Liebherr R 9100 - R 9100B 1132 / 1652 Hydraulic Excavator Operating Manual SN 26573 - PDF DOWNLOAD

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Operating Manual Hydraulic excavator R 9100- R 91008 from serial number 26573

Document identification ORIGINAL MANUAL Order number:

10361072

Edition:

12 / 2020

Valid for:

R 9100 - R 9100B from serial number 26573

Author:

LEC - Technical documentation department

Product identification Manufacturer:

Liebherr-Mining Equipment Colmar SAS

Type:

R 9100 - R 9100B

Type no.:

1132 / 1652

Conformity: 0

N

0

N

C:

~

Address

'5

~

Liebherr-Mining Equipment Colmar SAS

c:5

49 rue Frederic Hartmann

UJ ....J

CS 50038, F-68025 Colmar Cedex

copyright© Liebherr-Mining Equipment Colmar SAS 2020

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Fig. 1-1

Machine and construction equipment - backhoe attachment

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Fig. 1-2

Machine and construction equipment - shovel attachment

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Fig. 1-3

Uppercarriage

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Fig. 1-4

Undercarriage

Tab. 1-1

Vibration emissions

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Fig. 1-5

Sample EC Declaration of Conformity

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Tab. 1-2

Working technical data

Tab. 1-3

Working technical data for machine with Extra Wide (EW) undercarriage

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Fig. 2-1

Arrangement of signs on the machine

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Fig. 2-2

Arrangement of signs on the cab

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Fig. 3-1

Control cab

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Fig. 3-2

Operator’s standing position, seen from the operator’s point of view

Fig. 3-3

Switches on the joysticks

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Fig. 3-4

Joystick, right (3) and left (4)

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Fig. 3-5

Keyboard

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Fig. 3-6

Control board

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Fig. 3-7

Monitoring display

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Fig. 3-8

Main screen on cab display

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Fig. 3-9

General indicator field

Fig. 3-10

Dials and error warning symbols field

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Fig. 3-11

Camera views

Fig. 3-12

Links field

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Fig. 3-13

Monitoring menus

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Fig. 3-14

Menu "Diag"

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Fig. 3-15

Submenus of the menu "Check"

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Fig. 3-16

Submenus of the menu "Info"

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Fig. 3-17

Submenus of the menu "Settings"

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Fig. 3-18

Indicators and error warnings on the main screen

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Fig. 3-19

Example of engine error symbol

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Fig. 3-20

Enter or leave the cab

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Fig. 3-21

Sliding access ladder

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Fig. 3-22

Button S122: Disable of ladder control position

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Fig. 3-23

45° access ladder and control box E1022_3

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Fig. 3-24

Button S122: Disable of ladder control position

Fig. 3-25

Emergency valve of access ladder

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Fig. 3-26

Emergency ladder

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Fig. 3-27

Safety lever

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Fig. 3-28

Standard operator’s seat

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Fig. 3-29

Setting the weight

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Fig. 3-30

Setting the height

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Fig. 3-31

Setting the armrests

Fig. 3-32

Setting the seat

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Fig. 3-33

Setting the backrest

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Fig. 3-34

Setting the horizontal

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Fig. 3-35

Safety belt

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Fig. 3-36

Emergency hammer location

Fig. 3-37

Emergency exit label

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Fig. 3-38

Fire extinguisher fixing location

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Fig. 3-39

Windscreen washing fluid container

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Fig. 3-40

Field of view

Tab. 3-1

Fields of view depending on the machines

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Fig. 3-41

Uppercarriage lighting configuration

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Fig. 3-42

Cab lighting configuration

Fig. 3-43

Attachment lighting configuration

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Fig. 3-44

Button S126

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Fig. 3-45

Control box E1022 and button S127

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Fig. 3-46

Air-conditioning system control device

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Fig. 3-47

Switching on the control unit

Fig. 3-48

Setting the desired cab temperature

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Fig. 3-49

Air-conditioning

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Fig. 3-50

Recirculated air and fresh air

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Fig. 3-51

Position of front air vents and vents on the rear cab wall

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Fig. 3-52

Rotary switch for additional cab heater

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Fig. 3-53

Cab preheating actuators

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Fig. 3-54

Ignition key S1 in electrical box E1005

Fig. 3-55

Principal battery switches

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Fig. 3-56

Speed indication on the main menu of the display

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Fig. 3-57

Starting aids - Configurations A and B

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Fig. 3-58

Backhoe (up) and shovel (down) attachments position

Fig. 3-59

Additional tarpaulins, louvers and covers (if installed)

