements: Diagonal movement of a joystick results in a combination of the associated working movements. Operators can thus complete different attachment movements simultaneously.

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Control, operation

Operating manual

Working with the machine

3.4.7

Lowering the working attachment when diesel engine is shut off

Fig. 3-66

Lowering attachment when the diesel engine is off

In the event of an emergency, the attachment can be lowered even if the diesel engine is not running.

Turn the ignition key to contact position 1.

Operate the joysticks or pedals until the attachment is fully lowered.

Note The attachment is lowered with the residual pressure in the control oil unit. This reserve is however limited and allows only for a limited number of operations of the pilot control units.

Therefore only use the joysticks to lower the attachment and do not attempt to complete other movements.

3.4.8

Swivelling uppercarriage Caution!

All machines are equipped with the PCSA control as standard.

On special request, the machine can be fitted with a different control system (e.g.

LIEBHERR control). For such machines, observe the instructions in the respective separate operating manual.

The joystick functions described here apply only to the PCSA control.

The uppercarriage is swivelled by means of the left joystick.

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Operating manual

Control, operation Working with the machine

Fig. 3-67

Swivelling uppercarriage

Move the joystick to the left c.

The uppercarriage is swivelled to the left.

Move the joystick to the right d.

The uppercarriage is swivelled to the right.

If required, also adjust the sensitivity of the slewing gear (see chapter "Display", Torque Slew menu):

Fig. 3-68

3.4.9

Torque Slew menu

Halting uppercarriage The uppercarriage can be hydraulically slowed down in its movement and halted.

The mechanical slewing gear brake allows the operator to secure the uppercarriage in any desired position.

Applying hydraulic brake: Move the left joystick 4 to its neutral position.

The uppercarriage is slowed down hydraulically.

Move the left joystick 4 in the opposite direction.

The uppercarriage is stopped with the maximum hydraulic force.

Mechanical slewing gear brake: Caution!

The mechanical slewing gear brake might be damaged, if it is applied while the uppercarriage is moving.

Therefore apply the slewing gear brake only when the uppercarriage is standing still.

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Control, operation

Operating manual

Working with the machine

Press the switch S17.

Slewing gear brake is applied.

The LED in the switch is on.

Press the switch S17 again.

Slewing gear brake is released.

The LED indicator in the switch is off.

Checking of the mechanical slewing gear brake: Ensure that the uppercarriage is standing still.

Press the switch S17.

Slewing gear brake is applied.

The LED in the switch is on.

Move the left joystick 4 to the right and then to the left stop.

The uppercarriage must not move.

The slewing gear brake is working properly.

Positioning slewing brake (optional equipment): The positioning slewing brake is used for the progressive and precise slowing down of the uppercarriage.

Fig. 3-69

positioning slewing brake

Note!

Increased wear.

Do not use the positing slewing brake as a working brake, but only for special halting and parking manoeuvres of the slewing gear.

The uppercarriage should normally be stopped with the hydraulic brake.

Actuate the pedal 10; if required, carefully slow down the uppercarriage.

The uppercarriage is held in the desired position.

3.4.10

Adjustment of tool attachment The machine can operate a range of tool attachments (additional consumers) with various pressure and flow rate settings. The respective selections are made in the operator's menu (see "Tool Control" menu).

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Operating manual

Control, operation Working with the machine

Caution!

If an incorrect operating mode is chosen, the tool attachment might be damaged or its functions might be restricted.

Make sure that you have all the necessary information regarding the technical data of the tool attachment.

Use the tool attachment exclusively with the prescribed settings (Tool option).

In the operator's menu, select the pressure and flow settings required for the tool attachment you wish to operate (see chapter "Tool option").

3.4.11 A

Operation of attachment (optional equipment) Caution!

Incorrect pressure or flow reduction preselections may result in damage to the attachment (e.g. hydraulic hammer) or restricted functionality (e.g. boom regulating cylinder).

Danger!

If a large or wide tool attachment (e.g. grapple) is swung near the operator's cab, it might collide with the cab or even break through it, causing danger to the machine operator.

Fig. 3-70

Operation of tool attachment

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Control, operation

Operating manual

Working with the machine

Fig. 3-71

Tool Option menu

Select the pressure and flow settings required for the respective tool attachment on the display (see chapter "Display", Tool Option menu).

Press the switch S241 to activate the tool attachment: Press the switch S241 down.

The tool attachment is activated.

The indicator light in the switch is on.

Press the foot pedal k down.

The scrap shears or the sorting grapple are closed.

- alternatively The hydraulic hammer is actuated.

Press the foot pedal m down.

The scrap shears or the sorting grapple are opened.

Press the switch S241 up.

The tool attachment is deactivated.

The indicator light in the switch is off.

When the tool attachment is operated, a separate symbol (black dot) is shown beside the selected option (see Fig. 3-71).

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Operating manual

Control, operation Working with the machine

3.4.12

Changeover of the control system (optional equipment)

Fig. 3-72

Changeover of the control system

On request, the machine can be equipped with a changeover unit of the control system kit. With this unit, it is possible to change the "tilt cylinder actuation" (e and f) over to the actuation of the tool (m and k).

Select the pressure and flow settings required for the respective tool on the display (see chapter "Display", Tool Control menu).

Changing over control: To change over, turn the key switch S405.

Turn the key switch S405 to position 1.

The indicator light H322 is on.

The control functions are changed over.

Turn the key switch S405 back to position 0.

The indicator light H322 is off.

The control system is changed back to its initial function.

Function

S405 off (0)

S405 on (1)

Bucket tilt function / grapple

e+f

m+k

Working tool

m+k

e+f

Tab. 3-2

Changeover of the control system

Operate working tool and bucket tilt function (grapple) according to the chosen changeover.

Note!

The switchover is only available for working tools, the bucket tilt function and the grapple. The boom is still operated by means of the pedals m and k.

Y268 on/off

Fig. 3-73

Y268 on/off menu

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Control, operation

Operating manual

Working with the machine

Use this menu to activate the pedals for boom adjustment while an attachment (e.g. mower rake) is operated.

Setting values: For a description, see chapter "Operator's menu", submenu "Y268 on/off".

3.4.13

Operating attachment tool (mini joystick control, optional equipment) Danger!

The working attachment can cause serious or even fatal injury to persons.

Ensure that no persons are standing inside the danger zone of the machine.

It is strictly forbidden to guide the attachment tool by hand.

Danger!

If a large or wide attachment tool (e.g. grapple) is swivelled towards the operator's cab, it might collide with the cab or even break through it, causing danger to the machine operator.

Always keep a safe distance between the moving attachment tool and the operator's cab.

3.4.13.1

Working functions

Fig. 3-74

Mini joystick, operating attachment tool

The working functions of the attachment tool are controlled by means of a mini joystick located on the right joystick.

The further the mini joystick is moved in a particular direction, the faster the attachment tool is moved.

In this control mode, it is not necessary to activate the attachment tool with a separate switch as these functions are automatically activated when the servo control is switched on.

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Operating manual

Control, operation Working with the machine

Example: hydraulic hammer Push the mini joystick to the left 1.

The hydraulic hammer is operated.

Example: sorting grapple, scrap shears Push the mini joystick to the left 1.

The attachment tool closes.

Push the mini joystick to the right 2.

The attachment tool opens.

3.4.13.2

Rotating and adjusting

Fig. 3-75

Rotation and adjustment of attachment tool by means of mini joystick

1 2

Rotator (e.g. for rotating grapple) Lock bolts of a hydraulic quick-change adapter system

3

Swivelling ditch cleaning bucket

L/R

Direction of movement

The mini joystick on the left joystick is used to rotate or change the attachment tool.

The rotating function corresponds to the "rotate grapple" function used for grapples and other attachment tools.

The further the mini joystick is moved in a particular direction, the faster the attachment tool is moved.

In this control mode, it is not necessary to activate the attachment tool with a separate switch. as these functions are automatically activated when the servo control is switched on.

Push mini joystick to the left L. The attachment tool turns (swivels) to the left.

The lock bolts are extended.

Push the mini joystick to the right R. The attachment tool turns (swivels) to the right.

The lock bolts are retracted.

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Control, operation

Operating manual

Working with the machine

3.4.14

Changeover of joystick control (optional equipment)

Fig. 3-76

Changeover of control

Depending on the selected mode, the attachment tool is operated with the mini joystick (movement 1 and 2) or with the joystick (movement e and f).

To change from one control mode to the other, turn the key switch S405 in the right control console.

Turn the key switch S405 to position 1.

The indicator light H322 is on.

Control changeover is activated.

Turn the key switch S405 back to position 0.

The indicator light H322 is off.

Control changeover is deactivated.

If the control is changed over, the tilting system is disabled.

Function

Changeover off (0)

on (1)

Tilting system

e+f

-

Attachment tool

1+2

e+f

Operate the attachment tool according to the current control mode.

3.4.15

Super Finish (optional equipment) With the Super Finish function, the movement of the attachment can be slowed down, so that tasks can be carried out with greater precision. This is achieved by a flow reduction, which slows down the movement of the machine proportionally.

Super Finish (SF) can be activated by means of the rocker switch S382 in the left joystick.

Press the rocker switch down.

Super Finish is activated.

The Super Finish (SF) indicator light is on.

Operate the attachment and check the working speed.

Press the rocker switch up.

Super Finish is deactivated.

The Super Finish (SF) indicator light is off.

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Operating manual

Control, operation Working with the machine

Adjust the flow Super Finish settings, if necessary (see chapter "Operator’s menu", SF-Flow menu).

3.4.16

Attachments in continuous operation (optional equipment) This function allows for the operation of an attachment (e.g. mower rake). The function must first be activated.

Fig. 3-77

Operating elements for continuous mode operation

Preselecting continuous operation: The continuous mode is preselected with the switch S124.

The working tool must be activated (S241), and servo control (S35) must be switched on.

Press the switch S124.

The indicator light in the switch is on.

Continuous mode is now preselected.

Switching attachment on/off: Continuous mode is activated/deactivated at the left joystick.

Press the rocker switch S451 down.

The indicator light H329 is on.

The attachment is switched on (in continuous mode).

Press the rocker switch S451 down.

The indicator light H329 is off.

The attachment is switched off.

Continuous operating mode is also switched off in the following cases: – Servo control S35 is switched off.

– The safety lever is moved up.

– The working tool is deactivated (switch S241 off).

– The ignition is switched off.

Deactivating continuous mode: To terminate continuous mode operation, press the switch S124.

The indicator light in the switch is off.

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Control, operation

Operating manual

Working with the machine

Y268 on/off

Fig. 3-78

Y268 on/off menu

Use this menu to activate the pedals for boom adjustment while an attachment (e.g. mower rake) is operated.

Setting values: For a description, see chapter "Operator's menu", submenu "Y268 on/off".

Modified operation of Super Finish (optional equipment) With the Super Finish function, the movement of the attachment can be slowed down, so that tasks can be carried out with greater precision. This is achieved by a flow reduction, which slows down the movement of the machine proportionally.

Press the switch S382 down.

Super Finish is activated.

The Super Finish (SF) indicator light is on.

Operate the attachment and check the working speed.

Press the switch S382 up.

Super Finish is deactivated.

The Super Finish (SF) indicator light is off.

Adjust the flow reduction settings, if necessary (see chapter "Operator's menu", SFFlow menu).

3.4.17

Stroke limitation (optional equipment) The stroke limitation determines the maximum permissible working height of the working attachment. Stroke limitation might be required on sites where the vertical working area is restricted by obstacles (e.g. overhead power lines).

When activated, the stroke limitation function stops the upward movement of the working attachment as soon as the maximum permissible working height is reached.

The maximum permissible working height can only be set correctly in connection with a LIEBHERR attachment whose factory settings are correct. After a change or adjustment to the LIEBHERR working equipment, the stroke limitation settings must be re-adjusted by LIEBHERR. If the machine has been moved to a new location, the stroke limitation settings must be checked and adjusted, if necessary.

Danger!

The stroke limitation is an auxiliary tool designed to assist the machine operator!

For functional reasons, the working attachment cannot be brought to a sudden stop.

The faster it is moved, the longer its braking distance. Risk of accident!

Please note that the machine operator is responsible for the correct adjustment of the relevant settings!

Avoid fast movements of the working attachment when it is operated near the maximum permissible working height.

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Operating manual

Control, operation Working with the machine

Setting stroke limitation: For a description, see chapter "Operator's menu", submenu "hbg max point".

Application of stroke limitation:

Fig. 3-79

Operating elements of the stroke limitation function

Park the machine on level ground.

Turn the key switch S249 to position 0.

The stroke limitation function is activated.

The following operating statuses are indicated on the display: S249

Display

Operating status

0

Stroke limitation on The stroke limitation function is activated.

The working tool can only be lifted to the maximum permissible working height.

0

Stroke limitation, preliminary shut-down The preliminary shut-down function slows down the upward movement of the working attachment before the maximum permissible working height is reached (indicator light H159 on).

0

Stroke limitation, shut-down The shut-down point of the maximum permissible working height is reached.

0

Stroke limitation overridden The stroke limitation function is overridden so that the working attachment can be moved without restrictions.

Tab. 3-3

Operating status - display

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Control, operation

Operating manual

Working with the machine

Overriding stroke limitation: Danger!

Risk of injury and damage to equipment!

If the stroke limitation function is overridden, there is a risk of serious damage and injury, as the equipment might collide with another object.

When overriding the limitation function, operate the machine with extreme caution.

Press the switch S291.

The stroke limitation function is temporarily overridden.

After the switch has been pressed, the equipment can be moved for 10 seconds to a height above the shut-down point.

The stroke limitation is automatically reactivated and the switch must be pressed again, – if the attachment is moved back to the permissible operating range – after a 10-second period has lapsed

3.4.18 3.4.18.1

Stick cylinder shut-off function (optional equipment) Operating principle When the boom is moved, it can reach great heights and outreaches. The stick with attached load might collide with the operator's cab or impact on other objects.

There is even a risk of collision with the operator's cab or the object, which would likely result in injury to the operator, and damage to equipment or the attached load.

In order to assist the machine operator, the range of movement of the stick is limited by the electronic stick cylinder shut-off function.

This means that the stick can only be moved within a preset angle range (defined by a minimum and a maximum angle). The reach of the attachment thus depends on the stick cylinder shut-off point and the angle of the boom.

3.4.18.2

Use of stick cylinder shut-off function If the stick is to be moved beyond the shut-off limit, the stick shut-off function can be overridden.

If the machine is to be operated with movement limitation, the stick cylinder shut-off must be set to the maximum values.

The stick cylinder shut-off function – is always activated during operation – cannot be switched off – can only be overridden for short periods of time Danger!

The electronic stick cylinder shut-off function is not a safety device in the narrow sense of the word and serves only as a utility for the machine operator!

Please note that the machine operator is responsible for the adjustment of the relevant settings!

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Operating manual

Control, operation Working with the machine

Danger!

Despite the stick cylinder shut-off function, there remains a risk of damage to the operator's cab and objects in the vicinity of the machine. The machine might vibrate or swing! Risk of accident!

Possible causes: – Oscillation of the working tool such as a grapple swinging from its stick, or where the size of a working tool is considerably increased when it is opened.

– Delayed shut-off. The shut-off travel might be extended by up to 0.5 m, depending on the oil temperature and the type of attached working tool. Under certain conditions, it might even be extended by up to 1.0 m (depending on the retracting speed and the grapple content).

– Jerking shut-off.

Adjust the stick cylinder shut-off so that there is a sufficient safety distance, even if the working tool is oscillating or if the shut-off is delayed.

Avoid fast movements of the stick when it is moved near the shut-off limits.

The following operating statuses are indicated on the display: Display

Operating status Shut-off point reached when stick is being retracted.

Shut-off point overridden during stick retraction.

Shut-off point for stick extension reached *).

Shut-off point overridden during stick extension *).

*)

Special equipment: The movement range of the stick can also be restricted when it is extended.

Tab. 3-4

3.4.18.3

Operating status - display

Overriding stick cylinder shut-off function Danger!

Risk of injury and damage to equipment!

While the stick cylinder shut-off function is overridden, there is a risk that the attachment might collide with the operator's cab.

When overriding the stick cylinder shut-off function, operate the machine with extreme caution.

After the stick shut-off function has stopped the movement of the stick: The stick cylinder shut-off function can be overridden by pressing the switch S216.

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Control, operation

Operating manual

Working with the machine

Press the switch S216.

The indicator light in the switch is on.

The stick cylinder shut-off function is overridden. The buzzer (warning signal) sounds.

For the next 10 seconds, the stick can be moved across the limits of the shutoff function.

Display:

Carefully move the stick beyond the shut-off point into the danger range.

The buzzer is automatically switched off as soon as the stick is again within the permissible working range.

The stick cylinder shut-off function is automatically reactivated after 10 seconds.

Press the switch S216 again, – to move the attachment back to the permissible operating range – after the 10-second period has lapsed

3.4.18.4

Adjusting the stick cylinder shut-off function Adjust the settings according to the respective equipment: 1. Mechanical stick cylinder shut-off function 2. Electronic stick cylinder shut-off function

1. Adjusting mechanical stick shut-off function

Fig. 3-80

Shut-off point

Move the elevating operator's cab (optional equipment) to its most forward extended position (see Fig. 3-80).

Move the attachment (boom) to its highest position.

Carefully retract the stick with the respective attachment (e.g. grapple) to the desired position.

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Operating manual

Control, operation Installation and removal of attachment parts

Fig. 3-81

Setting shut-off point

Loosen the screws 1.

Move the limit switch 2 at the elongated hole until the outer edge 3 of the boom intersects the voltage field of the limit switch.

Tighten the screws 1.

Test the stick cylinder shut-off function.

2. Adjusting electronic stick shut-off function Adjusting values: For a description, see chapter "Display and operator's menu", submenu "stick limit".

3.5 Installation and removal of attachment parts 3.5.1 3.5.1.1

Safety Instructions Installation and removal of attachment parts – Equipment and attachment parts made by other manufacturers or those which do not have LIEBHERR’s general approval for installation may not be installed on the machine without prior written approval by LIEBHERR. LIEBHERR must be provided with the required technical documentation necessary for this purpose.

– Set the machine on a level and stable ground prior to any work with attachments.

– Lock the uppercarriage with the locking pin to the undercarriage.

– Do not position yourself under a raised attachment that has not been adequately and securely supported.

– Never place yourself under a machine while it is elevated.

– Remove hydraulic system pressure before working on any attachments (as described in this operating manual).

– Do not attempt to lift heavy parts. Use suitable lifting devices with sufficient load carrying capacity.

– Insure any lifting system or lifting device that is used is in good repair and adequately rated for the component or machine to be supported. Always wear work gloves when handling wire cables.

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Control, operation

Operating manual

Installation and removal of attachment parts

– When working on the equipment: Switch off the diesel engine, remove the key and turn the safety lever upward.

– During repairs: Make sure that the hydraulic lines are properly attached and that all fittings and connections are properly tightened.

– As soon as an attachment part is removed and supported, cover or cap the openings in the hydraulic circuit to prevent dirt infiltration. Permit only authorized persons near the machine or the lifting device.

3.5.1.2

Removal and installation of attachment pins – Never use your fingers to align pin bores. If possible, always use a hydraulic pin pulling device to push out the pins on the attachment.

– If pins must be removed with a sledge hammer, use a punch and a guide tube held by another person.

– To drive out a pin, install the impact screw from the tool box in the threaded bore of the pin and hit the screw only.

– For the installation of a pin retained with castle nut and cotter pin, drive the pin in first to the stop, then install the castle nut by hand until contact and tighten it only to the point where the cotter pin can be installed.

3.5.2

Installation and removal of digging tool

Fig. 3-82

Installation and removal of digging tools

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Operating manual

Control, operation Installation and removal of attachment parts

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

3.5.2.1

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

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

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

3.5.2.2

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

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

Guide in pin 4 and secure it with plate 6.

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

Guide in pin 3 and secure it with plate 5.

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

3.5.2.3

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

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

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

Note!

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

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Control, operation

Operating manual

Installation and removal of attachment parts

3.5.3

Attachment of grapple to bucket stick

Fig. 3-83

Attaching grapple to bucket stick

Danger!

Risk of injury Ensure that the machine operator follows the instructions of the instructor when moving the equipment.

Two workers are required to attach or remove the grapple.

3.5.3.1

Attaching grapple Before attaching a clamshell grab or multiple grab, ensure that the necessary hydraulic lines for grapple operation are mounted to the bucket stick.

The grapple must be in a stable position (grabs fully opened).

If necessary, dismantle the digging bucket.

Move the attachment in order to position the bucket stick between the bearing points of the grapple suspension 1.

Insert the bolts 2 and secure them with the plate 3.

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Operating manual

Control, operation Installation and removal of attachment parts

Caution!

The hydraulic lines are under pressure.

Before connecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick and press the buttons of the "Rotate grapple" function).

Move the safety lever up.

Connect the hydraulic hoses 4 and 5 (for the supply of the grab cylinders) to the pipelines.

For grapples with hydraulic rotator, also connect the hydraulic hoses 6 and 7 to the pipelines for this auxiliary equipment.

3.5.3.2

Attachment of connecting link

Fig. 3-84

Securing of connecting link

After the grapple has been removed, secure the connecting link 1. There are various ways to do this (depending on the machine equipment).

Fully retract the bucket tilt cylinder 6.

Attach the holder 5 to the change lever 2.

Insert the securing device 3 in the connecting link 1 and mount it to the holder 5.

Insert securing plugs 4 on both sides.

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3.5.3.3

Changeover to grapple operation

Fig. 3-85

Valve block for tilt cylinder operation / grapple operation

Two hydraulic lines on the bucket stick are used for the operation of the tilt cylinder or the grapple.

The lines are switchable by means of a valve block: – a - Tilt cylinder operation (for digging buckets) – b - Grapple operation (for grapples, scrap shears, etc.)

Note If the machine is equipped with a quick-change adapter and LIKUFIX, there is no need for this changeover. The valve block is therefore omitted.

Turn the two square head screws on the valve block until the marks are aligned in the direction of travel (position b, grapple operation).

Complete all working movements several times without load (opening and closing grapple, moving grapple to the right and left) in order to let any trapped air escape from the hydraulic circuits.

3.5.3.4

Removing grapple If necessary, remove the securing device 3 from the connecting link.

Fully open the grabs and place the grapple in a vertical position on level ground.

Caution!

The hydraulic lines are under pressure.

Before disconnecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick and press the buttons of the "Rotate grapple" function).

Move the safety lever up.

Disconnect the hydraulic hoses from the pipelines on the bucket stick.

Immediately seal open lines to prevent dirt from entering the system.

Prop up the grapple to ensure that it cannot topple over.

Unscrew the plate 3 and carefully drive out the bolt 2. To do this, you might have to start the diesel engine and lift the attachment slightly from the ground.

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3.5.4

Installation and removal of grapple on industrial stick

Fig. 3-86

Installation and removal of grapple on industrial stick

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

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

Danger!

Danger of injury.

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

3.5.4.1

Installing the grapple Position the grapple with the fully opened shells.

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

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Guide in pin 4 and secure it with plate 6.

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

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

3.5.4.2

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

3.5.4.3

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

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

To relieve the grapple rotator press the two push buttons in the left (or left and right – option) joystick for “Rotate grapple”.

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

Close off open lines immediately to prevent dirt infiltration.

Support the grapple so that it is stable.

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

3.5.5 3.5.5.1

Multi-coupling system (optional equipment) Overview

Fig. 3-87

Overview

1

Stick

2

Coupling

3

Hand lever

4

Locking mechanism

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5

Securing mechanism

6

Protective cover

7

Coupling plate of working tool

8

Multi-function lever

9

Pressure release device

The multi-coupling system allows you to connect and disconnect several hydraulic lines at the same time. The working tool can thus be quickly connected to the stick.

Fig. 3-88

Securing mechanism

A safety pin retains the locking lever, thus preventing inadvertent opening of the coupling. The coupling is properly secured when the safety pin is engaged. The locking lever is only released by the safety pin after the pressure has been fully released. The coupling can then be opened.

3.5.5.2

Pressure release device

Fig. 3-89

Pressure release device of the coupling

Caution!

The hydraulic lines are under pressure! The hand lever could thus be moved back with force, causing injury to the operator.

Before connecting/disconnecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick and press the buttons of the "Rotate grapple" function).

Open the pressure release device of the coupling.

The pressure release device of the coupling is operated with the multi-function lever from the toolbox.

Attach the multi-function lever and turn it as follows: A = Pressure release device closed (operation)

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B = Pressure release device open (opening/closing coupling)

3.5.5.3

Working tool

Fig. 3-90

Positioning grapple

When opening or closing the coupling, ensure that the working tool is in a stable position. The grapple must be positioned between the machine and the stick (see Fig. 3-90). This allows for better access to the coupling.

Before connecting the coupling, attach the working tool to the machine (see respective chapter).

Remove the working tool from the machine only when the coupling has been opened.

Check the coupling parts for dirt and clean them if necessary with a clean oilsoaked cloth.

After connection with the coupling, test the working tool functions.

3.5.5.4

Opening coupling

Fig. 3-91

Opening pressure release device, releasing locking mechanism and moving hand lever down

Complete pressure release from the machine (joystick).

Attach the multi-function lever and open the pressure release device of the coupling.

Pull the locking mechanism upwards and move the hand lever down.

The coupling is opened.

Pull out the coupling plate (or protective cover).

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3.5.5.5

Closing coupling

Fig. 3-92

Inserting the coupling plate, moving hand lever up and closing pressure release device

Fully insert the coupling plate (or protective cover) in the coupling to the stop.

Move the hand lever up.

The coupling is closed, and the lines are connected.

Ensure that the safety pin is engaged.

Close the pressure release device of the coupling.

Remove the multi-function lever.

3.5.6

Mechanical quick-change adapter (optional equipment) The mechanical quick-change adapter allows for the fast and easy exchange of working tools.

3.5.6.1

Safety information – First familiarise yourself with the functions and operation of the quick-change adapter (without attached working tools).

– Before locking or releasing the quick-change adapter, tilt the safety lever upwards.

– Ensure that the working tool cannot be moved by a third party while you carry out this task.

– When attaching and removing working tools, ensure that no persons are located in the working area of the tool.

– During mounting and removing, move the working tool only at minimum speed, and only if absolutely necessary.

– Position the working tool as little above the ground as is necessary before starting the locking or release procedure, in order to avoid dangerous movements.

– If required, use a pedestal or working platform to reach the locking bolts and connections. Do not stand on the working tool.

– Check the locking screw every day to ensure that it is properly tightened. In addition to the above check, carry out a dummy run with the working tool: Tilt the working tool in and out (without load), lifting it only as far as this is necessary to check proper connection (e.g. pin in bolt eye).

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– The lifting capacity of the quick-change adapter or the integrated load lift hook might be greater or smaller than that of the basic machine. Always observe the load capacity values of the machine.

3.5.6.2

Overview

Fig. 3-93

3.5.6.3

Mechanical quick-change adapter

1

Locking bolt (extended)

2

Locking screw

3 5

Crank Load lift hook

4

Mounting hook for working tool

Releasing and locking

Fig. 3-94

Releasing and locking

Turn the locking screw anticlockwise and remove it (A).

Insert the crank into the locking bolt and turn it anticlockwise until both locking bolts are inserted to the stop (B).

The quick-change adapter is released.

Remove or attach the working tool.

Insert the crank into the locking bolt and turn it clockwise until both locking bolts are screwed out to the stop (C).

The quick-change adapter is locked.

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Turn the locking screw clockwise (D).

The quick-change adapter is secured.

3.5.6.4

Attaching working tool

Fig. 3-95

Positioning attachment

The working tool must be placed on the ground in a stable position.

Position the stick and the working tool.

Fully retract the bucket tilt cylinder.

Screw out locking screw.

Release the quick-change adapter.

Fig. 3-96

Taking up working tool, step 1

Position the quick-change adapter in such a way that the working tool can be taken up with the mounting hooks.

Fig. 3-97

Taking up working tool, step 2

Lift the working tool a little from the ground and fully extend the bucket tilt cylinder until the bearing plate of the working tool touches the stop of the quick-change adapter.

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The bores of the quick-change adapter and the working tool must be properly aligned.

Danger!

Prior to locking, there is no secured connection between the working tool and the quick-change adapter. The working tool might become dislodged and cause serious injury.

Approach the quick-change adapter with great care.

Position the working tool as little above the ground as is necessary before starting the locking procedure, in order to avoid dangerous movements.

Lock the quick-change adapter.

Screw in the locking screw.

Caution!

The hydraulic lines are under pressure.

Before connecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick).

Connect all hydraulic or electrical lines (e.g. for the attachment of a grapple).

The safe mounting of the working tool must be checked with a proper visual inspection.

3.5.6.5

Dismantling working tool The working tool must be in a stable position.

If the working tool (e.g. grapple) cannot be placed in an upright position, it must be removed in a horizontal position.

Caution!

The hydraulic lines are under pressure.

Before disconnecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick).

Disconnect all hydraulic or electrical lines to the working tool (e.g. for the removal of a grapple).

Fully extract the bucket tilt cylinder.

Place the working tool in a slightly elevated position from the ground.

Fig. 3-98

Aligning working tool for release

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Danger!

Risk of injury!

After the working tool is released, it is fully disconnected from the machine. The working tool might become dislodged and cause serious injury.

Approach the quick-change adapter with great care.

Position the working tool as little above the ground as is necessary before starting the release procedure, in order to avoid dangerous movements.

Screw out locking screw.

Release the quick-change adapter.

Fig. 3-99

Placing the working tool on the ground

Slowly retract the bucket tilt cylinder and lower the working tool to the ground.

Move the attachment away from the working tool.

3.5.7

Hydraulic quick-change adapter (optional equipment) The hydraulic quick-change adapter allows for the fast and efficient exchange of working tools without having to leave the operator's cab.

When operated in conjunction with the LIKUFIX quick-coupling system (optional equipment), the connecting lines are automatically connected and disconnected.

3.5.7.1

Safety information – First familiarise yourself with the functions and operation of the quick-change adapter (without attached working tools).

– When attaching and removing working tools, ensure that no persons are located in the working area of the tool.

– During mounting and removing, move the working tool only at minimum speed, and only if absolutely necessary.

– Position the working tool as little above the ground as is necessary before starting the locking or release procedure, in order to avoid dangerous movements.

– If the buzzer and the "quick-change adapter" icon are on, when you are not carrying out an intended locking or release procedure, immediately shut down the machine. If these indicating elements are not on when you are carrying out an intended locking or release procedure, immediately stop the procedure.

The alarm signals can be triggered if a locking pin has inadvertently become dislodged, or if a mechanical, hydraulic or electrical fault occurs. Only resume operation after the defective part has been repaired or replaced.

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– Check the working tool every day to ensure that it is properly secured. In addition to the above check, carry out a dummy run with the working tool: Tilt the working tool in and out (without load), lifting it only as far as this is necessary to check proper connection (e.g. pin in bolt eye).

– The lifting capacity of the quick-change adapter or the integrated load lift hook might be greater or smaller than that of the basic machine. Always observe the load capacity values of the machine.

– Switch on the magnet system (optional equipment) while attaching or removing the working tool.

3.5.7.2

Overview

Fig. 3-100 Hydraulic quick change adapter

3.5.7.3

1

Locking bolt (extended)

3

Load lift hook

2

Mounting hook for working tool

Releasing and locking

Fig. 3-101 Control elements, releasing (R)

Fig. 3-102 Control elements, locking (L)

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S47 R

Push button / quick-coupling system Push button / release (lock pin is retracted)*

L

Push button / locking (lock pin is extended)*

For safety reasons, two control elements must be operated simultaneously to move the lock pin.

With one hand, press the button S47 and then press the button L or R with the other hand (two-hand control).

You can then release the button S47, and continue to operate the lock pin with the buttons L or R (holding function). *

Standard equipment; with other options of the "Rotate grapple" function (optional equipment), the operation can be carried out by means of the left or right joystick.

Releasing and locking:

Fig. 3-103 Overview of control elements The auxiliary function must be activated (switch S19).

Press and hold the button S47.

The quick-change adapter is activated.

Press and hold the right button R. The buzzer sounds.

The locking bolts are retracted.

The quick-change adapter is released.

Press and hold the left button L. The buzzer is off.

The lock bolts are extended.

The quick-change adapter is locked.

The quick-change adapter indicator light and the buzzer (warning signal) are on, indicating that the quick-change adapter has been released or is not properly locked.

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3.5.7.4

Attaching working tool

Fig. 3-104 Positioning attachment The working tool must be placed on the ground in a stable position.

Switch off the magnet system (if installed).

Position the stick and the working tool.

Fully retract the bucket tilt cylinder.

Release the quick-change adapter.

Release all buttons.

Fig. 3-105 Taking up working tool, step 1 Position the quick-change adapter in such a way that the working tool can be taken up with the mounting hooks.

Fig. 3-106 Taking up working tool, step 2 Lift the working tool a little from the ground and fully extend the bucket tilt cylinder until the bearing plate of the working tool touches the stop of the quick-change adapter.

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The bores of the quick-change adapter and the working tool must be properly aligned.

Danger!

Risk of injury!

Before the working tool is locked, the working tool and the adapter are not properly connected. The working tool might become dislodged and cause serious injury.

Position the working tool as little above the ground as is necessary before starting the locking procedure, in order to avoid dangerous movements.

Lock the quick-change adapter.

Release all buttons.

Caution!

The hydraulic lines are under pressure.

Before connecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick).

Connect all hydraulic or electrical lines (e.g. for the attachment of a grapple).

The safe mounting of the working tool must be checked with a proper visual inspection.

3.5.7.5

Dismantling working tool The working tool must be in a stable position.

If the working tool cannot be placed in an upright position, it must be removed in a lying position.

Switch off the magnet system (if installed).

Caution!

The hydraulic lines are under pressure.

Before disconnecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick).

Disconnect all hydraulic or electrical lines to the working tool (e.g. for the removal of a grapple).

Fully extract the bucket tilt cylinder.

Place the working tool in a slightly elevated position from the ground.

Fig. 3-107 Aligning working tool for release

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Danger!

Risk of injury!

After the working tool is released, it is fully disconnected from the machine. The working tool might become dislodged and cause serious injury.

Position the working tool as little above the ground as is necessary before starting the release procedure, in order to avoid dangerous movements.

Release the quick-change adapter.

Release all buttons.

Fig. 3-108 Placing the working tool on the ground Slowly retract the bucket tilt cylinder and lower the working tool to the ground.

Attach the other working tool.

- alternatively To switch off the buzzer, lock the quick-coupling system without attaching a working tool.

3.5.8

Hydraulic quick-change adapter with LIKUFIX (optional equipment) The LIKUFIX quick-coupling system allows for the fast and efficient exchange of working tools without having to leave the operator's cab. Hydraulic and electrical connections are thereby automatically disconnected and connected.

Fig. 3-109 Quick-change adapter with LIKUFIX

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1

Protective cover of quick change adapter

2

3

LIKUFIX hydraulic coupling at quick- 4 change adapter

Protective cover of working tool LIKUFIX hydraulic coupling at working tool

For mounting and dismantling instructions, see chapter "Hydraulic quick-change adapter". Please observe the following additional instructions: Before attaching the device, remove the protective covers.

Always keep the hydraulic couplings clean.

Before connecting the tool, check the connections for dirt. If necessary, clean all coupling parts and sealing surfaces with a clean cloth and oil.

When connecting or disconnecting the hydraulic coupling, proceed slowly and with the necessary care.

Tilt the quick change adapter at the attachment so that the coupling plates can easily be connected due to the weight of the working tool.

After completion of the work, and especially before transport, mount the protective covers.

Note!

If the hydraulic coupling cannot be easily connected to each by their own weight, check whether a foreign object (stone, etc.) is jammed between the parts. If this is the case, clean the coupling parts to prevent damage through subsequent coupling.

3.5.8.1

Acknowledging buzzer signal (warning signal) After the working tool has been removed, the buzzer (warning signal) sounds as long as the system is not locked.

If the overload warning system is switched on, the warning buzzer can be acknowledged.

If no working tool is to be mounted, it is useful to deactivate the warning signal. This is also recommended to ensure that another buzzer sound (i.e. from the overload warning system) is actually audible.

Press the switch S360.

The buzzer is switched off.

The "quick-change adapter" icon remains displayed.

Note!

The acoustic warning signal is automatically reactivated when the system is locked again.

In order to activate the warning buzzer, lock the system once.

The buzzer and warning sound are on at the next release process.

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3.6 General working methods 3.6.1

Tips for the proper operation of the machine preventing damage and wear In order to prolong the service life of the machine and to prevent avoidable damage, observe the following instructions: – Do not use the machine for work where its attachment is used to hammer against a hard material to remove it. Repeated impact of the working attachment against hard materials results in damage to the steel structure and the machine components.

– Under certain circumstances, where a particular type of boom, stick and working tool are combined, there is a risk that the tool collides with the operator's cab. This can result in damage to the operator's cab, and the operator might suffer injury.

– The use of the slewing gear for drilling material is not permitted.

– Do not lift the machine by propping it up with the attachment. If this happens by accident, slowly lower the machine back onto the ground. Do not lower the machine quickly onto the ground, and do not attempt to dampen this movement with the hydraulics, as this can damage the machine.

Caution!

Incorrect operation of the attachment (e.g. backhoe bucket, concrete crusher, scrap shear, hydraulic hammer, swivelling rotator, stick extension) might result in an excessive load of the attachment.

The load on the attachment is greatest – when the hydraulic cylinders are fully retracted (in end position) – when the hydraulic cylinders are fully extended (in end position) – when the attachment is fully extended There is a risk of damage to parts of the equipment, to the hydraulic cylinders and to the machine.

Do not fully extend or retract the hydraulic cylinders.

When the hydraulic cylinders are near the end positions (limit range), move them only slowly and with great caution.

When swivelling the attachment, maintain a minimum distance of 10° to the end position to the tilt cylinder.

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Fig. 3-110 Permissible working range for hydraulic cylinders

3.6.2

1

Possible swivel range

2

Permissible working range with 10 ° distance to end position

3 5

Limit range Hydraulic cylinder

4

Boom or stick

Preparation

Fig. 3-111 Safe working: observe machine range and danger zones Danger!

Risk to life and limb when the machine is swivelled.

Ensure that no persons are standing inside the danger area r of the machine.

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Caution!

Risk of injury during work.

Always wear safety footwear. If required by the nature of the work to be carried out, wear hard hat and protective goggles.

Always wear the safety belt.

Before starting work, operate the horn to warn other workers.

Position the transport vehicle and the machine in such a way that the machine operator can properly supervise the transfer of the load.

If possible, position the machine at a higher point than the transport vehicle, in order to avoid unnecessary lifting of the load.

Lock the oscillating axle.

Extend the supports until the wheels are fully lifted from the ground.

3.6.3

Working with grapples Danger!

Risk to life and limb or damage to the machine by swinging grapple: – The grapple can collide with and damage the operator's cab and injure the operator.

– The grapple can also injure other persons.

– A swinging grapple can also affect the stability of the machine.

Prevent the grapple from swinging near the operator's cab.

Ensure that the stick is in a position where the grapple cannot collide with the machine when the excavator travels or when the brakes are applied.

Move the joystick slowly and smoothly to prevent swinging of the grapple.

Ensure that the moving grapple cannot collide with persons.

Do not lift heavy loads with a fully extended boom and stick. Do not move loads to the far right or left.