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Fig. 3-60

Circuit breakers of the special preheating batteries

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Fig. 3-61

Devices for coolant preheating

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Fig. 3-62

Control unit U106 of the coolant heater

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Fig. 3-63

Warning lights of coolant preheating

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Fig. 3-64

Switch for hydraulic oil preheating (if installed)

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Fig. 3-65

External socket (if installed)

Fig. 3-66

Warning light H103: external Gen-Set connected

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Fig. 3-67

Additional connection for warm air duct (if installed)

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Fig. 3-68

Circuit breaker of the special preheating batteries

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Fig. 3-69

Devices for coolant preheating

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Fig. 3-70

Control unit U106 of the coolant heater

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Fig. 3-71

Warning lights of coolant preheating

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Fig. 3-72

Additional connection for warm air duct (if installed)

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Fig. 3-73

Diagnostic unit system

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Fig. 3-74

Auxiliary start receptacle (optional)

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Fig. 3-75

Cab emergency stop S100_1

Fig. 3-76

S100_2 emergency stop

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Fig. 3-77

S100_4 emergency stop (if installed)

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Fig. 3-78

Safety control for the Diesel engine start

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Fig. 3-79

Safety control for the Diesel engine speed

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Fig. 3-80

Safety control for swing and travel brakes

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Fig. 3-81

Safety fans control

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Fig. 3-82

Travel straight ahead

Fig. 3-83

Turn on the spot

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Fig. 3-84

Turn with one track chain

Fig. 3-85

Hand levers to operate the travel movements manually

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Fig. 3-86

Turn the uppercarriage

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Fig. 3-87

Working position – machine

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Fig. 3-88

Operating the stick cylinder

Fig. 3-89

Operating the boom cylinder

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Fig. 3-90

Operating the boom down with pressure

Fig. 3-91

Float position

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Fig. 3-92

Operating the bucket cylinder

Fig. 3-93

Operating the bottom dump shovel bucket

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Fig. 3-94

Deactivation of attachment damping system

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Fig. 3-95

Lowering the attachment when engine is not running

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Fig. 3-96

Working position – machine

Fig. 3-97

Hazard area

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Fig. 3-98

Aligning the stick and backhoe bucket

Fig. 3-99

Taking up grab material

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Fig. 3-100 Raising grab material

Fig. 3-101 Emptying grab material

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Fig. 3-102 Digging

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Fig. 3-103 Unloading of the bucket

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Fig. 3-104 Straightening the stick

Fig. 3-105 Closing the grab shells

Fig. 3-106 Raising grab material

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Fig. 3-107 Emptying grab material

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Fig. 3-108 Hydraulic hammer

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Fig. 3-109 Permissible A and not permissible B work areas of the machine with hydraulic hammer

Fig. 3-110 Taking up the load

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Fig. 3-111 Transporting a load

Fig. 3-112 Skimming

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Fig. 3-113 Example of low loader

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Fig. 3-114 Hazard area r

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Fig. 3-115 Sticker for lifting and lashing operations

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Fig. 4-1

LIEBHERR service

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Fig. 4-2

Location of electrical box E50

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Fig. 4-3

Fuses and relays of electrical box E50

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Fig. 4-4

Locations of the electrical plates in E1005

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Fig. 4-5

Fuses and relays of electrical plate A161

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Fig. 4-6

Fuses and relays of electrical plate A1002

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Fig. 4-7

Fuses of electrical plate A1004

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Fig. 5-1

Access doors on the machine

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Tab. 5-1

Access doors

Fig. 5-2

Door lock

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Fig. 5-3

Horizontal middle bar on handrail (example)

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Fig. 5-4

Welded anchor point (example)

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Fig. 5-5

Drilled anchor point (example)

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Fig. 5-6

Lubrication chart - R9100

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Tab. 5-2

Lubrication chart key

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Tab. 5-3

Lubricant chart

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Tab. 5-4

Operating material chart

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Fig. 5-7

Service station

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Fig. 5-8

Grease warning light H109

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Fig. 5-9

Grease control box E1043_2

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Fig. 5-10

Grease couplings

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Fig. 5-11

LIEBHERR oils for hydraulic system

Fig. 5-12

Engine oils for hydraulic system

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(ISO VG68)