Observe the load lift chart showing the permissible lift loads that can be attached to the end of the stick, depending on its actual extension.

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3.6.4

Excavating and moving material with grapples Put the machine into its working position.

Fig. 3-112 Clamshell bucket: align stick, close jaws, lift excavated material Align stick (1): Open the claws fully.

Lower the stick vertically to excavated area.

Closing jaws (2): Danger!

When being closed, the clamshell bucket might lift the machine. As a result, the machine might inadvertently roll away.

Avoid situations where the machine could become unstable by lifting the equipment sufficiently before closing the grapple.

Close the jaws.

Lift the stick only slightly in order to relieve the pressure on the ground.

To lift excavated material (3): Close the jaws.

Lift the boom.

Move the machine to the unloading area (e.g. transport vehicle).

Fig. 3-113 Releasing excavated material

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Swivel the stick as far possible in order to prevent any risk from the slewing bucket.

Open the jaws and release the excavated material.

3.6.5

Loading operation Danger!

There is always a risk that the hydraulic excavator might topple over! Subsiding of the supports could have disastrous consequences!

Always inspect the bearing surface of the supports (load-bearing capacity of the ground).

All machine movements must be controlled with particular care.

Observe the load lift chart showing the permissible lift loads that can be attached to the end of the stick, depending on its actual extension.

Fig. 3-114 Taking up the load Note!

Maximum lifting capacity is given, when the load is taken up as closely as possible near the undercarriage.

Fig. 3-115 Loading operation

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Carefully lift the load.

Keep the load as close as possible to the undercarriage, while keeping a sufficient safety distance to the operator's cab (swinging grapple!). Keep the load as near as possible to the ground when moving.

Swivel the attachment carefully across the loading platform of the transport vehicle or across the unloading area.

Place the load on the platform (open the grapple).

Danger!

Risk to life and limb from suspended loads that become dislodged during loading onto the transport vehicle.

Do not overload the transport vehicle and ensure that the load cannot fall from the platform.

While loading the vehicle, ensure that no persons are in the danger area of the excavator or in the transport vehicle.

Never swivel the equipment over the driver's cab.

Caution!

Especially when moving timber, it might be necessary to move the machine while the loaded attachment is lifted. In this case, the centre of gravity of the machine is shifted vertically and thus higher than normal. The travel behaviour of the machine is greatly affected by this.

Observe the instructions in chapter "Safe use of machine for goods handling".

3.6.6

Load lifting operation Load lifting operation includes all manoeuvres where loads attached to the machine with lifting tackle (cables, chains, etc.) are lifted, transferred and lowered, whereby the load must be attached manually to the machine. Loading operations thus also include lifting and lowering of pipelines, shaft rings and vessels.

Danger!

The machine may only be used for lifting operations, if it is equipped with the necessary safety devices and when these devices are in proper working order.

According to the European standard EN 474-5, machines used to lift loads must be equipped with the following safety devices: – Lifting tackle that allows for the safe attachment of a load (optional equipment) An example of a safe lifting tackle are lift hooks that are attached to the machine instead of the digging bucket. Load lift hooks may be replaced with safety hooks welded to the digging bucket.

– Overload warning system (optional equipment) If the actual load reaches or even exceeds the permissible load according to the load lift chart, the overload warning system must generate a visual and audible alarm signal to the machine operator.

– Pipe fracture safety valve at the boom cylinders The pipe fracture safety valve must conform to the requirements laid down in ISO 8643.

– Load lift chart in the operator's cab

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If one or more of the above requirements is not met, the machine may not be used for load lifting operations.

3.6.7

Use of quick-change adapter for load lifting operation

Fig. 3-116 Lifting operation with load hook 1 3

Load lift hook 2 Lifting tackle Hook for working tool (not suitable for load lifting operation)

A Permissible swivelling range The quick-change adapter is equipped with two integrated load lift hooks for lifting operation.

The maximum lifting capacity of the individual load lift hooks is indicated at the quickchange adapter. The load capacity might be below or above that of the basic machine. Always observe the load capacity values of the machine.

Load-lifting work can be carried out with or without an attached working tool. If a working tool is mounted and the machine is used to lift loads, we recommend fully retracting the locking pins. This prevents that the lifting tackle is deflected by the locking pins, as this could cause damage.

Danger!

If a load is lifted incorrectly, it might become dislodged, which in turn could result in serious accidents.

To lift loads, always use the load hooks 1 and never the hook for the working tool.

Adjust the quick-change adapter position so that the load hook 1 opens upwards and is within the permissible swivel range A. Attach the load to the load hook according to the instructions in chapter "lifting operation".

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Control, operation General working methods

3.6.8 3.6.8.1

Overload warning system (optional equipment) General The overload warning system warns the machine operator with a visual signal (indicator light overload warning) and an acoustic signal (buzzer sound) when the permissible maximum load is reached.

The overload warning system therefore helps prevent dangerous situations where the permissible load moment is inadvertently exceeded. In the event of a warning signal, reduce the extension of the attachment or lower the load to the ground without increasing the extension.

Even if the overload warning system is used, it remains the responsibility of the machine operator to ensure that only loads of a known weight that is below the maximum permissible load of the machine are lifted. Also observe the applicable statutory accident prevention regulations.

The permissible maximum load depends on the machine equipment (undercarriage, attachments) and is shown on the load table in the operator's cab.

When the machine is standing on firm and level ground, the above values allow for the swivelling of the uppercarriage by 360°.

The load capacity values in the table correspond to max. 75 % of the tip load or 87 % of the hydraulic lifting force according to ISO 10567.

If the overload warning system is defective, it is prohibited to lift loads. The system must be repaired by a specialist technician.

Note!

The load capacity values might vary, depending on the mounted tools and attachments.

Note!

The overload warning system must be tested prior to the commissioning of the machine and then every year by a specialist technician, in accordance with the testing and setting installations in the service manual.

3.6.8.2

Operating principle The overload warning system consists of a pressure switch connected to the piston side of the hoist cylinders.

If the hydraulic pressure in the hoist cylinders reaches the limit value, the pressure switch generates a signal. This signal switches on the overload warning indicator light and triggers the buzzer sound.

The limit value is set within the range of the stability factors.

3.6.8.3

Commissioning Danger!

The overload warning system does not disable the machine when the permissible load moment is exceeded. The operator is only informed that the limit value is exceeded.

When the overload warning system has been triggered, do not exceed the load or outreach.

copyright by R 317 Litronic Industrie / 11140224

MJFCIFSS

3 - 109

Control, operation

Operating manual

Parking and exiting machine

Press the switch S18 down.

The overload warning system is activated.

The indicator light in the switch is on.

3.6.8.4

Functional test Before each shift, the machine operator must check whether the overload warning system is working properly: Lift the boom and extend the hoist cylinders to the stop.

Continue moving the joystick in direction "lifting boom".

The indicator light of the overload warning system must be on.

The buzzer must sound.

3.7 Parking and exiting machine Shut down the diesel engine.

Turn the ignition key to contact position.

Release the pressure from the pressure lines by carefully moving the joystick several times.

Move the safety lever up.

The parking brake is applied.

The slewing gear brake is applied.

Remove the ignition key.

Close all doors, hoods and covers of the machine and lock them.

3.8 Transport 3.8.1

Safety instructions – Insure that the transporting vehicle or truck trailer is rated for the intended machine weight and size.

– Park the machine on a level surface and chock the track chains and/or wheels.

– During transport, remove parts of the attachment that create an over width or length condition, if necessary.

– Clean the undercarriage. The undercarriage must be swept clean, meaning, the chains / wheels must be free of snow, ice and sludge prior to driving onto the transporting vehicle.

– Align the machine precisely with the loading ramp.

– Attach the manual lever for sensitive driving (crawler excavator) to the driving pedals.

– Have another person guide and signal the operator.

copyright by

3 - 110

MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Control, operation Transport

– On wheel models equipped with an uppercarriage locking mechanism, the uppercarriage must be secured to the undercarriage with the locking pin after loading onto the trailer.

– Secure the machine and any loose components with tiedowns in accordance with any applicable national regulations.

– Release all pressure lines (as described in this operating manual), remove the ignition key and pull the safety lever up prior to leaving the machine.

– Close all cab and panel doors.

– Verify that no one remains on the machine during the transport.

– Investigate the travel route, specifically in reference to limits for width, height and weight prior to the transport.

– Pay special attention when driving under electrical lines and bridges and when passing through tunnels.

– Use the same care for unloading as for loading.

3.8.2 3.8.2.1

Transportation on low-loader Preparation Prior to driving the excavator onto a low-loader, make the following preparations: Hold wheel chocks ready.

Remove dirt, ice and snow from the chains, ramps and loading platforms.

Remove the stick and/or working attachment, if required.

If required, use a suitable ramp. Angle of inclination: max. 10°

Fig. 3-117 Loading ramp

Fig. 3-118 Manual steering system of travel gear Attach the supplied manual levers (1 and 2) to the chassis pedals.

copyright by R 317 Litronic Industrie / 11140224

MJFCIFSS

3 - 111

Control, operation

Operating manual

Transport

3.8.2.2

Loading machine onto a low-loader Danger!

The machine might slide sideward or tip over while being moved onto the lowloader.

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

Drive and steer the machine with extreme care.

If necessary, disconnect the semi-trailer from the tractor vehicle.

Position the machine in line with the low-loader and drive onto the platform.

Connect the semi-trailer to the tractor vehicle and lift low-loader.

Lower the boom.

Switch off the diesel engine.

Turn the ignition key to its contact position and depressurise all pressure lines by carefully operating the joysticks repeatedly in all directions.

Remove the ignition key and tilt the safety lever upwards.

Close all doors, hoods and covers of the machine and lock them.

Fold in the rear mirror.

Secure the machine:

Fig. 3-119 Securing the machine Danger!

Shifting of the machine on the low-loader can result in serious accidents.

Secure the machine against shifting.

Place chucks at the wheels and secure the equipment with cables and chains.

Using tension chains, secure the machine by attaching the chains to the points labelled as lashing points (see Fig. 3-119).

Secure the cables and chains at the provided points on the low-loader.

3.8.3

Loading with crane Danger!

Risk of injury!

It is forbidden to stand on the lifted machine!

copyright by

3 - 112

MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Control, operation Transport

Danger!

Improper loading can result in shifting load.

Employ only experienced personnel with the attachment of the load and the guiding of the crane operator.

The signaller must be positioned within sight of the crane operator. Alternatively, the signaller and the operator might be in contact through walkie-talkies or similar devices.

Ensure that the crane tackle is sufficiently long.

Use only suitably dimensioned lifting gear. We recommend using special lifting gear available from LIEBHERR. Loading of machine with gooseneck boom:

Fig. 3-120 Attachment of machine with gooseneck boom Lower the attachment, retract the stick and tilt in the digging bucket to the stop.

Switch off the diesel engine.

Turn the ignition key to its contact position and depressurise all pressure lines by carefully operating the joysticks repeatedly in all directions.

Remove the ignition key and tilt the safety lever upwards.

Close all doors, hoods and covers of the machine and lock them.

Fold in the rear mirror.

Attach the lifting tackle to the points provided.

To recommission the machine, strictly adhere to the instructions in the operator's manual.

copyright by R 317 Litronic Industrie / 11140224

MJFCIFSS

3 - 113

Control, operation

Operating manual

Transport

Loading of machine with adjustable attachment:

Fig. 3-121 Suspension of machine with adjustable attachment Lower the attachment, place the stick in a vertical position and tilt in the digging bucket to the stop.

Switch off the diesel engine.

Turn the ignition key to its contact position and depressurise all pressure lines by carefully operating the joysticks repeatedly in all directions.

Remove the ignition key and tilt the safety lever upwards.

Close all doors, hoods and covers of the machine and lock them.

Fold in the rear mirror.

Attach the lifting tackle to the points provided.

Carefully lift the machine with the crane and place it on the transport vehicle.

To recommission the machine, strictly adhere to the instructions in the operator's manual.

copyright by

3 - 114

MJFCIFSS

R 317 Litronic Industrie / 11140224

4 Malfunctions Malfunctions are indicated by indicator lights or icons on the monitoring display. In certain cases, an acoustic warning signal is issued. Additional information that facilitates the elimination of the problem is provided by error codes.

Malfunctions are frequently caused by incorrect operation of the machine or improper maintenance.

Each time you encounter a malfunction, read the relevant chapter in the operator’s manual.

Identify the cause of the malfunction and eliminate it or have it eliminated.

Note!

If you are unable to identify the cause of the malfunction, contact the LIEBHERR service department.

Do not carry out any work for which you are not qualified.

When contacting the LIEBHERR service department, describe the malfunction and all associated circumstances in as much detail as possible.

Quote the machine type, the serial number and the year of manufacture of your equipment.

4.1 Error code list Error code

Effect

Cause

Remedy

E1001

Slewing gear failure

Plug connection loose

Check cabling, contact LIEBHERR customer service

Line fault Solenoid valve defective E1002

Insufficient hydraulic power of tool attachment

Plug connection loose Line fault

Check cabling, contact LIEBHERR customer service

Solenoid valve defective E1003

Fan rotates at maximum speed

Plug connection loose Line fault

Check cabling, contact LIEBHERR customer service

Solenoid valve defective

copyright by R 317 Litronic Industrie / 11140224

MJFCIFSS

4-1

Malfunctions

Operating manual

Error code list

Error code

Effect

Cause

Remedy

E1004

Super Finish or flow reduction for tool attachment not working properly (only with Tool Control / Tool Control Plus)

Plug connection loose

Check cabling, contact LIEBHERR customer service

Oscillating axle locked and cannot be opened

Plug connection loose

E1005

Line fault Solenoid valve defective

Line fault

Check cabling, contact LIEBHERR customer service

Solenoid valve defective E1006

Insufficient hydraulic power of machine

Plug connection loose Line fault

Check cabling, contact LIEBHERR customer service

Solenoid valve defective E1007

Travel alarm not triggered

Plug connection loose Line fault

Check cabling, contact LIEBHERR customer service

Travel alarm E1008 E1009

Travelling not possible, travel direction indicators for forward and reverse travel flash simultaneously

Plug connection loose, line fault, solenoid valve defective

Check cabling, contact LIEBHERR customer service

Bolt of quick-change adapter without function

Plug connection loose

Check cabling, contact LIEBHERR customer service

E1010 E1011

Line fault Solenoid valve defective

E1012

Working attachment cannot be moved

Plug connection loose Line fault

Check cabling, contact LIEBHERR customer service

Solenoid valve defective E1013 E1014 E1015

"Rotate grapple" function only working in one direction

Plug connection loose Line fault Solenoid valve defective

Check cabling, contact LIEBHERR customer service

Fan rotates at maximum speed, power reduction at diesel engine

Cooling water temperature too high

Operate diesel engine without load; if fan speed is not reduced, contact LIEBHERR customer service

Internal control error Solenoid valve defective

E1016

Fan rotates at maximum speed

E1017

Fan rotates at maximum speed, power reduction at diesel engine

Hydraulic oil temperature not monitored

Check cabling, contact LIEBHERR customer service

Temperature sensor defective Intercooling air temperature too high Internal control error

Operate diesel engine without load; if fan speed is not reduced, contact LIEBHERR customer service

Solenoid valve defective E1018

Idle automatic does not work

Plug connection loose Line fault

Check cabling, contact LIEBHERR customer service

Right joystick defective E1019

Idle automatic does not work

Plug connection loose Line fault

Check cabling, contact LIEBHERR customer service

Left joystick defective E1020

Travelling not possible, travel direction indicators for forward and reverse travel flash simultaneously

Plug connection loose Line fault

Check cabling, contact LIEBHERR customer service

Pressure switch defective E1021

Insufficient hydraulic power of machine

Internal control error Plug connection loose

Shut down and restart diesel engine, check cabling, contact LIEBHERR customer service

Line fault Solenoid valve defective E1022 E1023

Possible faults at oscillating axle, travelling pedal, slewing gear, coolant level, fuel tank indicator, joystick

Incorrect power supply to sensors

Contact LIEBHERR customer service

copyright by

4-2

MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Malfunctions Error code list

Error code

Effect

Cause

Remedy

E1024

Flow reduction of tool attachment (e.g. hammer) not working properly (only with Tool Control Plus)

Plug connection loose

Check cabling, contact LIEBHERR customer service

Line fault Solenoid valve defective

E1025

Flow reduction of tool attachment (e.g. hammer) not working properly (with Tool Control Plus)

Plug connection loose Line fault

Check cabling, contact LIEBHERR customer service

Solenoid valve defective E1027

Power loss at tool attachment if SF function is activated (only with Tool Control Plus)

Plug connection loose Line fault

Check plug connection at solenoid valve, contact LIEBHERR customer service

Solenoid valve defective E1028

Fault in boom/stick shut-down, dogwalk steering, all-wheel gear, power loss at tool attachment (only with Tool Control Plus)

Internal control error

Contact LIEBHERR customer service

E1029

Fuel indicator indicates that tank is empty while fuel tank is full

Plug connection loose

Check plug connection at tank sensor, contact LIEBHERR customer service

Line fault Tank sensor defective

E1030

Indicator light on, acoustic warning signal (continuous signal)

Incorrect engine oil pressure

Shut down diesel engine, check engine oil level; adjust, if necessary

E1031

Continuous audible warning signal

Coolant temperature too high

Shut down diesel engine, allow machine to cool down, check coolant level, clean radiator

Radiator dirty E1032

Indicator light on, acoustic warning signal (interval signal)

Hydraulic oil temperature too high

Shut down diesel engine, allow machine to cool down, clean radiator

E1033

Power loss at diesel engine, indicator light on

Air filter contaminated

Shut down diesel engine, replace filter element

E1034

Travelling not possible, travel direction indicators for forward and reverse travel flash simultaneously

Travel direction switch defective, internal control error

Contact LIEBHERR customer service

E1035

Current operating hours data is not saved

Internal control error

Contact LIEBHERR customer service

E1036

Grapple / quick-change adapter disabled, audible warning signal (continuous signal), indicator light flashes

Plug connection loose

Contact LIEBHERR customer service

Switching of adjustable boom cylinder to hammer operation not possible

Plug connection loose

Power loss at slewing gear

Plug connection loose

E1037

Line fault

Line fault

Check cabling, contact LIEBHERR customer service

Solenoid valve defective E1038

Line fault

Check cabling, contact LIEBHERR customer service

Pressure sensor defective E1039

Audible warning signal (interval signal)

Overvoltage

Contact LIEBHERR customer service

E1040

Power loss at diesel engine

Plug connection loose

Shut down and restart diesel engine, check cabling, contact LIEBHERR customer service

Line fault Engine control unit defective Diesel engine components defective E1041

Power loss at diesel engine

Incorrect fuel supply to diesel engine

Contact LIEBHERR customer service

E1042

Power loss at diesel engine

Plug connection loose

Contact LIEBHERR customer service

Line fault Fuel pressure of diesel engine too low

copyright by R 317 Litronic Industrie / 11140224

MJFCIFSS

4-3

Malfunctions

Operating manual

Error code list

Error code

Effect

E1043

Display of symbol at display

Cause Water level in fuel filter too high

Dewater fuel filter

Plug connection loose

Check cabling, contact LIEBHERR customer service

Line fault E1044

Diesel engine fails to start

Remedy

Plug connection loose Line fault

Check cabling, contact LIEBHERR customer service

Start relay defective E1045

Diesel engine fails to start

Plug connection loose Line fault

Check cabling, contact LIEBHERR customer service

Magnet switch defective E1046

Diesel engine dies

E1047

Error in diesel engine control

Internal control error Engine control unit defective Plug connection loose Line fault

Contact LIEBHERR customer service Check cabling, contact LIEBHERR customer service

Ambient pressure sensor defective E1048

Air filter contaminated Plug connection loose

Clean/change air filter; if fault persists, contact LIEBHERR customer service

Line fault Underpressure sensor defective E1049

Incorrect battery voltage

Contact LIEBHERR customer service

E1050

Auxiliary heater failure

Contact LIEBHERR customer service

E1051

Fault in fuel injection

Contact LIEBHERR customer service

E1052

Backfiring

Contact LIEBHERR customer service

E1053

Fault in fuel injection

Contact LIEBHERR customer service

E1054

Fault in fuel injection

Contact LIEBHERR customer service

E1055

Fault in fuel injection

Contact LIEBHERR customer service

E1056

Fault in fuel injection

Contact LIEBHERR customer service

E1057

Incorrect cooling water level

Check cooling water level and adjust if necessary; if fault persists, contact LIEBHERR customer service

E1058

Incorrect cooling water temperature

Contact LIEBHERR customer service

E1059

Power loss at diesel engine; fan rotates at nominal speed

Internal control error

Operate diesel engine at upper idle speed without load; if fault persists, contact LIEBHERR customer service

E1060

Power loss at diesel engine, black fumes

Incorrect intercooling pressure

Check air intake system for leakage; if fault persists, contact LIEBHERR customer service

E1061

Incorrect engine oil temperature

Plug connection loose

Check engine oil level and adjust, if necessary; check plug connection

Line fault Temperature sensor defective E1062

Indicator light on, acoustic warning signal (continuous signal)

Incorrect engine oil pressure

Shut down diesel engine, check engine oil level; adjust, if necessary

E1063

Engine speed too high

Speed sensor defective

Contact LIEBHERR customer service

copyright by

4-4

MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Malfunctions Error code list

Error code

Effect

E1064

Cause

Remedy

Fuel temperature too high

Contact LIEBHERR customer service

Temperature sensor defective E1065

Engine control unit defective

Contact LIEBHERR customer service

E1066

Temperature in engine control unit too high

Contact LIEBHERR customer service

E1067

Engine control unit defective

Contact LIEBHERR customer service

E1068

Engine control unit defective

Contact LIEBHERR customer service

Plug connection loose

Check cabling, contact LIEBHERR customer service

E1071

Servo control disabled; attachment cannot be moved

Line fault Solenoid valve defective

E1072

Basic boom cannot be moved upwards

Plug connection loose

Basic boom cannot be moved

Plug connection loose

Line fault

Check cabling, contact LIEBHERR customer service

Solenoid valve defective E1073

Line fault

Check cabling, contact LIEBHERR customer service

Solenoid valve defective E1074

Boom cannot be moved upwards

Plug connection loose Line fault

Check cabling, contact LIEBHERR customer service

Solenoid valve defective E1075

Basic boom cannot be moved

Plug connection loose Line fault

Check cabling, contact LIEBHERR customer service

Potentiometer at basic boom defective E1076

Boom cannot be moved upwards

Plug connection loose Line fault

Check cabling, contact LIEBHERR customer service

Potentiometer at boom defective E1077

Plug connection loose Line fault

Check cabling, contact LIEBHERR customer service

Solenoid valve defective E1078

E1079

E1080

No automatic alignment of wheels when changing between standard steering/four-wheel steering/dogwalk steering

Plug connection loose

No automatic alignment of wheels when changing from four-wheel steering/dog-walk steering to standard steering

Plug connection loose

"Dog-walk" steering mode cannot be preselected

Plug connection loose

Line fault

Check cabling, contact LIEBHERR customer service

Solenoid valve defective

Line fault

Check cabling, contact LIEBHERR customer service

Solenoid valve defective

Line fault

Check cabling, contact LIEBHERR customer service

Solenoid valve defective E1081

"All-wheel" steering mode cannot be preselected

Plug connection loose Line fault

Check cabling, contact LIEBHERR customer service

Solenoid valve defective E1082

Possible faults at oscillating axle, travelling pedal, slewing gear, coolant level, fuel tank indicator, joystick

Incorrect power supply to sensors

Contact LIEBHERR customer service

copyright by R 317 Litronic Industrie / 11140224

MJFCIFSS

4-5

Malfunctions

Operating manual

Troubleshooting

Error code

Effect

E1083

Stick cannot be moved

Cause

Remedy

Plug connection loose

Check cabling, contact LIEBHERR customer service

Line fault Solenoid valve defective E1084

Stick cannot be moved

Plug connection loose

Check cabling, contact LIEBHERR customer service

Line fault Potentiometer at boom defective E1085

Working attachment cannot be moved

Parameters for boom and stick limitation cannot be read by control

Shut down and restart diesel engine; contact LIEBHERR customer service

E1086

Basic boom and stick cannot be moved

Maximum permissible moving ranges of basic boom and stick not detected

Contact LIEBHERR customer service to adjust boom and stick cylinder shut-down

E1087

Basic boom and stick cannot be moved

Solenoid valves of stick cylinder shut-down are switched off

Contact LIEBHERR customer service to adjust boom and stick cylinder shut-down

E1088

For information purposes only

EEPROM parameters reconstructed

–

E1089

For safety reasons, certain functions cannot be selected

When starting the control system, each parameter of the control checks whether it is within the permissible value range; if this is not the case, the respective default parameter is loaded

Shut down and restart diesel engine; contact LIEBHERR customer service

E1090

Tool attachments cannot be locked with the hydraulic quick-change adapter or become released when the lock bolts are operated

Hydraulic lines at quick-change adapter have been confused; the direction of movement of the lock bolts of the quick-change adapter does not correspond to that of the electric control

Connect hydraulic lines correctly

4.2 Troubleshooting 4.2.1 Error / fault Diesel engine fails to start

Diesel engine and fuel system Cause

Remedy

Fuel tank nearly/completely empty

Add fuel and bleed fuel system

Underpressure in the tank

Open the tank lid and close it again

Fuel filter dirty

Clean or change filter and bleed the fuel system; drain off fuel / clean tank

Ambient temperature below 0 °C

For operation and control under extreme conditions, see operating manual

Starter failure

Check line connections, service starter

Batteries flat

Recharge / replace batteries

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4-6

MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Malfunctions Troubleshooting

Error / fault

Cause

Engine starts, but stops immediately or runs irregularly

Remedy

Fuel tank empty (underpressure in tank)

Add fuel and bleed fuel system

Fuel filter dirty

Clean or change filter and bleed fuel system (tank)

In winter: engine oil viscosity too high

Use an engine oil that is suitable for the respective ambient temperature

Dry air filter contaminated

Clean or change

Air in fuel system

Bleed fuel system

Bleeding valve in fuel tank blocked

Clean

Fuel line kinked

Check line and repair, if required

Diesel engine emits grey or black fumes

Dry air filter contaminated

Clean or change

White steam emitted by diesel engine

Water in combustion room

Consult customer service department

Diesel engine does not reach full speed

Speed not set to maximum value

Set speed to maximum value

Injection unit settings incorrect

Consult customer service department

Dry air filter contaminated

Clean or change

Insufficient fuel supply

Clean or replace fuel filter; check lines, drain water from tank

Insufficient amount of coolant

Add coolant, check for tightness

Water pump defective

Repair

Thermostats fail to work

Replace thermostats

Radiator dirty

Cleaning radiator

Insufficient oil pressure in diesel engine Note!

Immediately switch off the diesel engine!

Oil level too low

Correct oil level

Oil pressure indicator defective

Change oil pressure switch

Diesel engine uses too much oil

Leakage on diesel engine

Retighten screws; replace seals, if required

Diesel engine too hot

Oil in coolant or coolant in oil

Consult customer service department

Unusual noises / noise at exhaust air side

4.2.2

Leakage in exhaust gas system

Check / repair exhaust gas system

Hydraulic system

Error / fault

Cause

Remedy

Unusual noises / noise from hydraulic pumps Note!

Immediately switch the engine to its lower idle speed and shut it down!

Stop valve at the hydraulic tank closed

Open stop valve

Hydraulic pumps take in air

Check oil level in the hydraulic tank, check suction lines for leakage

Engine stalls

No performance adjustment

Activate emergency mode; consult customer service department

copyright by R 317 Litronic Industrie / 11140224

MJFCIFSS

4-7

Malfunctions

Operating manual

Troubleshooting

Error / fault

Cause

Remedy

Radiator dirty

Cleaning radiator

Fan or fan control defective

Eliminate fault / consult customer service department

Hydraulic oil level too low

Oil loss

Repair leak, replace hoses, add oil through the return filter

Travel function not available

Safety lever moved up

Move safety lever down

Slewing gear failure

Servo control not working

Move the safety lever down

Slewing gear brake activated

Move safety lever down

Servo control not working

Move safety lever down

No servo pressure

Consult customer service department

No pump high pressure

Consult customer service department

Hydraulic oil temperature too high

Release slewing gear brake No working movement

4.2.3

Travel gearbox

Error / fault

Cause

Remedy

Oil escaping at running rollers, support rollers or idler

Seal defective

Replace seal

Chain guide at idler defective

Excessive play of idler guide system at the running roller frame

Adjust pay of idler guide system

Chain jumps from guides

Insufficient chain tensions / chain wheel worn

Adjust chain tension

Correctly tightened chain becomes loose after short operation

Chain tensioning cylinder defective

Check chain tensioning cylinder; replace or reseal, if necessary (to be done by authorised specialist technician)

Running or support roller stiff

Drive extremely dirty

Clean drive

4.2.4

Electrical system

Error / fault

Cause

Remedy

Battery charging indicator light does not go off

V-belt of alternator loose or broken

Tighten or replace V-belt

Alternator defective

Replace alternator

Batteries are not sufficiently charged

Batteries defective

Replace batteries

Battery connections dirty / oxidised

Clean battery connections

Cable loose or defective

Connect or replace cable

Failure of indicator light or indicating instrument

Incandescent lamp burnt out; indicating instrument defective

Replace defective part

Failure of one or more instrument panel functions

Adapters disconnected or defective; earth connector disconnected; short circuit - fuse blown

Plug in or change adapter; eliminate cause of short circuit; replace fuse or reset automatic cut-out

copyright by

4-8

MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Malfunctions Troubleshooting

Error / fault

Cause

Engine speed adjustment not possible

Idle automatic without function; speed fails to drop Slewing gear brake cannot be released with switch

4.2.5

Remedy

Excavator electronics for speed adjustment not working

Consult customer service department

Idle automatic is activated

Grab the joystick or deactivate the idle automatic Consult customer service department

No signal from speed sensor

Consult customer service department

Permanent sensor signal

Consult customer service department

Deactivate idle automatic

Activate idle automatic

Switch defective

Replace switch

Heating and air-conditioning system

Error / fault

Cause

No warm air escaping from heating system

Heating blower not working

Low air circulation rate in operator's cab

4.2.6

Remedy

Stop valves of coolant line on the diesel engine closed

Open stop valve

Engine not at operating temperature

Heat engine to operating temperature

No power

Check fuse and cable; replace if required

Blower motor defective

Replace blower motor

Ambient air filter / recirculation air filter contaminated

Clean air intake openings; replace ambient air filter

Air outlets closed

Open air outlets

Working attachment

Error / fault

Cause

Remedy

Cylinder responds to load

Piston seal on cylinder defective

Service cylinder

Excessive bearing play in attachment

Bearing points worn

Replace bearing components

Grapple / bucket cannot be moved

Valve block at tilt cylinder connected incorrectly

Change connections to valve block

Attachment cannot be rotated, swivelled or operated

Auxiliary function not activated

Activate respective additional function

Lines not connected

Connect lines

copyright by R 317 Litronic Industrie / 11140224

MJFCIFSS

4-9

Malfunctions

Operating manual

Fuses and relays

4.3 Fuses and relays Danger Incorrect or bridged fuses do not provide the protection required for the safety of the machine operator and the electrical equipment.

Use only original fuses (replacement fuses can be ordered from LIEBHERR).

Never bridge electrical fuses.

Before changing fuses, switch off the electrical system.

4.3.1

Fuse box E50

Fig. 4-1

Fuse box E50

The fuse box E50 is located at the rear side of the hydraulic tank.

F300

50 A

Main fuse

F301 F302

50 A 7.5 A

Pre-heating not assigned

F303

7.5 A

not assigned

F332 F370

25 A 25 A

Starter Engine control

K_F K288

Relay terminal 50 Relay terminal 15

K302 K476

Relay of pre-heating Engine control relay

* optional equipment

copyright by

4 - 10

MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Malfunctions Fuses and relays

4.3.2

Control console C

Fig. 4-2

Fuses and relays in control console C

The fuses are accessible when the cover is removed.

F307

7.5 A

Parking light, left

F308 F309

7.5 A 7.5 A

Parking light, right Travel light, left

F310

7.5 A

Travel light, right

F311 F317

15 A 7.5 A

Windscreen wiper / washing system Beacon*

F323 F324

15 A 15 A

Work headlight, attachment* Work headlight, rear roof light*

F343

7.5 A

Roof window wiper*

F358 K414

15 A

Work headlight, front roof light* Relay of interval control device

K447 K448

Relay of roof work headlight, front* Relay of roof work headlight, rear*

K449

Relay of work headlight, attachment*

* optional equipment

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Malfunctions

Operating manual

Fuses and relays

4.3.3

Control console

Fig. 4-3

Fuses and relays, right control console

The fuses are accessible when the cover is removed (see arrow).

K386

Relay of safety lever

K370 F304

15 A

Relay of servo control UEC, control unit, ignition

F305

15 A

Internal lighting, cigarette lighter

F306 F312

15 A 7.5 A

Terminal 30 not assigned

F313 F314

5A 7.5 A

not assigned Safety lever

F315

15 A

Control unit

F316 F318

7.5 A 20 A

Control console Heating

F319 F320

15 A 15 A

Heating Terminal 15

F321 F322

15 A 15 A

Terminal 15 Voltage transformer

F325

7.5 A

not assigned

F326

15 A

Fast travel, SW

F327

15 A

UEC UB2

F328 F329

15 A 15 A

UEC UB3 Servo control

F330

15 A

Super Finish, AS1, AHS11, AHS12

F331

15 A

Servo control, UEC UB4

F336

20 A

Lighting

F337 F338

15 A 15 A

Slewing gear brake Horn/seat electrics

F339 F363

20 A 15 A

Air-conditioning system UEC UB0/1

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Operating manual

Malfunctions Fuses and relays

F372

7.5 A

Indicating elements

S467

Fuse test switch

Fig. 4-4

Fuses and relays, right control console, side

The fuses are accessible when the cover is removed (see arrow).

4.3.4

K315

–

K391

Horn relay

V175

Quick-change adapter control amplifier

Battery box

Fig. 4-5

Fuses in battery box

F344

7.5 A

F359

7.5 A

Indicating instrument P50, auxiliary heating

F375

15 A

Auxiliary heating

Emergency lowering, lift frame

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Malfunctions

Operating manual

Emergency mode

4.4 Emergency mode 4.4.1

Purpose The emergency operation function is an auxiliary function that enables operators to restore machine functions that have failed. Depending on the situation, this auxiliary function might need to be activated, for example to remove a machine quickly from the construction site after a fault occurred.

When in emergency mode, various functions are directly controlled, so that the control and operating elements that are faulty are bypassed. The function is intended exclusively for temporary use in the event of an emergency and is not a substitute for proper repair.

The options available in emergency mode depend on the type and extent of the malfunction or fault. The following emergency mode functions are available:

emergency mode

Purpose

Shut-down systems, restrictions (functions that limit the range of movement of the machine)

Moving the machine away from the construction site or a dangerous position (immediate repair is required)

For instructions on how to operate the machine in emergency mode, see next chapter.

Danger!

In emergency mode, certain safety functions of the control system are disabled.

This can lead to accidents or damage to the machine.

Use emergency mode only for the intended purpose.

Inform all persons involved in the operation and maintenance of the machine that it is in emergency mode.

Immediately switch off the emergency mode when it is no longer required.

Have the machine repaired as quickly as possible.

4.4.2

Emergency lowering of the operator's cab In the event of a failure of the diesel engine or the control system of the elevating operator's cab, it can be lowered manually by releasing the operating pressure.

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Operating manual

Malfunctions Emergency mode

Emergency lowering of the operator's cab:

Fig. 4-6

Emergency lowering valve at cab base

Move the lever 1 to position b.

The operator's cab is gradually lowered as long as the lever is held in position b.

Emergency lowering from outside the operator's cab:

Fig. 4-7

Emergency lowering valve on lift frame

Move the lever 1 to position b.

The operator's cab is gradually lowered as long as the lever is held in position b.

Note!

While the lever is in position b, the operator's cab cannot be lifted.

After lowering the cab, return the lever to position a.

4.4.3

Towing the machine Towing the machine is a dangerous manoeuvre, and the responsibility for any damage in connection with towing rests with the operator.

The machine may only be towed in exceptional situations, e.g. if the machine must be moved for safety reasons or if it must be repaired at the workshop.

Injuries to persons or damage to equipment caused by towing of the machine are not covered by the manufacturer's warranty.

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Malfunctions

Operating manual

Emergency mode

Danger!

Incorrectly dimensioned towing rods or cables might break. Steel chains are generally prone to breaking during towing.

There is a serious risk of injury or damage to equipment.

Never use a chain for towing.

Tow the vehicle with a adequately dimensioned towing rod or cable.

Note!

When towing the machine, ensure that the brakes of the travel gear are released.

The diesel engine must be running in order to build up the necessary pressure.

If the diesel engine cannot be started or if there is a fault in the hydraulic system, the required pressure must be built up manually. For instructions, consult the LIEBHERR customer service department.

Fig. 4-8

Towing the machine

Ensure that the towing rod or steel cable used for towing is of a sufficient tensile strength.

Attach the towing rod or steel cable to the eyelet on the undercarriage.

For machines that are not equipped with an eyelet (machines equipped with blade support): place the steel cable around the blade support.

Towing speed: max. 2 km/h

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5 Maintenance 5.1 Safety instructions 5.1.1

General safety instructions – Maintenance and repairs may only be carried out by trained expert technicians.

– Always note the frequency intervals for inspections as contained in this operating manual.

– Insure that an adequately equipped workshop is available to perform these tasks, and note the designated qualifications of the personnel responsible for each inspection.

– The maintenance and inspection schedule sets out precisely who should, or is allowed to carry out which jobs.

The machine operator (and his staff) are allowed to carry out certain jobs, but other jobs must be carried out only by qualified and trained staff.

– Spare parts must meet the technical requirements set forth by the manufacturer.

This is always ensured with original spare parts. Spare parts that do not meet the technical requirements of the manufacturer might impair the safety and proper operation of the machine.

– Wear task-appropriate personal protective equipment at all times. Example: In addition to a protective helmet and safety boots, for certain jobs protective goggles and gloves are also necessary.

– Keep unauthorized personnel away from the machine during maintenance.

– Secure a wide-ranging area for maintenance, as necessary.

– Inform the operator before starting to carry out special tasks and maintenance work. Make sure he knows the person who is in charge of the work.

– Perform all maintenance operations on the machine on a level and stable ground with the working equipment lowered and the diesel engine turned off, unless described otherwise in the operating manual.

– Hang a well visible warning label “do not switch on“ onto the ignition during maintenance operations, especially when working under the machine. Remove the ignition key and set the main battery switch to position 0.

– Re-torque all bolts at the completion of the maintenance procedure to the required torque specification.

– If the dismantling of safety equipment is necessary, the safety equipment must be re-attached and inspected directly upon conclusion of the operations.

5.1.2

Checking for cracks – Machines are subject to different loads, depending on application, job site, duration of use and conditions of use. The different load conditions result in different service lives for various machines components. This could lead to cracks and loose connections, particularly on load-bearing parts. This applies particularly to machines used in material handling or industrial applications or for machines with special equipment, such as demolition excavators. To ensure that operating safety is maintained, the machine must be checked regularly for cracks, loose connections or other visible damage.

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5-1

Maintenance

Operating manual

Safety instructions

– To check for cracks, it is necessary to keep the machine clean and to clean it regularly.

– The inspection must be carried out according to the inspection and maintenance schedule.