(ISO VG100) (ISO VG46)

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Fig. 5-13

Hydraulic oil for hydraulic system

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Fig. 5-14

Oil changes at pre-set intervals

Fig. 5-15

Oil changes at optimized intervals

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Fig. 5-16

Swing gear and travel gear oils

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Tab. 5-5

Tab. 5-6

Tab. 5-7

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Tab. 5-8

Fig. 5-17

Gear oils for use as splitterbox oil

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Fig. 5-18

Sampling pump

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Fig. 5-19

Sampling valve 1 for splitterbox oil

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Fig. 5-20

Sampling valve 1 for front swing gear oil

Fig. 5-21

Sampling valve 1 for rear swing gear oil

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Fig. 5-22

Sampling valve 1 for rear swing gear oil on service station (if installed)

Fig. 5-23

Oil sampling points 1 for travel gear oil

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Fig. 5-24

Sampling valve 1 for hydraulic oil

Fig. 5-25

Sampling valve 1 for Diesel engine oil

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Fig. 5-26

Dipstick for indication of Diesel engine oil level

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Fig. 5-27

Oil filter cover and oil pan of the Diesel engine

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Fig. 5-28

Diesel engine connection of the service station

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Fig. 5-29

Oil filler neck of the Diesel engine

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Fig. 5-30

Oil filter element

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Fig. 5-31

Mounting screws of the Diesel engine

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Fig. 5-32

Elastic bedding

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Fig. 5-33

Splitterbox mounting screws

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Fig. 5-34

Mounting screws

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Fig. 5-35

Splitterbox elastic bedding

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Fig. 5-36

Breather filter on splitterbox

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Fig. 5-37

Expansion tank

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Fig. 5-38

Coolant drain plug

Fig. 5-39

Coolant connection of the service station

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Fig. 5-40

Coolant filter

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Fig. 5-41

Lockable fuel tank cap

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Fig. 5-42

Fuel connection under the fuel tank

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Fig. 5-43

Drain valve of fuel tank

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Fig. 5-44

Fuel prefilters assembly

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Fig. 5-45

Fuel fine filters assembly

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Fig. 5-46

Fuel-water separator on fuel prefilter

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Fig. 5-47

Fuel-water separator on fuel prefilter

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Fig. 5-48

Filter element of fuel prefilter

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Fig. 5-49

Filter element of fuel prefilter

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Fig. 5-50

Fuel drain line

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Fig. 5-51

Connection of the fuel drain line of the service station

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Fig. 5-52

Filter elements of fuel fine filter

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Fig. 5-53

Filter elements of fuel fine filter

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Fig. 5-54

Air intake system

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Fig. 5-55

Vacuum indicator

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Fig. 5-56

Primary filter element

2

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Fig. 5-57

Safety element

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Fig. 5-58

Precleaner

Fig. 5-59

Precleaner dome with head down

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Fig. 5-60

Housing of air filter elements

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Fig. 5-61

Air intake hoses, tubes and elbow tubes

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Fig. 5-62

Machine check position for hydraulic oil level check or level adjustment

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Fig. 5-63

Hydraulic tank oil level

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Fig. 5-64

Release the hydraulic pressure

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Fig. 5-65

Return filter on the hydraulic tank

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Fig. 5-66

Bleeding valve of the hydraulic tank

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Fig. 5-67

Oil filter parts

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Fig. 5-68

Piloting oil filter location

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Fig. 5-69

Replenishing oil filter location

Fig. 5-70

Replenishing oil filters parts

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Fig. 5-71

High pressure filters on valve bank

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Fig. 5-72

High pressure filter parts

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Fig. 5-73

Pumps aspiration (intake hoses)