– It is advisable to carry out these inspections with the machine supported, on firm and level ground.

– Specific attention should be given to the following: • The steel structure undercarriage with axle and gear mounting, support, lower slewing ring seating with tower and slewing ring.

• The steel structure uppercarriage with bearing block for boom and boom cylinder, upper slewing ring seating, cab bearing, mounting of slewing gear and counterweight.

• Steel structure of working attachments, e. g. boom, stick, quick change adapter, digging tool and grapple.

• Hydraulic cylinder, axles, steering, pins and pin connections, steps, ladders and mounting elements.

– Check for cracks visually. If a crack is suspected or is in areas which are not easily visible, such as the slewing ring seating, then the dye penetration procedure should be used to check for cracks.

– Any damage found must be fixed immediately. Welding on load-bearing parts of earth moving machines, material handling and transport units may only be made by certified welders in accordance with acceptable welding practices. Contact LIEBHERR Service to discuss suitable measures.

5.1.3

Welding – Welding, cutting and grinding should only be done with the specific approval of LIEBHERR. Prior to any welding, cutting or grinding, clean the machine and surrounding area to remove dust and flammable materials.

– Insure adequate ventilation.

5.1.4

Fuels, lubricants and process chemicals – When handling oils, greases and other chemical substances, always observe the applicable safety regulations for the corresponding product.

– Ensure safe and environmentally friendly disposal of operating and service fluids as well as exchange parts.

– Handle hot operating and service fluids carefully (danger of burning and scalding).

5.1.5

Repair – Do not attempt to lift heavy parts. Use lifting devices with sufficient load carrying capacity. When replacing parts or large sub-assemblies, use appropriate and functioning lifting devices and adequate load carrying capacity to insure safe movement during installation. Never stand or work under suspended loads.

– Always wear work gloves when handling wire ropes.

– Only permit experienced personnel to secure loads and signal the crane operator.

The guide must position himself within view of the operator or be in voice contact with him.

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Operating manual

Maintenance Safety instructions

– When working overhead, use appropriate safe access ladders and working platforms.

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

Wear a harness when working at great heights.

Keep handles, steps, railings, platforms, and ladders free of dirt, ice and snow.

– When working on the attachment (for example when replacing teeth), make sure the machine is properly supported. Never use metal-on-metal support.

– Never stand underneath a machine that has been raised with the aid of work equipment unless it has been properly and securely supported.

– Always support the machine in such a ways that any shifting weight will not endanger the stability of the machine and avoid metal to metal contact.

– Work on travel gears, brake and steering systems may only be carried out by specially trained expert personnel.

– If the machine must be repaired on an incline, block the track chains with chocks and secure the uppercarriage to the undercarriage with the locking pin.

– Only qualified, specially trained personnel may work on the hydraulic system.

– Do not check for hydraulic leaks with your hand. Use cardboard or similar material to detect leaks. Wear work gloves.

– Do not loosen any lines or bolts before lowering the equipment, turning off the diesel engine and relieving the hydraulic system. After the diesel engine has been turned off, you must move all pilot controls (right handed joystick and pedals) into all directions to reduce the control pressure and the dynamic pressure in the work cycles. Then release the pressure in the tank, as described in this operating manual.

5.1.6

Electrical system – Check the electrical system regularly.

All defects, such as loose connections, burnt out fuses and bulbs, burnt or damaged wires or cables must be repaired immediately by an electrician or specially trained personnel.

– Only use original fuses with the correct amperage.

– Only qualified technicians should attempt troubleshooting or repairs on high voltage systems.

– DO NOT work on energized attachments.

– When working on mid and high voltage components, shut off the voltage and connect the supply cable to the ground to discharge any stored energy.

– Check all disconnected parts if they are truly free of current, ground them and short circuit them. Insulate adjacent, current carrying parts.

– Disconnect the battery before working on the electrical system or before carrying out any arc welding work on the machine.

5.1.7

Pressure accumulator – Pressure accumulators contain stored energy and operate at high pressures.

Only specially trained personnel may work on pressure accumulators.

– Do not operate damaged pressure accumulators.

– You must reduce the pressure in the hydraulic system as described in this operating manual prior to working on a hydraulic accumulator.

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5-3

Maintenance

Operating manual

Safety instructions

– Do not weld or solder on the pressure accumulator and do not carry out any mechanical work on them.

– Fill the pressure accumulator only with nitrogen.

– The accumulator housing can become hot during operation, there is a danger of burning.

– New pressure accumulators must be charged to the required pressure for the application before use.

– The operating data (minimum and maximum pressure) is marked permanently on the pressure accumulators. Make sure that the marking remains visible.

5.1.8

Hydraulic hoses and lines – Hydraulic lines and hoses may never be repaired!

– All hoses, lines and fittings must be checked every two weeks for leaks and visible damage. Damaged parts must be replaced immediately. Remember that escaping high pressure oil can penetrate skin. Escaping oil can also cause fires.

– Even if hoses are properly stored and used, they undergo a natural aging process. For that reason, their service life is limited.

• Improper storage, mechanical damage and impermissible use are the most frequent causes of failure.

• Using hoses and lines close to the limit ranges of permitted use can shorten the service life (for example in high temperatures, frequent work cycles, extremely high impulse frequencies, multi shift operation).

– Hoses and lines must be replaced when the following conditions are found during inspection: • Damage to the outer layer as far as the intermediate layer (e.g. chafing, cuts and cracks); • Brittleness of the outer layer (hose material cracking); • Deformations, which differ from the natural shape of the hose or hose line, when under pressure or not under pressure, or in bends (e.g. separation of layers, blisters or bubbles); • Leaks; • Failure to follow installation instructions; • Damage or deformation of hose fittings, which reduce the strength of the fitting or the hose / fitting connection; • Hose slipping out of the fitting; • Corrosion on the fittings, which reduces function and strength; – When replacing hoses and lines, observe the following: • Use only original spare parts.

• Route and install hoses and lines properly, observe correct connection points.

• Always ensure that the hoses and lines are free of torsion when routing. On high pressure hoses, always attach the screws of half clamps or full flange on both ends of hose first and then tighten.

• When using high pressure hoses and lines with a bent fitting, always tighten the end with the bent fitting first when tightening the flanges, then the end with the straight fitting.

• Any existing mounting clamps in the centre of the hose may only be installed and tightened thereafter.

• Check daily to ensure that all clamps, covers and protective devices are properly mounted. This prevents vibration and damage during operation.

• Route the hoses and lines in such a way that chafing with other hoses or other structures is prevented.

• A minimum distance of approximately ½ of the outer hose diameter to the other parts is recommended. The distance should not be less than 10 to 15 mm (1/2 inch).

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Operating manual

Maintenance Maintenance access doors

• When replacing hoses and lines on movable parts (e.g. from boom to stick), check for hose interference and kinking over the complete range of motion.

5.1.9

Cab protection (FOPS) For certain machine applications LIEBHERR offers optional cab protection systems of various designs. These systems consist of a full length FOPS (falling objects protective structure) or a top guard and front guard to protect the operator's cab and windscreen area from falling objects (for example rocks or debris).

The full length FOPS wraps around the operator's cab, is mounted to the uppercarriage and is a stand-alone system.

The top and front guards are either bolted individually or in combination to the cab structure. In that case the operator's cab is also part of the cab protection system and is subject to the following instructions.

– Never operate a machine if one of these protections is damaged in any way.

– Damages may occur due to: • structural modifications or repairs (for example welding, cutting or drilling) • deformation after an accident • falling objects – Structural modifications or repairs of any kind are prohibited without the expressed, written approval of LIEBHERR.

5.2 Maintenance access doors 5.2.1

Overview of access doors

Fig. 5-1

Access doors on the machine

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5-5

Maintenance

Operating manual

Maintenance access doors

1 3

Engine hood Side door, left

2 4

Side door, right Cover battery box

The machine has 4 access doors for maintenance. The locks integrated in the handles must be unlocked before starting to travel.

Access door

Lock

Access to:

Engine hood

Gas pressure spring

– Diesel engine – Radiator – Hydraulic pump

Cover battery box

Gas pressure spring

– Batteries – Battery master switch

Side door, left

Mechanical retainer

– Electric box E50 – Servo oil unit – Engine hood release

Side door, right Tab. 5-1

5.2.2

Mechanical retainer

– Refuelling pump

Access doors

Door lock

Fig. 5-2

Door lock

To stop the access doors from moving unintentionally (e.g. due to wind), open them fully and allow the door lock (see arrow) to engage.

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Operating manual

Maintenance Cleaning machine

5.2.3

Engine hood release

Fig. 5-3

Engine hood release

Unlock the engine hood by opening the remote control 1 behind the left side door and push up.

Before closing the engine hood, close the remote control again.

5.3 Cleaning machine The machine should be cleaned before carrying out any maintenance or repair work.

In particular, the connections and screws should be cleaned of oil, fuel and residue of cleaning agents.

Note!

High-pressure water jet cleaners (steam cleaners) can damage the coating.

Do not use high-pressure water jet cleaners during the first two months after commissioning (or after recoating).

Observe the prescribed safety distances.

Before cleaning the machine: Before cleaning the machine with water or with a steam cleaner (high-pressure water jet cleaner), carry out the following tasks to protect the equipment against penetrating water.

Lubricate all bearing points, bolt connections and the slewing ring; if necessary, use the central lubrication system to do this.

Cover or seal all openings that must be protected against penetrating water for safety reasons (particularly at risk of damage are electric motors, electric components, switch cabinets, plug connections, measuring sensors and air filters).

Cleaning: Use flint-free cleaning cloths.

Do not use aggressive detergents or flammable liquids.

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5-7

Maintenance

Operating manual

Care for rubber components

When cleaning the engine compartment, ensure that the temperature sensor of the fire alarm and extinguishing systems (if installed) are not accidentally brought into contact with the hot cleaning solution, After cleaning: Remove all seals and covers.

Check all fuel, engine oil and hydraulic lines for leakage, loose connections, chaffing and damage.

Repair any defects without delay.

Lubricate all bearing points, pin connections and the slewing ring to remove any water that might have been penetrated.

If required, renew the preservation layer (anti-corrosion protection) on components and surfaces.

5.4 Care for rubber components The service life of rubber seals can be prolonged by treating them with a rubber care product.

Clean and regularly treat the rubber seals on doors and panelling elements with a care product. This helps prevent premature wear and protects the rubber seals during the cold season.

Recommended care products: Silicone, talcum powder, deer tallow

5.5 Fuels, lubricants and process chemicals 5.5.1

General information Observe the instructions for lubricants and process chemicals. Lubricate the machine and change the oils at the prescribed intervals. For more information, see lubrication chart and inspection and maintenance schedule.

Keep workplaces for these activities clean. This enhances the service life and reliability of the machine.

All work on the machine must be carried out while it is standing on firm and level ground.

Switch off the diesel engine, remove the ignition key and set the battery main switch to position 0 (OFF).

Clean lubricating nipples before adding grease.

Clean all filling points and the area around them before opening the caps and screws.

The oil should be changed while it is at operating temperature.

After each oil change or refilling, check the fill level in the respective unit (the specified fill levels are guide values).

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Operating manual

Maintenance Fuels, lubricants and process chemicals

Collect old oil and chemicals in suitable containers and dispose of them according to the applicable statutory regulations.

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5-9

Maintenance

Operating manual

Fuels, lubricants and process chemicals

5.5.2

Lubricating chart

Fig. 5-4

Lubricating chart

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Operating manual

Maintenance Fuels, lubricants and process chemicals

Symbol

Description Diesel engine, check oil level Hydraulic tank, check oil level Gearbox or axle, check oil level Carry out first oil change Change oil Lubricate machine Lube point Medium filling point Observe operating manual

Tab. 5-2

5.5.3

Key to lubrication chart

Lubricant table

Designation

Recommended lubricant

Diesel engine

Adhere to the instructions of the engine manufacturer (see Deutz manual)

15,0

Hydraulic system (system capacity / oil change volume / tank capacity)

Liebherr Hydraulic Basic 68 Liebherr Hydraulic Basic 100 Liebherr Hydraulic HVI Liebherr Hydraulic Plus Liebherr Hydraulic Plus Arctic

300 / 170 / 150

Slewing gear mechanism

Liebherr Gear Basic 90 LS

4,4

Travel gear mechanism

Liebherr Gear Basic 90 LS

9.0 each

Tracks and gearing of the slewing ring, bearing of the equipment

Liebherr Universalfett 9900

-

Hinges, joints, locks

-

Tab. 5-3

Symbol

-

Volume (litre)*

-

Lubricant table

* = guide values

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Maintenance

Operating manual

Specifications for fuels, lubricants and process chemicals

5.5.4

Fuels, lubricants and process chemicals

Medium

Fuel tank

Conventional diesel fuel with <= 0.5 % sulphur content

290

Coolant

Corrosion inhibitor and antifreeze agent

25,0

Windscreen washer system

Conventional windscreen cleaning agent or denatured alcohol

Tab. 5-4

Symbol

Volume (litre)*

Designation

-

3,0

Fuels, lubricants and process chemicals

* = guide values

5.6 Specifications for fuels, lubricants and process chemicals 5.6.1

Fuels and lubricant for the diesel engine For details and specifications regarding the diesel fuel, lubricant and coolant for the diesel engine, see Deutz manual.

5.6.2

Hydraulic oil Hydraulic oils must meet the requirements outlined below.

Maximum water content of hydraulic oil: < 0.1 %

5.6.2.1

Liebherr hydraulic oil LIEBHERR recommends using the following hydraulic oils in its machines (depending on temperature range):

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Operating manual

Maintenance Specifications for fuels, lubricants and process chemicals

Fig. 5-5

Liebherr hydraulic oil, viscosity grade selection based on temperature

A Ambient temperature B Cold-start range with warm-up instruction C Operating range Liebherr Hydraulic Plus and Liebherr Hydraulic Plus Arctic are suitable for both long-term use and use in environmentally sensitive areas.

If LIEBHERR oils are not available locally, use one of the engine oils listed in section "Engine oils for use as hydraulic oils" (before choosing an oil, contact the respective customer service department).

5.6.2.2

Engine oils for use as hydraulic oils When using engine oils (third-party products) as hydraulic fluids, we advise customers to request a certificate from the oil manufacturer, confirming that the product meets the following specifications.

Engine oils that are to be used as hydraulic oils must meet the following specifications: Single-grade oils (1)

API - CD / ACEA - E1 (MB 226.0 and 227.0)

Multigrade oils (2)

API - CD, CE, CF / ACEA - E2, E3, E4 (MB 227.5, 228.1, 228.3 and 228.5)

Tab. 5-5

Classification of products, engine oils for use as hydraulic oils

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Maintenance

Operating manual

Specifications for fuels, lubricants and process chemicals

Fig. 5-6

Engine oil for use as hydraulic oil, viscosity grade selection based on temperature*

A Ambient temperature

1

Single-grade oils

B Cold-start range with warm-up instruction

2

Multigrade oils

C Operating range *

5.6.2.3

for deviating viscosity grade, consult LIEBHERR customer service.

Warm-up instruction The black bar B indicates ambient temperatures that are up to 20 °C below the operating range C. For cold starting at an ambient temperature below range B, the following warm-up instruction for the hydraulic oil applies: 1. Start the diesel engine and set it to medium speed (not exceeding 50% of maximum speed).

2. Carefully activate the working hydraulics. Operate the hydraulic cylinders and move them briefly to the stop.

3. After approx. 5 minutes, start the travel hydraulics. Total warm-up time: approx.

10 minutes.

For cold starting at lower ambient temperatures, follow the warm-up instruction below: Before starting the engine, warm up the hydraulic oil tank. Then proceed according to the warm-up instruction in 1.

5.6.2.4

Biodegradable hydraulic oil Caution!

Do not mix hydraulic oil products!

When mixing different ester-based biodegradable hydraulic oils or mixing such products with mineral oils, aggressive chemical reactions might occur, causing damage to the hydraulic system.

Therefore never mix biodegradable hydraulic oils from different producers, and never mix bio hydraulic oils with mineral oils!

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Operating manual

Maintenance Specifications for fuels, lubricants and process chemicals

Liebherr recommends using the following hydraulic oils in its machines (depending on the temperature range): Liebherr Hydraulic Plus or Liebherr Hydraulic Plus Arctic When using these hydraulic oils, bypass filtration might be omitted.

If these oils are not available locally, use a fully saturated hydraulic environmental ester synthetic (HEES) fluids (before choosing an oil, contact the respective customer service department).

Caution!

The use of synthetic ester-based oils without a bypass filter causes damage to the hydraulic system!

If synthetic ester-based oils are to be used, bypass filtration is mandatory, as the water content in the oil must be kept below 1000 ppm (0.1%).

Always use a bypass filter (optional equipment).

When using such fluids, we recommend replacing the hydraulic hoses every 4000 operating hours or latest every 4 years.

Do not use vegetable oils, as they do not possess the necessary thermal stability.

Under certain circumstances, the use of polyglycols is permitted, although they can cause damage to seals or the paintwork. Do not use oils containing polyglycols without first consulting the customer service department.

When using third-party products, we advise customers to request a certificate from the oil manufacturer, confirming that the product meets the above specifications.

5.6.2.5

Oil change, oil analysis and filter change Oil change Note!

Liebherr recommends carrying out regular oil analyses (see chapter , "Oil analysis" on page 16).

Oil change Not for use in environmentally sensitive areas without oil analysis

with oil analysis* (optional)

For use in environmentally sensitive areas (only permissible with oil analysis*)

LIEBHERR mineral oil Liebherr Hydraulic HVI Liebherr Hydraulic Basic 68 Liebherr Hydraulic Basic 100

every 3000 h

every 6000 h

- ***

Liebherr-PAO** Liebherr Hydraulic Plus Liebherr Hydraulic Plus Arctic

every 4000 h

every 8000 h

every 8000 h

Third-party product - mineral oil

every 2000 h

every 2000 h

- ***

Third-party product - fully saturated synthetic ester

- ***

- ***

every 2000 h

Oil type

Tab. 5-6

Oil change intervals

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Maintenance

Operating manual

Specifications for fuels, lubricants and process chemicals *

If the result of the oil analysis is satisfactory, you may continue using the oil for a longer period.

If the result of the oil analysis is negative, immediately change the oil. ** PAO = polyalphaolefin *** not permissible

Use in environmentally sensitive areas: machines operated in such areas must be filled with biodegradable hydraulic oil.

If the machine is operated for less than 1000 hours per year, an oil sample must be taken at least once a year. If a hydraulic oil remains in the machine for a prolonged period of time, it must be changed at least every 4 years (mineral oils and fully saturated synthetic esters) or every 6 years (Liebherr-Plus oils).

If the machine is not in use for a period of more than 6 months, carry out an oil analysis before restarting it.

Oil analysis For regular oil analyses, LIEBHERR recommends contracting the specialist company OELCHECK and changing the oil when indicated by the test results in the lab report.

– Yellow kit for biodegradable hydraulic oils – Green kit for mineral oils See also customer service and product information.

Reasons for regular oil analyses: – Reduction of costs thanks to prolonged oil change intervals – Detailed information regarding the hydraulic system, its components and the medium – Better protection of resources and the environment Oil sampling / operating conditions Oil sampling in machines operated under normal operating conditions

Oil sampling in machines operated under extremely dusty conditions

The oil sampling interval is determined by the actual operating conditions (for more information, see chapter "Dust-intensive applications, reduction of oil contamination").