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Fig. 5-74

Bleeding of the working pumps

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Fig. 5-75

Bleeding of the swing pump

Fig. 5-76

Bleeding of the cooling fans pumps

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Fig. 5-77

Bleeding of valve blocks

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Fig. 5-78

Oil cooler protection filter

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Fig. 5-79

Auxiliary hydraulic outlet

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Fig. 5-80

Piston rod mounting

Fig. 5-81

Machine with piston rods retracted

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Fig. 5-82

SAE flanges

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Tab. 5-9

Tightening torques for SAE flanges

Fig. 5-83

Sealing flange 1 and hydraulic block 2

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Fig. 5-84

Criss-cross tightening

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Fig. 5-85

Oil change in swing gear

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Fig. 5-86

Expansion tanks of swing gears

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Fig. 5-87

Swing gears connections of the service station

Fig. 5-88

Oil filler neck

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Fig. 5-89

Oil change on travel gear

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Fig. 5-90

Special expansion tank of Lifetime interspace

Fig. 5-91

Oil change on the Lifetime interspace

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Fig. 5-92

Oil change on the splitterbox

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Fig. 5-93

Splitterbox connection of the service station

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Fig. 5-94

Undercarriage components

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Fig. 5-95

Travel gear fastening (right and left sides)

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Fig. 5-96

Track pad fastening

Fig. 5-97

Carrier roller fastening

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Fig. 5-98

Track roller fastening

Fig. 5-99

Fastening of idler and tension unit

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Fig. 5-100 Track guide fastening

Fig. 5-101 Fastening of travel motor protection

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Fig. 5-102 Track correctly tensioned

Fig. 5-103 Check of the track tension

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Fig. 5-104 Tightening the track

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Fig. 5-105 Raising the machine

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Fig. 5-106 Connectors on engine

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Fig. 5-107 Battery care

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Fig. 5-108 Electrical components location

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Fig. 5-109 Coolant shutoff valve on the Diesel engine

Fig. 5-110 Heater/evaporator

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Fig. 5-111 Fresh air filter

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Fig. 5-112 Heater/evaporator

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Fig. 5-113 Condenser

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Fig. 5-114 Location of the dryer/receiver unit

Fig. 5-115 Dryer/receiver unit

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Fig. 5-116 Air-conditioning compressor on Diesel engine

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Fig. 5-117 Fan motor in the heater

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Fig. 5-118 Aeration device

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Fig. 5-119 Counterweight bolts

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Fig. 5-120 Swing ring bolts

Fig. 5-121 Fuel tank bolts

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Fig. 5-122 Hydraulic oil tank bolts

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Fig. 5-123 Bolts of swing gear and swing motor

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Fig. 5-124 Hydraulic pumps bolts

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Fig. 5-125 Cab bolts

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Fig. 5-126 Cab elevation bolts

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Fig. 5-127 Side frames bolts

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Fig. 5-128 Preheating devices for Diesel engine coolant

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Fig. 5-129 Fuel filter of coolant heater

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Fig. 5-130 Location of the water drain plug

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Fig. 5-131 Coolant heater pump

Fig. 5-132 Bleed valve of additional cab heater (if installed)

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Fig. 5-133 Assembling screws

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Fig. 5-134 Preheating devices for Diesel engine coolant

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Fig. 5-135 Water system of the coolant heater

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Fig. 5-136 Bleeding valve of the additional cab heater (if installed)

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Fig. 5-137 How to use the check lists (in addition to the daily maintenance)

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or

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Tab. 5-10 Daily maintenance schedule - R9100

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Tab. 5-11 250 Hours maintenance schedule - R9100

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Tab. 5-12 500 Hours maintenance schedule - R9100

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Tab. 5-13 1000 hours maintenance schedule - R9100

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Tab. 5-14 2000 hours maintenance schedule - R9100