Tab. 5-7

Symbols: Oil sampling depending on operating conditions

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Operating manual

Maintenance Specifications for fuels, lubricants and process chemicals

Oil sampling Not for use in environmentally sensitive areas (oil analysis optional)

For use in environmentally sensitive areas (oil analysis mandatory)

LIEBHERR mineral oil Liebherr Hydraulic HVI Liebherr Hydraulic Basic 68 Liebherr Hydraulic Basic 100

every 1000 h

every 250 h

- **

- **

Liebherr-PAO* Liebherr Hydraulic Plus Liebherr Hydraulic Plus Arctic

every 1000 h

every 250 h

first at 0 h, then every 1000 h

first at 0 h, then every 250 h

Third-party product - mineral oil

first at 1000 h, then every 500 h

every 250 h

- **

- **

Third-party product - fully saturated synthetic ester

- **

- **

first at 0 h, then every 500 h

first at 0 h, then every 250 h

Oil type

Tab. 5-8

Oil sampling depending on operating conditions

* PAO = polyalphaolefin ** not permissible

Filter change Filter change / operating conditions Filter change in machines operated under normal operating conditions

Filter change in machines operated under extremely dusty conditions

The filter change interval is determined by the actual operating conditions (for more information, see chapter "Dust-intensive applications, reduction of oil contamination").

Tab. 5-9

Symbols: Filter change depending on operating conditions

Change of return filter (use only LIEBHERR filters)

every 1000 h

every 500 h

Tab. 5-10 Filter change depending on operating conditions

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Maintenance

Operating manual

Specifications for fuels, lubricants and process chemicals

Change of bypass oil filter LIEBHERR filter

Filters from other manufacturers

every 2000 h or as indicated

every 500 h

every 250 h

Tab. 5-11 Filter change depending on operating conditions

5.6.2.6

Dust-intensive applications, reduction of oil contamination If the machine is normally operated with a hydraulic hammer or under similar conditions (considerable dust generation), the hydraulic oil might become more contaminated than under normal working conditions.

To prevent premature wear of the hydraulic components, the oil change and sampling intervals must be shortened.

Observe the following: – The filter cartridge(s) in the return filter must be replaced every 500 operating hours and after every hydraulic oil change.

– Use 10-µm filter cartridges instead of the standard 20 / 5-µm cartridges.

– The 2-µm breather filter must be replaced every 500 operating hours and after every hydraulic oil change.

Machines delivered with a hydraulic hammer attachment and retrofitted hydraulic hammer kits are already equipped with 10-µm filter cartridges in the return filter.

Please take this into account when ordering spare parts.

5.6.3 5.6.3.1

Lubricants for axles and gearboxes Quality Recommended lubricant

Specification

Liebherr Gear Basic 90 LS

API: GL-5 MIL-L: 2105 D ZF: TE-ML 05C, 12C, 16E, 21C

Liebherr Gear Plus 20W-40

API: Niveau von GL4 ZF: TE-ML 05F, 06K, 17E

Liebherr Gear Hypoid 90 EP

API: GL 5 MIL-L: 2105 B, C, D ZF: TE-ML 05A, 12A, 16C, 17B, 19B

Liebherr Hypoid 85W-140 EP

API: GL-5 MIL-L: 2105 D, PRF-2105 E ZF: TE-ML 05A, 07A, 16D, 21A

Liebherr Hydraulic-Gear ATF

GM: Dexron II D ZF: TE-ML 03D, 04D, 11A, 14A, 17C

Liebherr Syntogear Plus 75W-90

API: GL-4, GL-5, MT-1 MIL-L: 2105 D, PRF-2105 E ZF: TE-ML 02B, 05B, 07A, 12B, 16F, 17B, 19C, 21B

Tab. 5-12 Lubricating oil specifications

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Operating manual

Maintenance Specifications for fuels, lubricants and process chemicals

If LIEBHERR oils are not available locally, use an oil that conforms to the specifications (before choosing an oil, contact our customer service department).

5.6.3.2

Viscosity

Fig. 5-7

Temperature-based selection of the SAE class

A Ambient temperature 1 Use in gearboxes 2

Use in automatic transmissions

3 4

Use in axles Use in pump distributor gear systems

*

If the pump distributor gear is equipped with an oil cooler, the oil is not suitable for the marked temperature range (shaded area).

The choice of the lubricating oil viscosity is based on the SAE classification (Society of Automotive Engineers). The SAE classification does not provide any indication as regards the quality of a lubricating oil. The relevant factor for the correct choice of SAE class is the ambient temperature. Incorrect viscosity can impair the operation of axles and gearboxes.

The temperature ranges shown in the diagram are approximate ranges that might temporarily be exceeded.

5.6.4

Lubricating oil for transmission Recommended lubricant

Specification

Liebherr Motoroil 10W-40

API: CF

If LIEBHERR oils are not available locally, use an oil that conforms to the specifications (before choosing an oil, contact our customer service department).

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Maintenance

Operating manual

Specifications for fuels, lubricants and process chemicals

5.6.5

Grease

5.6.5.1

Quality Recommended lubricant

Specification

Liebherr Universalfett 9900

Soap-base grease (lithium complex) KPF 2 N - 25 (DIN 51502) NLGI grade: 2 (DIN 51818) VKA welding force: > 6000 N (DIN 51350 / 4)

- Liebherr Universalfett Arctic (for lowtemperature operation)

Soap-base grease (lithium complex) KPFHC 1 N - 60 (DIN 51502) NLGI grade: 1 (DIN 51818) VKA welding force: > 5500 N (DIN 51350 / 4)

The grease is used for both automatic and manual machine lubrication. it is supplied by the central lubrication system or through lubrication nipples to the respective lube points.

Examples: – Slewing ring bearings – Crown gears, geared wheels – Bolts, axles and screws – Attachments

5.6.5.2

Operating temperature

Fig. 5-8

Operating temperature for Liebherr greases

A Grease temperature *

The grease is not suitable for the temperature range (shaded), if used in a central lubrication system.

** The grease may only be within the temperature range (shaded) for short periods of time. Peak temperatures of max. 200 °C (392 °F) are possible.

5.6.6

Lubricants and care products for electrical and mechanical components Medium, purpose

Product (manufacturer)

Contact spray for slip rings

Cramolin

Lubricant for pistons, piston nuts and for the mounting of piston rod bearings at hydraulic cylinders

Gleitmo 800

Special corrosion inhibitor for mounting recesses of sealing elements at hydraulic cylinders

Rostilo Tarp CFX

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Operating manual

Maintenance Diesel engine

5.6.7

Grease and other process chemicals Medium

Description / manufacturer

Grease for central lubrication system, general lube points

Liebherr recommends using the following products for the lubrication of the machine, and in particular of the slewing ring roller bearings, bolts, crown gears, axles and screws: - Liebherr Universalfett 9900 - Liebherr Universalfett Arctic (for low-temperature operation) The grease must conform to specification KP2k, consistency grade 2, NLGI grade according to DIN 51818 and DIN 51825 or EP 2 according to NF-T-60 132.

The grease must consist of a lithium complex with a VKA value of minimum 2300 N according to DIN 51350 or ASTM D 2596 respectively.

Contact spray for slip rings

Cramolin

Lubricant for pistons, piston nuts, also used for the mounting of piston rod bearings at hydraulic cylinders

Gleitmo 800

Special corrosion inhibitor for mounting recesses for sealing elements at hydraulic cylinders

Castrol-Tarp

Tab. 5-13 Grease and other process chemicals

5.7 Diesel engine 5.7.1

Check oil level Danger!

Risk of injury from burning.

When the machine is at operating temperature, the engine oil is very hot.

Avoid skin contact with hot oil or parts containing oil.

Ensure that the machine is standing on level and firm ground.

Switch off the engine.

Wait until the oil has collected in the oil pan.

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Maintenance

Operating manual

Cooling system

Fig. 5-9

Checking the oil level

Check oil level in the engine.

The oil level must be between the min and max mark on the dip stick.

If necessary, add engine oil through the filler neck until the level reaches the max mark.

5.7.2

Changing the oil For instructions, see Deutz manual.

Note!

The oil change must be carried out when the engine is warm.

5.8 Cooling system 5.8.1

Checking and cleaning the cooling system

Fig. 5-10

Cleaning cooling fins

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Operating manual

Maintenance Cooling system

The machine is equipped with a combined oil-water cooling system.

A clean cooling system is a prerequisite for optimum cooling.

It is also necessary to regularly check the engine, fan and radiator for damage and to clean these parts.

Regularly inspect the cooling network according to the maintenance schedule.

Cleaning cooling fins If necessary, release the fan 1 from its lock and tilt it to the side. Clean the cooling fins with compressed air or steam jet (from the inside out, see arrow).

Tilt back the fan 1 and secure it.

Check the state and tightness of the coolant hoses, and the connecting hoses between the coolant radiator and the engine.

5.8.2

Checking coolant level Danger!

Risk of burns from hot coolant.

When the temperature is near the operating temperature, the engine cooling system is hot and pressurised.

Do not touch any parts containing coolant. Avoid contact with the coolant.

Check the coolant level only after the engine has cooled down.

Fig. 5-11

Expansion tank

Turn the lid by 180 degrees (see arrow).

In this position, release any excess pressure, if necessary. When the tank is depressurised, carefully turn the lid further to remove it.

The coolant level must be between the MIN and MAX marks.

If necessary, add coolant.

Close the lid.

After coolant has been added, switch on the engine and let it run for a short time, while the heating is on. Then check the coolant level again.

Check the pressure relief valve (lid). If there is leakage, replace it.

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Maintenance

Operating manual

Cooling system

5.8.3

Corrosion inhibitor and antifreeze agent The system must be filled with an antifreeze agent at all times.

When delivered, the cooling water contains antifreeze agent protecting the circuit to a minimum temperature of -37 °C (corresponds to a antifreeze concentration of approx. 50 %) The mixing ratio of the antifreeze agent must be regularly checked in the course of routine maintenance.

Filling volume: see lubricant table Note!

Do not exceed a corrosion inhibitor and antifreeze agent concentration of 60 %!

Higher concentrations tend to result in poor cooling and antifreeze protection.

5.8.4

Changing coolant Danger!

Risk of burns from hot coolant.

The coolant must be changed when the engine is cold.

When changing the coolant, observe the following instructions: – The coolant of the entire cooling circuit must be replaced every two years.

– The coolant should be changed while the stop valves remain closed.

– After refilling of the circuit, bleed it.

Draining coolant

Fig. 5-12

Drain valve

Slowly open the radiator lid of the expansion vessel.

Remove the cover plate at the base of the engine.

Place a suitable container under the engine.

Remove the cap of the drain valve 1 at the bottom of the radiator (arrow) and connect the hose from the tool box.

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Operating manual

Maintenance Fuel system

Fig. 5-13

Water taps on the diesel engine

Close the water taps.

Filling in coolant Disconnect the hose from the bottom of the radiator and close the valve.

Add coolant to the expansion vessel, until it reaches the filler neck.

Open the water taps.

Switch on the heating and let it run at maximum level. Run up the diesel engine.

Check the coolant level and add coolant, if necessary.

5.9 Fuel system Danger!

Danger of explosion!

Avoid open flames when working on the fuel system and when refuelling.

Do not smoke.

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Maintenance

Operating manual

Fuel system

5.9.1 5.9.1.1

Refuelling Fuel tank cap

Fig. 5-14

Fuel tank cap

Unscrew tank cap 1 Add fuel via the strainer.

5.9.1.2

Electric refuelling pump (optional equipment)

Fig. 5-15

Electric refuelling pump

The electric refuelling tank is used to refill fuel into the fuel tank of the machine.

It is located behind the side door at the fuel tank.

To refuel and then store away the hoses, proceed as follows: Remove the tank lid.

Connect the suction hoses 1 and 2.

Insert the free end of the suction hose 3 into the fuel container.

Open the stop cock 4.

Switch on the refuelling pump with the switch S25 (green) on the control unit 5 to pump fuel into the tank of the machine.

The pump is automatically switched off when the maximum fill level is reached.

The refuelling pump can be switched off at any time with the switch S59 (red).

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Operating manual

Maintenance Fuel system

Caution!

Prevent the pump from running dry!

Ensure that the fuel level does not drop below the suction height of the suction hose.

Close the stop cock 4.

Before storing away the hose, ensure that no fuel is left in the suction hose 1 (2).

Roll up the suction hose and store it away it in the storage place.

Close the flap.

Replace the tank lid.

5.9.2

Draining the water from the fuel tank The condensation in the fuel tank and fuel system should be drained daily. If conditions of use and fuel quality permit, the maintenance interval can be increased to once a week.

Note To reduce condensation in the tank, keep the fuel level as high as possible.

Fig. 5-16 1

Fuel tank

Tank cap

2

Strainer

3

Drain plug

The bottom of the tank is equipped with a drain plug 3.

Open the drain plug 3 on the underside of the fuel tank by two turns.

Drain off water until fuel emerges, close the plug again.

5.9.3

Emptying and cleaning the fuel tank To empty, remove the tank cap 1 and the drain plug 3 and allow the fuel to flow into a suitable container.

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Maintenance

Operating manual

Fuel system

Clean the tank.

Check the tank and strainer2 regularly for contamination.

5.9.4

Fuel pre-filter If there is excessive condensation (during cold season), the installed humidity sensor of the pre-filter might respond before the regular maintenance interval is reached.

The indicator light for water in the fuel filter is switched on.

Draining off water:

Fig. 5-17

Fuel pre-filter

1

Drain hose for condensate

2

Stop valve

3

Electric cable

4

Condensate tank

5 7

Filter cartridge Bleeder screw

6

Hand pump

Place the collecting vessel for the condensate / fuel under the drain hose 1 end.

Close the stop valve 2 a little.

The water in the condensate tank 4 flows through the drain hose into the collecting vessel provided.

Close the stop valve 1.

Replacing filter cartridge: Note The filter cartridge can easily be damaged by excessive tightening!

Do not use any tools when tightening the filter cartridge.

Place the collecting vessel for the condensate / fuel under the drain hose 1 end.

Disconnect the electrical cable 3.

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Operating manual

Maintenance Fuel system

Close the stop valve 2 a little.

Water mixed with fuel flows through the drain hose into the collecting vessel provided.

Unscrew the condensate tank 4 and remove the filter cartridge 5.

Apply a little oil to the seals of the filter head and condensate tank (arrows).

Insert a new filter cartridge and condensate tank.

Close the stop valve.

Reconnect the electrical cable.

Note Before bleeding the fuel pre-filter, release the push button of the hand pump 6!

To release it, turn the push button to the left.

Loosen the bleeder screw 7 on the fuel pre-filter and turn it out by approx. 1/4 revolution.

Operate the hand pump, until fuel escapes free of bubbles from the bleeder bore.

Insert and tighten the bleeder screw.

After bleeding is completed, push in the push button of the hand pump to the stop while turning it to the right to engage it.

5.9.5

Replacement of fuel filter cartridge (fine filter)

Fig. 5-18

Fuel inlet filter

Unscrew the fuel filter cartridges 1.

Apply a little oil to the rubber sealing ring of the new filter cartridges.

Note The filter cartridge can easily be damaged by excessive tightening!

Do not use any tools when tightening the filter element.

Insert new filter cartridge and tighten by hand.

Bleed the fuel system.

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Maintenance

Operating manual

Dry air filter

5.10 Dry air filter The engine can only be protected from abrasion caused by dust and thus excessive wear, if the air filter is regularly cleaned or replaced.

The dry air filter is designed in such a way that it provides excellent protection with relatively long maintenance intervals.

For safety reasons, we strongly recommend not washing out the filter inserts.

Fig. 5-19

Dry air filter

The maximum permissible suction underpressure might be reached, if the dry air filter is contaminated or if the dust removal valve 1 is blocked.

When this value is reached, the underpressure indicator 2 at the clean air connection and the air filter contamination indicator light are on.

5.10.1

Cleaning the dust removal valve Every week, open the discharge slot of the dust removal valve 1 by hand.

Remove the dust.

If the valve is cleaned regularly, it is less likely to become blocked quickly again.

5.10.2

Replacing filter elements Note!

Frequent removal and remounting of the filter elements might result in damage to the seals between the filter element and the filter housing.

Do not replace the dry air filter elements more frequently than specified in the maintenance schedule.

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Operating manual

Maintenance Dry air filter

Fig. 5-20

Change of filter cartridges

1 2

Filter housing lid Main element

4 5

Dust removal valve Seal

3

Safety element

6

Filter housing

Replace the main element 2 at least once a year, and also if the maximum permissible intake underpressure is exceeded.

Replace the safety element 3, at least once a year, and after three replacements of the main element.

Replacing the main element: Shut down the engine and remove the lid 1.

Remove the dirty main element 2.

Clean the inside of the air filter housing and the sealing surface in the vessel with a damp cloth.

Caution!

Ensure that no dirt particles enter the engine intake system!

Do not clean the filter housing by blowing it out with compressed air.

Carefully clean the seal 5, the sealing surfaces and the inside of the filter housing.

Inspect sealing surfaces for damage.

Insert the new main element, and ensure that it is positioned tightly and firmly in its seat.

Close the lid 1 of the filter housing 6.

Changing the safety element: Note!

If a visual inspection reveals that the safety element is heavily contaminated, replace it without delay.

Remove the main element 2.

Remove the safety element 3.

Carefully clean the inside of the air filter housing with a moist cloth.

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Maintenance

Operating manual

Hydraulic system

Clean the sealing surfaces in the housing and examine for damage.

Carefully insert the new safety element 3.

Insert the new main element 2 and ensure that it is positioned tightly and firmly in its seat.

Close the lid 1 of the filter housing 6.

5.10.3

Checking the clean air line

Fig. 5-21

Clean air line

Check the clean air line 1 between the filter outlet and the motor intake pipe for damage and leakage every time a filter element is replaced.

Fig. 5-22

Please note that certain clamps may not be retightened.

Note!

Clamps with spring packs (3, see arrow) can compensate changes in diameter.

Retightening might interfere with their function.

Do not retighten clamps with spring packs.

If necessary, retighten clamps 2.

5.11 Hydraulic system Maintenance work on the hydraulic system is basically limited to the hydraulic tanks (change of return filter and oil change) and the control oil unit (change of control oil filter).

All other components of the unit do not require any special maintenance or servicing.

The network of pipes and hoses must however be inspected regularly for leaks.

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Operating manual

Maintenance Hydraulic system

Danger!

High-pressure liquid might penetrate the skin and cause damage.

At operating temperature, the hydraulic oil is hot and might even be under pressure.

Escaping oil can cause serious injury.

Before carrying out any work on the hydraulic system, you must fully depressurise it.

Do not use your bare hands to check the equipment for leaks.

Avoid skin contact with hot oil or parts containing oil.

Note!

Cleanliness is of particular importance for the proper working of the hydraulic system.

For this reasons, the following intervals must be strictly adhered to: – Change of return filter, bypass oil filter* – Cleaning of oil cooler – Oil change * optional equipment

5.11.1

Checking the oil level in the hydraulic tank

Fig. 5-23

Oil level gauge at the hydraulic tank

The oil level in the tank is indicated by means of oil level gauges at the rear of the tank.

The lower mark - MIN - indicates the minimum oil level when all cylinders are fully extended.

To check the minimum oil level, ensure that the following conditions are fulfilled: The hydraulic excavator is standing on level ground.

The working attachment is fully lifted, the boom regulating cylinder, boom cylinder, stick cylinder and bucket tilt cylinder are fully extended (stick and digging bucket tilted in).

The blade and/or outrigger supports are fully extended (lowered).

-The oil level may not drop below the - MIN - mark.

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Maintenance

Operating manual

Hydraulic system

The upper mark - MAX - indicates the maximum oil level when all cylinders are fully retracted.

To check the maximum oil level, ensure that the following conditions are fulfilled: The hydraulic excavator is standing on level ground.

The working attachment is placed on the ground, and the stick and the bucket tilt cylinder are fully retracted.

The blade and/or outrigger supports are fully retracted (lifted).

- The oil level may not exceed the - MAX - mark.

Check the oil level and add oil, if necessary.

5.11.2

Releasing the pressure from the hydraulic system Switch off the diesel engine.

Operate the pilot control devices (joystick and pedals) in all directions (while the ignition key is in contact position).