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Fig. 6-1

Hydraulic tube and hose assembly

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Fig. 6-2

Marking of hose

Fig. 6-3

Marking of hose assembly

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Fig. 6-4

Clean magnetic rod

Fig. 6-5

Magnetic rod with metal collection

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Fig. 6-6

Filters on the hydraulic tank

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Fig. 6-7

Return lines on VB1

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Fig. 6-8

Return lines on VB2

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Fig. 6-9

Leak oil circuit of working pumps

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Fig. 6-10

High pressure hoses between valves blocks and working pumps

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Fig. 6-11

Intake lines of working pumps

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Fig. 6-12

Intake lines connected to the working pumps circuit

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Fig. 6-13

Leak oil hoses of swing pumps

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Fig. 6-14

Leak oil hoses of swing motors

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Fig. 6-15

Working pressure lines

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Fig. 6-16

Intake and replenishing hoses

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Fig. 6-17

Leak oil hoses of fan motors

Fig. 6-18

Leak oil hose of cooling pumps

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Fig. 6-19

Working pressure lines of fan motors

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Fig. 6-20

Intake line of cooling pumps

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Fig. 6-21

Leak oil circuit of travel motors

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Fig. 6-22

Working pressure circuit on the undercarriage

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Fig. 6-23

Working pressure circuit on the uppercarriage

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Fig. 6-24

Hydraulic lines on the uppercarriage

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Fig. 6-25

Hydraulic lines on the boom

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Fig. 6-26

Hydraulic lines on the uppercarriage

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Fig. 6-27

Hydraulic lines on the boom

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Fig. 6-28

Hydraulic lines of the boom cylinders

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Fig. 6-29

Hydraulic lines on the uppercarriage

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Fig. 6-30

Hydraulic lines on the attachment

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Fig. 6-31

Hydraulic lines on the bucket

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Fig. 6-32

Hydraulic lines on the uppercarriage

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Fig. 6-33

Hydraulic lines on the attachment

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Fig. 6-34

Hydraulic lines on the uppercarriage

Fig. 6-35

Hydraulic lines on the boom

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Fig. 6-36

Hydraulic tank cleaning

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Operating Manual

en

Operating Manual Centralized Lubrication Systems R9100

LEC / en / Edition: 09/2018

Product identification Manufacturer:

SKF Lubrication Systems Germany GmbH

Type:

R9100

Type no.:

1132

Address Heinrich-Hertz-Str. 2-8 69190 Walldorf - Germany

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Operating Manual

Table of Contents: 1

Guidelines --------------------------------------------------------------------------------------- 4 Explanation of symbols and signs ----------------------------------------------------------------- 4 Illustrations ---------------------------------------------------------------------------------------------- 6 Abbreviations ------------------------------------------------------------------------------------------- 6 Manufacturer and Service addresses ------------------------------------------------------------ 7 Warranty ------------------------------------------------------------------------------------------------- 7 Copyright ------------------------------------------------------------------------------------------------ 7

2

Safety information ----------------------------------------------------------------------------- 8 Disclaimer ----------------------------------------------------------------------------------------------- 8 Emergency stopping of the centralized lubrication system ---------------------------------- 8 Intended use -------------------------------------------------------------------------------------------- 8 Operation of the lubrication system or single components of it ---------------------------- 8 Foreseeable misuse ---------------------------------------------------------------------------------- 8 Unauthorised activities ------------------------------------------------------------------------------- 9 Conversions or modifications ----------------------------------------------------------------------- 9 Inspections ---------------------------------------------------------------------------------------------- 9 Warning labels on the centralized lubrication pump or system --------------------------- 10 Other applicable documents ---------------------------------------------------------------------- 10 Sources of hazard ----------------------------------------------------------------------------------- 10 Moving or rotating parts ---------------------------------------------------------------------------- 10 Energies ----------------------------------------------------------------------------------------------- 11 Lubricants --------------------------------------------------------------------------------------------- 11 Existing residual risks ------------------------------------------------------------------------------ 11 Persons authorized to operate the pump ------------------------------------------------------ 16 Protection of special groups of persons-------------------------------------------------------- 16

3

Safety recommendations to be complied with ---------------------------------------- 17 General behaviour when handling the system ----------------------------------------------- 17 Explosion protection -------------------------------------------------------------------------------- 17 Transport / installation / maintenance / repairs / servicing -------------------------------- 18 Laying of the lubrication lines --------------------------------------------------------------------- 20 Initial commissioning / daily start-up ------------------------------------------------------------ 21 Cleaning ----------------------------------------------------------------------------------------------- 21

4

Operator obligations ------------------------------------------------------------------------ 22 Determination of hazards -------------------------------------------------------------------------- 22 Inspection for correct use -------------------------------------------------------------------------- 22 Briefing of external technicians ------------------------------------------------------------------ 22 Provision of personal protective equipment --------------------------------------------------- 22 Training courses ------------------------------------------------------------------------------------- 22 Inspection of the delivery / returns -------------------------------------------------------------- 23

5

Lubricant --------------------------------------------------------------------------------------- 24 Filling of the reservoir------------------------------------------------------------------------------- 25 Inadvertent filling with incorrect lubricant ------------------------------------------------------ 25

2

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Provision of necessary information ------------------------------------------------------------- 22

Operating Manual Inspections prior to initial start-up --------------------------------------------------------------- 25 Activation of the pump------------------------------------------------------------------------------ 26