5.11.3

Releasing tank pressure

Fig. 5-24

Releasing tank pressure

Turn out the breather filter 1 by maximum one full turn.

The pressure in the hydraulic tank is gradually reduced.

The breather filter 1 can be rotated by hand when the safety pin 2 is inserted. If necessary, use an open-end spanner to open the filter.

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Operating manual

Maintenance Hydraulic system

5.11.4

Emptying and refilling hydraulic tank

Fig. 5-25 1

Draining and refilling hydraulic oil

Breather filter

2

Return filter

3

Drain valves

Depressurise the hydraulic system including the tank.

If possible, empty and refill the hydraulic system using a filler unit.

Draining oil: Remove the lid from the return filter 2.

Screw the drain hose onto the drain valves 3 at the bottom of the tank and let the oil drain into a suitable container.

Refilling hydraulic oil: Remove the lid from the return filter 2.

Refill oil through the filter cartridge until it reaches the centre mark in the sight glass.

Tighten the breather filter 1.

Replace the lid from the return filter 2.

Note!

After each hydraulic oil change, bleed the hydraulic pumps.

Draining condensate: Regularly drain the condensate from the system.

Place a suitable container under the machine.

Connect the drain hose to the drain valve 3 (see Fig. 5-25) until the oil flowing into the container does not contain any water.

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Maintenance

Operating manual

Hydraulic system

5.11.5

Changing return filter

Fig. 5-26

Return filter

The return filter is located inside the hydraulic tank and can be accessed when the cover 1 is removed.

At fixed intervals, the magnetic rods must be cleaned and the filter cartridges must be replaced.

Note!

In areas with excessive production of dust, observe the special instructions for the filter change.

Note!

LIEBHERR offers a bypass oil filter (optional equipment) for the return filter.

Where environmentally friendly hydraulic oils are used, LIEBHERR prescribes the use of bypass oil filters.

The bypass oil filter is designed to remove small particles and water from the hydraulic system.

Changing the standard return filter:

Fig. 5-27

Return filter

1

Cover

4

Protective cylinder of return filter

2 3

Magnetic rods Filter cartridge (return filter)*

5

Flat gasket

Depressurise the hydraulic system including the tank.

Loosen the four screws of the cover 1 and lift off the cover with the magnetic rod 2.

Carefully clean the magnetic rod 2 removing any persistent dirt.

Remove the spent filter cartridge 3 holding it by the bracket.

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Operating manual

Maintenance Hydraulic system

Insert the new filter cartridge 3 into the tank, holding it by the bracket, and push it slightly down. Place the bracket to the side at the tank ring.

Ensure that the filter cartridge is positioned vertically in the tank.

Centre and place the cover 1 with the magnetic rod 2 carefully on the filter cartridge. Ensure that the flat gasket 5 is not damaged and positioned correctly.

Tighten the screws of the cover 1.

After a filter change, you must also change the control oil filter.

Note!

The filling opening of the hydraulic tank is equipped with a protective cylinder 4.

This prevents foreign bodies entering the hydraulic tank. If required, the protective cylinder can be removed from the filling opening.

Changing the return filter with bypass oil filter (optional equipment):

Fig. 5-28

Return filter with bypass oil filter

1

Cover

5

Flat gasket

2 3

Magnetic rod Filter cartridge (return filter)

6 7

Filter cartridge (bypass oil filter)* Protective cylinder of oil bypass filter*

4

Protective cylinder of return filter

8

Cover of bypass oil filter*

* only in conjunction with bypass oil filter (optional equipment)

Depressurise the hydraulic system including the tank.

Loosen the four screws of the cover 1 and lift off the cover with the magnetic rod 2.

Remove the cover 1 from the magnetic rod 2.

Remove the protective cylinder 7, lift off the cover 8 and remove the spent filter cartridge 6.

Carefully clean the magnetic rod removing any persistent dirt.

Mount the protective cylinder 7 with the new filter cartridge 3 onto the magnetic rod. Replace the cover 8.

Screw the cover 1 onto the magnetic rod 2.

Remove the spent filter cartridge 3 holding it by the bracket.

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Maintenance

Operating manual

Hydraulic system

Insert the new filter cartridge 3 into the tank, holding it by the bracket, and push it slightly down. Place the bracket to the side at the tank ring.

Ensure that the filter cartridge is positioned vertically in the tank.

Centre and place the cover 1 with the magnetic rod 2 carefully on the filter cartridge. Ensure that the flat gasket 5 is not damaged and positioned correctly.

Tighten the screws of the cover 1.

After a filter change, you must also change the control oil filter.

Note!

The filling opening of the hydraulic tank is equipped with a protective cylinder 4.

This prevents foreign bodies entering the hydraulic tank. If required, the protective cylinder can be removed from the filling opening.

5.11.6

Changing control oil filter

Fig. 5-29

Control oil unit

1

Control oil unit

5

Seal ring of filter cartridge

2 3

Pressure filter Mounting stud

6 7

Filter pot Seal ring of filter pot

4

Filter cartridge

8

Accumulator

The pressure filter 2 is an integral part of the control oil unit 1 located at the rear of the hydraulic tank.

Note!

The cleaning of the filter cartridge is prohibited!

Each time you open the filter pot, replace the cartridge.

Depressurise the hydraulic system including the tank.

Remove the filter pot 6 of the pressure filter 2 and pull out the filter cartridge 4.

Clean the filter pot.

Apply a little hydraulic oil to the threads and sealing faces at the filter pot 6 and at the control oil unit 1 as well as to the sealing rings 5 and 7.

Carefully place the new filter cartridge 4 onto the mounting stud 2.

Screw in the filter pot 6 to the stop and tighten it by hand.

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Operating manual

Maintenance Hydraulic system

5.11.7

Checking the control circuit The actuators do not require any special maintenance or servicing.

Regularly inspect the pipelines and the connections of all units (pumps, pressure accumulators, pressure-relief valve, pressure filter, etc.) for leakage.

Danger!

The pressure accumulator 8 (see Fig. 5-29) ensures that the control circuit remains pressurised after the diesel engine is shut down so that a number of movements remain possible.

Prior to interfering with the control pressure circuit, it must be depressurised: To do this, place the attachment on the ground.

Switch off the engine.

Operate both joysticks (while the ignition key is in start position).

5.11.8

Bleeding hydraulic pump

Fig. 5-30

Hydraulic pump

After work on the hydraulic pump and after a hydraulic oil change, you must bleed the hydraulic pump.

Slightly loosen the hydraulic screw coupling of the leak oil hose 1 and let the air escape.

As soon as hydraulic oil begins to escape, close the hydraulic coupling.

Before restarting the pump after a repair or replacement, fill the pump housing with hydraulic oil through the above fitting.

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Maintenance

Operating manual

Hydraulic system

5.11.9 5.11.9.1

Maintenance of hydraulic cylinders Checking piston rod bearing

Fig. 5-31

Piston rod bearing

Note If there is a leak at the piston rod bearing of a hydraulic cylinder (arrow), we recommend having the seal kit replaced by a LIEBHERR technician.

5.11.9.2

Preservation of piston rods Prior to standstills of more than 4 weeks, and in particular prior to any sea transport of the machine, carry out the following tasks: If possible, position and transport the machine in such a way that the piston rods are fully retracted into the cylinders.

Exposed piston rods must be protected with a thick layer of acid-free corrosion protection grease.

Before loading the machine, check the piston rods again for proper preservation.

Also apply corrosion protection grease to the piston rods, if the respective cylinder is rarely operated during work. Piston rods that are not frequently retracted and extended are not properly lubricated with hydraulic oil.

Regularly check the preservation of rarely operated hydraulic cylinders.

5.11.10

Replacing hydraulic hoses

Fig. 5-32

High pressure hose with SAE fitting

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R 317 Litronic Industrie / 11140224

Operating manual

Maintenance Changing the oil on components

Danger!

A defective hydraulic hose can cause accidents and injuries.

Replace defective hydraulic hoses (bubbles, moisture, damaged top edge etc.) immediately.

Install new hydraulic hoses without torsion.

Ensure that the hydraulic hose is not twisted when mounting.

Installed high pressure hoses with SAE connections have a nominal diameter of 16, 20 or 25.

Tighten the mounting screws of SAE fittings with the following tightening torques. :

Screw

Grade

Torque

M10

10.9

68 Nm

M12

10.9

117 Nm

M14

10.9

185 Nm

Tab. 5-14 Tightening torques for SAE fittings

5.12 Changing the oil on components 5.12.1

General notes The machine must be in level position.

Shut down the engine.

Wait for a short time until the oil has collected in the oil pan.

If possible, drain the oil when it is at operating temperature.

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Maintenance

Operating manual

Changing the oil on components

5.12.2

Swin gear - oil change

Fig. 5-33

Changing the oil on the swing gear

1

Drain valve

3

Oil container

2

Drain hose

4

Cap

To drain the oil: Remove the cap 4.

Unscrew the cover of the drain valve 1 via the opening on the base plate of the swing platform.

Screw the provided drain hose 2 on the drain valve and allow the oil to flow into a suitable container.

Remove the hose 2.

Reinstall the cover of the drain valve 1.

To add the oil: Add the oil via the tank 3 until the level reaches the MAX mark.

Reinstall cover 4.

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Operating manual

Maintenance Drive

5.12.3

Travel gear - oil change

Fig. 5-34

Travel gear - changing oil

Before the oil change, ensure that the machine is at operating temperature: Draining oil: To drain off oil or to add oil, position the chassis in such a way that the screw plugs 1, 2 and 3 are in the positions indicated in the drawing.

Place a suitable collecting vessel (approx. 5 litres) under the screw plug 3.

Remove the screw plug 3.

Remove the screw plug 1 or 2.

Collect the escaping oil in the vessel.

Adding oil: Close the screw plug 3.

Add oil through the opening 1 until the oil level reaches the opening.

Insert and tighten the screw plugs 1 and 2.

5.13 Drive The running gear is maintenance-free, unless the running surfaces or the flanges requires regeneration or until all drive parts are completely worn.

The lifetime design of the support rollers, running rollers and idlers prolongs the service life of the drive, while the metal seals protect it against dirt.

5.13.1

Cleaning drive Do not start the machine, if stones, pieces or timber, metal, wire or cable sections are jammed in the drive.

Dry or frozen mud, stones and other extraneous material inside the drive components can cause serious damage to the machine, if it is started. Do not attempt to free the machine by means of engine power.

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Maintenance

Operating manual

Drive

If the ambient temperature is below zero, place the machine on planks to prevent the chains from becoming frozen to the ground.

Caution!

To prevent serious damage, do not attempt to free a machine frozen to the ground with force.

Frozen chains can be freed by carefully heating the base plates.

Fig. 5-35

Lifting machine

Caution!

Risk of the machine becoming dislodged.

When propping up the machine, secure it with timber beams.

Before placing the machine on the ground, remove the dirt from heavily contaminated drive components.

Remove sand and dirt from the sliding surfaces at the tensioning units and lubricate them.

To clean the drive, lift one side of the chassis from the ground, propping the machine up with the working attachment, (see Fig. 5-35).

5.13.2

Checking fixtures of drive components

Fig. 5-36

Fixtures of drive components

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Operating manual

Maintenance Drive

Carry out regular visual inspections of the securing screws of the base plates and the drives in order to find any loose bolts.

Check tightening torques.

• Mounting bolts 7 of the base plates: 520 Nm • Mounting bolts 8 of the drive: 620 Nm • Mounting bolts 9 of the tumbler wheel: 560 Nm • Mounting bolts 10 of the hydraulic motor: 280 Nm

5.13.3

Checking chain tension

Fig. 5-37

Check chain tension.

Release the chain by moving forward and back.

Place the measuring rod 1 onto the section between the idler and the support roller.

Measure the distance A between the measuring rod lower edge and the base plate.

Under normal operating conditions, the dip between the support roller and the idler should be between 20 to 40 mm.

If necessary, tension the chain.

5.13.4

Tensioning chain

Fig. 5-38

Chain tension insufficient (A) and correct (B)

As the chassis is exposed to normal wear, the chain tension must be regularly checked and retensioned, if necessary.

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Maintenance

Operating manual

Drive

Fig. 5-39

Tensioning chain

Remove the lid 3 from the longitudinal member of the undercarriage.

Screw the high pressure hose 1 to the hand grease gun.

Open the high pressure hose 1 to connect it with the lubrication nipple 2 of the grease tensioner.

Add grease until the chain is sufficiently tensioned.

Check chain tension.

5.13.5

Releasing chain

Fig. 5-40

Releasing chain

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Operating manual

Maintenance Electrical system

Danger!

Risk of injury from slacking chain or expelled grease.

When tensioning the chain, always wear protective goggles and gloves.

The lubrication nipple 1 may not be loosened.

When releasing the chain, keep your head away from the running roller frame.

When loosening the lubrication nipple extension 2 keep your hands away from the lubricating nipple. To loosen the lubrication nipple extension, always use suitable tools.

Clean the chain and remove any jammed objects.

Place machine on level ground.

Turn lubrication nipple extension 2 by a few revolutions until grease escapes from the longitudinal groove 3 of the lubrication nipple extension.

As soon as the desired chain tension is reached, tighten the lubrication nipple extension 2.

After adjustment, move the machine forward and back and then check the chain tension again.

5.13.6

Changing lubrication nipple Release the chain as described in section "Releasing chain".

As soon as no grease escapes from the longitudinal groove 3 of the lubrication nipple extension 2,(see Fig. 5-40): Fully unscrew the lubrication nipple extension.

Fully screw in and tighten the preassembled unit (lubrication nipple extension 2 and lubrication nipple 1).

Tension the chain as described in section "Tensioning chain".

5.14 Electrical system 5.14.1

Notes regarding the electrical system Danger!

Risk of injury from sparks.

When charging batteries or carrying out other work on batteries, keep away from sparks and naked flames.

Always wear goggles and protective gloves.

Regularly inspect the electrical system of the machine for defects.

Identify the cause of blown fuses and broken incandescent lamps, eliminate it and replace the fuse or the lamp.

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Maintenance

Operating manual

Electrical system

Defects such as loose connections, chaffed cables or poorly fixed clamps must be repaired without delay.

Before carrying out any work on the electrical system or carrying out electric arc welding work on the machine, disconnect the batteries.

Danger!

Risk of injury from sparks.

Disconnect the negative pole (-) first and reconnect it last.

5.14.2

Battery main switch Caution!

Do not interrupt the saving process of the engine control unit.

After switching off the diesel engine, the engine control unit remains activated for approx. 40 seconds in order to save system data. Switching off the battery main switch during saving might result in the loss of data so that the diesel engine cannot be restarted.

After switching off the diesel engine, wait for approx. 1 minute before switching off the battery main switch to ensure that the saving process is properly completed.

Caution!

Special care is required in connection with machines with built-in auxiliary heater.

Only switch off the battery main switch after the afterrun time of the auxiliary heater has lapsed.

Fig. 5-41

Battery main switch

Before carrying out any work on the electrical system or performing welding work on the machine, set the battery main switch to position 0 (off).

Before washing the machine, cover the electrical devices (in particular the alternator, generator, cabling, electrical components and measurement transducers) so that they are protected against splashing water.

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Operating manual

Maintenance Electrical system

When cleaning the engine with a water or steam jet, ensure that the measurement transducers (e.g. oil pressure switches) are not exposed to a direct water or steam jet.

Otherwise, water might penetrate the devices and cause corrosion of the contacts, leading to measuring failures.

Oil pressure switches cannot be designed as water-tight units due to the need for diaphragm ventilation.

Note!

The battery might discharge itself during prolonged standstills.

Prior to prolonged standstills, set the battery main switch to position 0 (off).

5.14.3

Battery care To ensure that the batteries work properly at all times, keep them clean.

Regularly clean the pole heads and cable terminals A and protect them with a thick layer of acid-proof grease, (see Fig. 5-42).

Danger Kinked rubber hoses of the central gas release system lead to a higher risk of explosion!

The hydrogen produced in the battery may not collect in the battery box and must be released from the enclosure through the rubber hoses. When installing the hoses of the central gas release system, ensure that they are not kinked.

Regularly check the hoses B for damage, especially after installation of the battery, (see Fig. 5-42).

The liquid level in the cells must be about 10 to 15 mm above the upper edge of the plate. If topping up is necessary, add only distilled water.

Fig. 5-42

Battery care

From time to time, check the acid density using a battery tester C. If the battery is fully charged, the density is 1.28 kg/l (31.5° Bé).

If the battery tester shows a lower value, the battery is discharged to some degree and might need to be recharged.

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Maintenance

Operating manual

Electrical system

5.14.4

Slip ring body (optional equipment)

Fig. 5-43

Slip ring body

Slip ring bodies are easily damaged by humidity, as oxide layers might form on the conducting surfaces, impairing electrical conductivity. As a consequence, the electrical consumers in the undercarriage are not sufficiently powered, which can result in malfunctions.

To prevent this, we recommend carrying out the following tasks every 500 operating hours: Unscrew the lock nuts 1.

Remove the slip ring housing 2.

Remove any oxidation from the slip ring body (use cleaning spray, if necessary).

Replace damaged (corroded) fork terminals.

Apply Cramolin contact spray to all slip ring elements.

Replace the housing 1.

Secure the housing 1 with the lock nuts 2 and tighten them all with the same torque.

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Operating manual

Maintenance Heating system

5.15 Heating system 5.15.1

Ambient air filter

Fig. 5-44

Ambient air filter

If the ambient air filter is dirty, the air flow is reduced. This in turn affects its performance and can result in frequent icing or shut-down of the a/c system (optional equipment).

Never operate the machine without filter, even for short periods, as this might result in blockage of the heat exchanger.

The ambient air filter must be cleaned or replaced every 500 operating hours (shorten interval, if the machine is operated in a particularly dusty environment).

Remove the windscreen detergent tank and the deflector 2.

Remove the ambient air filter 1.

Note!

Incorrect cleaning of the filter might damage it.

Never clean the filter elements with hot water of steam!

If the ambient air filter is damaged or in poor state, replace it.

Clean the ambient air filter 1 with compressed air or wash it with cold or tepid water.

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Maintenance

Operating manual

Heating system

5.15.2

Heating system

Fig. 5-45

Water taps on the diesel engine

If the heating remains switched off for a prolonged period of time (e.g. during the summer), close the water taps at the diesel engine (see arrows).

Every year at the start of the heating period, complete the following maintenance routine.

Check the entire coolant circuit for leakage.

Retighten the connections in the coolant circuit, the hose connections at the heat exchanger, the seals of the stop valves and the hose clamps.

The system may only be operated with coolant containing a suitable corrosion inhibitor and antifreeze agent.

Fig. 5-46

Combined heating-a/c system

Inspection of the heat exchanger Check the fins of the heat exchanger1 and the evaporator2 (a/c system, optional equipment) for damage.

If they are dirty, clean them with compressed air.

If necessary, realign the fins.

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Operating manual

Maintenance Automatic lubrication of the machine

5.15.3

Air-conditioning system (optional equipment) Switch on the a/c system every two to three weeks for about 10 minutes, irrespective of the season.

During the operating period, the following maintenance tasks must be carried out every 500 operating hours by a technician specialising in a/c systems: – Testing of thermostat, blower and pressure switch – Inspection of the electrical lines – Testing of the condenser (if necessary: cleaning) – Testing of a/c compressor – Testing of dryer-collector unit and replacement, if necessary (minimum once annually).

For this purpose, the a/c system must be drained, inspected for leakage and refilled. Check the hose lines for chaffing and replace them, if necessary. If required, retighten the hose connections.

5.16 Automatic lubrication of the machine 5.16.1

Central lubrication system The machine is equipped with a semi-automatic central lubrication system as standard. On request, it can be equipped with a fully automatic system (optional equipment).

This means that the uppercarriage and the boom cylinders of the attachment do not need to be lubricated manually.

Depending on the actual equipment, the attachment can be connected fully, or partly to the central lubrication system. In this case, the connected components do not need to be lubricated manually.

5.16.1.1

Semi-automatic central lubrication system

Fig. 5-47

Central lubricating pump, fully automatic

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Maintenance

Operating manual

Automatic lubrication of the machine

1

Grease tank

2

Adapter (filling of grease tank with filling pump 6)

3

Lubrication nipple, filling of grease tank

4

Lubrication nipple for manual lubrication

5

Safety valve

6

Filling pump

Starting lubrication cycle: To start a lubrication cycle, press the switch S84. As long as the switch is pressed, the electric pump continuously supplies grease to the connected bearing points.

Carry out at least one lubricating cycle during every shift.

Press the switch S84.

The indicator light in the switch flashes.

Grease is supplied to the connected bearing points.

Let the switch flash until grease escapes at the base of the boom cylinders.

Note!

The time required for lubrication depends on the grease temperature and the type and number of components connected to the central lubrication system. At very low ambient temperatures, the procedure might take up to 30 minutes.

Press the switch S84 up.

The indicator light in the switch is off.

The lubrication procedure is completed.

5.16.1.2

Fully automatic central lubrication system (optional equipment)

Fig. 5-48

Central lubricating pump, fully automatic

1

Grease tank

2

3

Lubrication nipple, filling of grease tank

4

5

Safety valve

6

Adapter (filling of grease tank with filling pump 6) Lubrication nipple for manual lubrication Filling pump

7/8 green / red LED

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Operating manual

Maintenance Manual lubrication of the machine

The lubrication process is started automatically after a preset delay and is automatically halted when all bearing points are fully lubricated. No operator intervention is required in this process.

During the lubrication cycle, the indicator light in the switch S84 is on.

Completing intermediate lubrication: If required, you can complete an additional lubrication cycle by pressing the switch S84.

Press the switch S84.

The central lubrication system is started and automatically stopped after a preset interval.

5.16.1.3

Adding grease to the grease tank Check the grease tank once every week and add product, if necessary.

Note!

To prevent contamination of the product, keep the grease tank closed.

Do not remove the lid of the tank to add product.

To add product to the grease tank, use the adapter 2.

Insert the grease cartridge into the supplied filling pump 5, connect it to the adapter 2 and press the cartridge content into the tank.

If no filling pump 5 or grease cartridge is available, the grease tank can be filled with a grease gun or a lubricant pump connected to the lubrication nipple 3.

After the grease tank is refilled, start a lubrication cycle and let it run for about 1 minute.

5.16.1.4

Please note: If the lubricating pump is defective, the lube points connected to the lubrication system can be greased centrally with a lubricating pump through the lubrication nipple 4.

For fully automatic central lubrication system only: In the event of a fault, the LEDs 7 and 8 flash.

Faults might be caused by: – Blockage or kinking of a feed line (grease escapes at the safety valve 5).

– Defective proximity switch (or defective supply cable).

– High grease viscosity due to low temperature.

– Insufficient product in grease tank.

– Fault in drive motor power circuit.

Identify and eliminate the cause of the fault.

5.17 Manual lubrication of the machine Certain parts of the working tools, attachments and the undercarriage are lubricated manually. The affected lubricating points are equipped with lubricating nipples.

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Maintenance

Operating manual

Manual lubrication of the machine

Note!

We recommend using a grease gun, as it reduces the force required and ensures that the grease is squeezed in slowly.

5.17.1

Digging buckets / bucket tilting device

Fig. 5-49

Lubricating bucket tilting device

The bucket tilting device and the digging buckets are not lubricated by the central lubrication system. The lube points of the digging bucket, switching lever and connecting link must be lubricated manually. The respective lube points are marked in red.

During normal operation, each lube point must be lubricated once per week. If the machine is operated under adverse conditions, the parts must be lubricated more frequently, for example once daily or once per shift.

Examples of adverse operating conditions: – Multiple-shift operation – Use in extremely abrasive material – Frequent contact with water or corrosive substances Lubricate the components with a grease gun until clear grease escapes at the bearing points.

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Operating manual

Maintenance Manual lubrication of the machine

5.17.2

Attachments (optional equipment)

Fig. 5-50

Lubricating attachment (example of grapple)

The attachments (e.g. grapple, quick-change adapter systems) must be lubricated manually. In grapples, the respective lubricating points are labelled.

For normal operation, the grapple must be lubricated daily or once per shift. Other working tools must be lubricated at weekly intervals.

Machines operated under adverse conditions (e.g. in contact with water or corrosive substances) should be lubricated more frequently.

Examine the attachment to detect all lubricating nipples.

Lubricate the attachment, using a grease gun. Press in grease until clean grease escapes at the respective bearing point (unless instructed otherwise).

If the attachment is equipped with a rotator, the moving parts must also be lubricated.

Lubricate the rotator (bearing, crown gear, pinion) using a grease gun, until clean grease escapes at the respective bearing point (approx. 2 lubricating strokes).

If the rotator is not equipped with a separate lubricating nipple, apply grease to the crown gear and the pinion.

5.17.3

Hydraulic quick change adapter The hydraulic quick change adapter is not greased via the central lubrication system.

The bearing points must be greased using the grease gun.

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Maintenance

Operating manual

Manual lubrication of the machine

Fig. 5-51

Lubricating the quick change adapter

Grease the locking pins via the grease fitting with a grease gun.

Note!

The hydraulic quick change adapter cannot be sufficiently greased if the locking pins are extended.

Make sure that the locking pins are retracted during the lubrication procedure.

5.17.4

Mechanical quick-change adapter The mechanical quick-change adapter is not lubricated by the central lubrication system. The respective bearing points must therefore be manually lubricated with a grease gun.

Fig. 5-52

Lubricating quick-change adapter

Lubricate the lube points through the lubrication nipple, using a grease gun.

Note!

If the mechanical quick-change adapter is lubricated while the bolt is extended, the cavity between the locking bolts is filled with grease, so that they cannot be retracted.

Therefore lubricate the system only, if the locking bolts are retracted.

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Operating manual

Maintenance Couplings of the quick-change adapter systems (optional equipment)

5.18 Couplings of the quick-change adapter systems (optional equipment) 5.18.1

Hydraulic coupling

Fig. 5-53

Hydraulic coupling plug

The LIKUFIX hydraulic coupling system and the multi-coupling system are equipped with hydraulic coupling plugs (see arrows).

The coupling plugs are maintenance-free. We recommend cleaning the system regularly. This prevents caking of dirt and icing up in winter. With regular cleaning, the seals of the system have a long service life.

Cleaning: Remove dirt and clean all coupling parts and sealing surfaces with a clean cloth and oil.

Changing seal ring:

Fig. 5-54

Changing seal ring

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Maintenance

Operating manual

Couplings of the quick-change adapter systems (optional equipment)

Caution!

The hydraulic lines are under pressure.

Before changing the seal ring, depressurise the system using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick).

In the event of leakage at the coupling plugs (A), change the seal rings.

Hold down the seal washer of the coupling plug with a screwdriver and lever out the defective seal ring using a pointed tool (B).

Squeeze the new seal ring and place it with its open side facing downwards onto the seal washer (C).

Push the washer into the groove, place the screwdriver onto the centre of the seal ring and remove your hand (D).

Let the seal ring expand into the groove (E).

Remove the screwdriver (F).

The seal washer must move upwards.

If this is not the case, push the seal ring into the groove until the seal washer can move.

5.18.2

LIKUFIX electric coupling The LIKUFIX hydraulic coupling system is equipped with an additional electric coupling (e.g. for the operation of a magnet system). This coupling must be regularly inspected and cleaned.

Fig. 5-55 1

Electric couplings

Electric coupling top section

2

Electric coupling bottom section

Switch off the magnet system (if installed).

Remove the working tool, if required.

Switch off the diesel engine.

Check the contacts for corrosion and wear (e.g. burn marks).

Clean the contacts of the electric couplings 1 and 2 with a dry cloth and apply contact spray (Cramolin), if necessary.

Check the electric couplings and the screwed connections for proper fixture.

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Operating manual

Maintenance Travel and swing brakes

Check the contacts of the top section 1 for play: it must be possible to push in the contacts against the spring force.

Check whether the seals at the contacts of the electric couplings (see arrows) are properly installed and undamaged.

Repair any damage and replace defective parts.

5.19 Travel and swing brakes Both the travel as well as the swing brakes are spring applied, pressure released multi-disk brakes. They are vented hydraulically and are fully sealed and integrated in the travel or swing gear.

Their use purely as a parking brake makes them wear free and therefore maintenance free.

5.20 General maintenance tasks 5.20.1

Replacing wear parts Apart from maintenance and care tasks that must be carried out at prescribed intervals, the following minor repairs can be made by the machine operator or a maintenance technician: – Replacement of worn teeth on digging tool.

– Replacement of defective seals on pipe and hose lines and at connections of the hydraulic units (with the exception of the pressure-relief valves, which are factorysealed).

– Replacement of high-pressure hoses, hydraulic lines and screw connections of the hydraulic unit.

Only use original LIEBHERR spare parts. This applies in particular to hoses and hydraulic lines that must be factory-mounted.

All other repairs, and in particular the removal of the counter weight, must be carried out by authorised specialist technicians.

5.20.2

Replacing teeth on digging tool If the teeth are heavily worn, excess force is required to move the digging tool into the material to be excavated. This can lead to damage to the tooth adapters.

Therefore replace worn teeth in due course.

Do not work with the machine, if there are teeth missing on the digging tool or if they are heavily worn.

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Maintenance

Operating manual

General maintenance tasks

U system:

Fig. 5-56

U system – replacing teeth on digging tool

Drive out the roll pin 2 using a hammer and mandrel 1 (A).

Remove the old tooth.

Place the new tooth on the adapter (B).

Drive in the roll pin 2 using a hammer (C).

Z system:

Fig. 5-57

Removing teeth from digging tool - Z system

1

Plug

2

Locking bolt

3 5

Square spanner Tooth adapter

4 6

Tooth Locking piece

Remove the plug 1 from the square recess of the locking bolt 2 (A).

Turn the locking bolt with the square spanner 3 counter-clockwise (a - turn by approx. 30°).

Drive out the locking bolt from the opposite side (B).

Take off the tooth 4 from the tooth adapter 5 and remove the locking piece 6 (C).

Note!

Before mounting a new tooth, check the state of the locking bolt and locking piece.

Replace any deformed or corroded parts.

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Operating manual

Maintenance General maintenance tasks

Fig. 5-58

Mounting teeth on digging tool - Z system

Insert the locking piece 6 into the recess of the tooth adapter 5 so that the flat locking piece side touches the tooth adapter (D).

Insert the new tooth into the tooth adapter.

Insert the locking bolt to the stop (E).

Turn the locking bolt with the square spanner -clockwise (b - turn by approx. 30°) (F).

The nose 2a of the locking bolt slides across the protruding part 6a of the locking piece and engages.

Insert the plug into the square recess of the locking bolt.

5.20.3

Welded parts on the machine All welding work on all main power-transmitting components (e.g. undercarriage frame, revolving deck, attachment parts, etc.) must be executed by the manufacturer or an authorised specialist workshop.

Before carrying out any arc welding work, disconnect the machine from the battery.

The negative pole (-) must be disconnected first and reconnected last.

Also switch off the battery main switch!

Caution!

Bearings or sealing elements might be damaged (scorched) by high electric currents!

When carrying out welding work, connect the earth cable as close as possible to the welding point so that the welding current does not travel through machine parts such as the slewing ring, joints, bearings, bushes, rubber elements or seals.

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Maintenance

Operating manual

Maintenance and inspection schedule

5.21 Maintenance and inspection schedule Note!

Careful maintenance is only possible, if the machine is clean. Especially visual inspections, e.g. for cracks can only be carried out properly on a clean machine.

Therefore clean the machine thoroughly before starting any maintenance work (see also chapter "Safe maintenance of machine", subchapters "Cleaning" and "Crack inspection").

Note!

The daily maintenance tasks of the machine operator include a functional test of the brakes (slewing gear brake, chassis brake) and the electrical and hydraulic system.

Also to be carried out is a daily visual inspection of the motor, hydraulic system and gearbox for leakage

WORK TO BE CARRIED OUT Type 1038, 1042, 1043

Maintenance/inspection at operating hours

by maintenance personnel (machine operator)

together with authorised specialist technicians

Initial and single interval Repeat interval Annually, at the start of the cold season When required

Initial and single interval Repeat interval

DIESEL ENGINE Check the oil level Visual inspection (leakage, dirt, damage) 1)

Change diesel engine oil Change oil filter insert (at least once a year) Belt drive: Check the belt for wear or damage; check the belt tension and adjust it, if necessary (change belt every two years) Check / adjust valve play, replace valve lid seal Check intake and exhaust systems for general condition, fixture and leakage Check oil pan, engine bearings, diesel engine brackets and clamps for proper fixture

3000

Check vibration dampers for deformation RADIATOR Check coolant level Check cooling and heating systems for general condition and leakage

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Operating manual

Maintenance Maintenance and inspection schedule

WORK TO BE CARRIED OUT Type 1038, 1042, 1043

Maintenance/inspection at operating hours

by maintenance personnel (machine operator)

together with authorised specialist technicians

Initial and single interval Repeat interval Annually, at the start of the cold season When required

Initial and single interval Repeat interval

Check corrosion inhibitor and antifreeze agent concentration in coolant 3000

Change coolant (at least every 2 years) FUEL SYSTEM Check water separator at the fuel pre-filter and drain off water, if necessary Drain water and deposit from fuel tank

4)

Check fuel system for leakage and general state

4)

Change fuel pre-filter (also in the event of a drop in performance) Change fuel fine filter Bleed fuel system AIR FILTER Check underpressure indicator of the air filter Clean dust removal valve of the air filter Change main element of the dry air filter (according to counterpressure indication / annually) Change safety element of the dry air filter (at every third main element change / annually) - do not clean or reuse!

Check clean air line (during maintenance of filters) ELECTRICAL SYSTEM OF THE DIESEL ENGINE Check control device bearing for general condition Check sensor devices and cable connections

DIESEL ENGINE - EXHAUST GAS SYSTEM WITH PARTICLE FILTER (optional equipment) Drain off condensate at the condensate trap Condensate trap: check and clean sintered metal filter, check connecting clamps for proper seat Condensate trap: replace sintered metal filter Clean particle filter and pre-filter; if required, clean before prescribed interval has lapsed

copyright by R 317 Litronic Industrie / 11140224

MJFCIFSS

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Maintenance

Operating manual

Maintenance and inspection schedule

WORK TO BE CARRIED OUT Type 1038, 1042, 1043

Maintenance/inspection at operating hours

by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season When required

together with authorised specialist technicians Initial and single interval Repeat interval

HYDRAULIC SYSTEM Check oil level in hydraulic tank Check degree of contamination of the bypass oil filter (special equipment); if required, change filter element Clean magnetic rod in return filter (daily during first 300 operating hours) 2)

Replace filter insert in return filter Replace filter cartridge in control oil unit Check components for proper mounting Check the hydraulic oil cooler for dirt; clean it, if necessary Drain water from hydraulic tank (max. permissible water content for environmentally friendly fluids: 0.1 %; insert bypass filter, take oil sample) Check hydraulic system for leakage; complete functional test Check / readjust servo, primary and secondary pressures

2), 3) 2)

Change hydraulic oil in tank (optimise interval by carrying out oil analyses) Change breather filter on hydraulic tank ELECTRICAL SYSTEM Check indicator lights and indicating devices upon start-up Check lighting Check acid density and level, wire terminals and terminal ports of the batteries, and all the plug connections Spray slip rings of the slewing gear connection with Cramolin contact spray Carry out functional tests of entire unit and all components SLEWING GEAR MECHANISM Check oil level; check system for leakage Carry out functional test of slewing gear brake Check gearbox and oil motor for proper mounting Change gear oil

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5 - 66

MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Maintenance Maintenance and inspection schedule

WORK TO BE CARRIED OUT Type 1038, 1042, 1043

Maintenance/inspection at operating hours

by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season When required

together with authorised specialist technicians Initial and single interval Repeat interval

SLEWING RING Check mounting bolts for press fit; slewing gear pining meshing TRAVEL GEAR Check oil level; check system for leakage Carry out functional test of travel brake Check gearbox and oil motor for proper mounting Change gear oil CHASSIS Visually check tension of chain; regulate, if necessary Clean chain (after work) Check base plates and tumbler wheels for proper mounting Clean and lubricate slide faces of tensioning mechanism Check idlers, support and running rollers for tightness OPERATOR'S CAB + HEATING Check / add detergent solution in windscreen washer tank Treat rubber seals of the operator's cab with silicone or talcum powder Treat rubber seals of the access doors in the uppercarriage with silicone or talcum powder Check function of heating Check heating system for leakage Check door and window hinges as well as locks Check water inlet valve for contamination, and clean, if necessary; carry out functional test of valve AIR-CONDITIONING SYSTEM Regularly switch on air-conditioning system (at least 1x every 14 days)

copyright by R 317 Litronic Industrie / 11140224

MJFCIFSS

5 - 67

Maintenance

Operating manual

Maintenance and inspection schedule

WORK TO BE CARRIED OUT Type 1038, 1042, 1043

Maintenance/inspection at operating hours

by maintenance personnel (machine operator)

together with authorised specialist technicians

Initial and single interval Repeat interval Annually, at the start of the cold season When required

Initial and single interval Repeat interval

Check condenser for contamination; blow clean, if necessary Clean re-circulated air / fresh air filter; replace, if necessary; shorten interval if there is excessive generation of dust Check compressor mounting bolts and drive belts Check dryer-collector unit (humidity, fill level); replace, if necessary Check evaporator unit; clean, if necessary Check electrical lines for chafe marks; check plug connections Complete functional test of excess pressure switch Check cooling performance Replace dryer-collector unit every 12 months; also check cooling circuit for leakage and change coolant and refrigeration oil.

Every 12 months, employ a refrigeration technician to carry out a functional test of the air flaps and the defrost thermostat UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENTS Lubricate bearing points, using the semi-automatic central lubrication system; exception: not required in units with fully automatic central lubrication system (optional equipment) Check grease level in the central lubrication system tank; add grease, if required Lubricate bearing positions (undercarriage and working attachments) Lubricate daily when required due to type of use and/or shift operation Inspect teeth for wear 250

Check parts for cracks

250

Check counter weight and tank for proper mounting Check lines and screwed connections for proper fit Check panelling hinges, quick fasteners and gas pressure springs of the caps Instruct operators in the proper use of the equipment Instruct the operator on how the machine must be lubricated according to the lubricating chart and make him aware of potential operator errors HYDRAULIC QUICK CHANGE ADAPTER Carry out a functional test of the visual and acoustic warning systems

copyright by

5 - 68

MJFCIFSS

R 317 Litronic Industrie / 11140224

Operating manual

Maintenance Maintenance and inspection schedule

WORK TO BE CARRIED OUT Type 1038, 1042, 1043

Maintenance/inspection at operating hours

by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season When required

together with authorised specialist technicians Initial and single interval Repeat interval

Carry out a visual inspection of the extended locking bolts Check hydraulic hoses and wire harness Lubricate locking bolts Clean mesh filter MECHANICAL QUICK CHANGE ADAPTER Carry out a visual inspection of the extended locking bolts Lubricate locking bolts GENERAL Check the entire machine to ensure that it is properly maintained and in safe working order Explain the machine documentation (in particular the operating manual and safety instructions) to the operating personnel 1 2 3 4

Replace motor oil more often, if temperatures and the quality of fuels and oils make this seem advisable.

In the case of applications with excessive dust generation, observe shortened maintenance intervals.

For environmentally friendly hydraulic fluids, adjust the maintenance interval on the basis of regular analyses.

The maintenance intervals might have to be shortened, depending on the operating conditions (e.g. generation of dust, barrel fuelling).

copyright by R 317 Litronic Industrie / 11140224

MJFCIFSS

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