6

Standard operation -------------------------------------------------------------------------- 27 Daily start-up ----------------------------------------------------------------------------------------- 27 Inspections -------------------------------------------------------------------------------------------- 27 Filling of the reservoir during operation -------------------------------------------------------- 27 Cleaning ----------------------------------------------------------------------------------------------- 27

7

Maintenance and repairs ------------------------------------------------------------------ 28 Safety instructions for maintenance and repairs --------------------------------------------- 28 Maintenance of the system ----------------------------------------------------------------------- 28

8

Technical data and operating instructions --------------------------------------------- 29 Operating pressure / operating temperature -------------------------------------------------- 29 Installation position, sound pressure level, weight, dimensions -------------------------- 29 Tightening torques ---------------------------------------------------------------------------------- 29 Output / connections -------------------------------------------------------------------------------- 29 Filling possibilities ----------------------------------------------------------------------------------- 29 Electrical connection (electrically driven products) ------------------------------------------ 29 Air pressure and air quality (air-operated products) ---------------------------------------- 29

9

Lubrication System: Description --------------------------------------------------------- 30 General design --------------------------------------------------------------------------------------- 30 9.1.1

Systems ----------------------------------------------------------------------------------------- 30

9.1.2

Allocation of the lubrication points -------------------------------------------------------- 30

9.1.3 Characteristics of lubrication points on the excavator (This section must only be available inside the SKF service Manual) -------------------------------------------------------------------- 32 System P1: Automatic lubrication --------------------------------------------------------------- 33 9.2.1

Configuration ----------------------------------------------------------------------------------- 33

9.2.2

Greasing cycle --------------------------------------------------------------------------------- 35

9.2.3

Single-line system----------------------------------------------------------------------------- 36

9.2.4

Pump station 27L ----------------------------------------------------------------------------- 36

9.2.5

Cabin greasing module U4-1 --------------------------------------------------------------- 37 System P3: Swing ring and swing gear lubrication ------------------------------------------ 39

10

9.3.1

Grease cycle ----------------------------------------------------------------------------------- 39

9.3.2

Pump P3 - Multi-line pump type P203 --------------------------------------------------- 40

Operation -------------------------------------------------------------------------------------- 41

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Greasing system – Cabin Location ------------------------------------------------------------- 41 System P1: Automatic lubrication --------------------------------------------------------------- 42 Pump P3: ---------------------------------------------------------------------------------------------- 43

11

Inspection and Maintenance -------------------------------------------------------------- 44

12

Troubleshooting ------------------------------------------------------------------------------ 45

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

For reasons of better legibility, in these instructions we mainly use the male form for general references. Of course, the female form is also always intended.

Please read these instructions thoroughly and heed the warning and safety notes. Please observe the warning and safety notes and exercise particular caution in these cases.

Inform also other users accordingly.

Text representations

Meaning

Bold print

Highlighting of particularly important words or passages Marks lists

List 1 o

List 2

Marks lists

(parenthesis)

Item numbers

Instructions

Instructions to personnel. These always appear in chronological order.

Explanation of symbols and signs Activities which generate actual hazards (to life and limb or possible damage to the material) are marked by warnings. Definitely observe the instructions given in the warnings.

You will find these symbols, which warn of specific dangers to persons, material assets, or the environment, next to all safety instructions in these operating instructions.

Please read these instructions thoroughly and heed the warning and safety notes. Please observe the warning and safety notes and exercise particular caution in these cases.

Inform also other users accordingly.

The following warnings are possible.

Consequence

Probability

DANGER

Death/ serious injury

imminent

WARNING

Serious injury

possible

CAUTION

Minor injury

possible

ATTENTION

Property damage

possible

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Warning level

4

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Operating Manual Symbol

Meaning General warning Activities which generate actual hazards (to life and limb or possible damage to the material)

Warning of suspended load

Risk of explosion Carry out work on electrical parts only if the atmosphere is not potentially explosive. Work has to be carried out by a specialist for maintenance and repairs in potentially explosive atmospheres.

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

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

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

Risk of fire Risk of fire and explosion when using inflammable cleaning agents.

Health hazard Hazard due to spouting lubricant / pressure injection due to a leakage (defective fitting, too high system pressure or other damages).

Crushing hazard

Slipping hazard

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Hot surfaces

Symbol

Meaning Disposal Environmentally sound disposal and recycling

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Operating Manual Disposal Environmentally sound disposal of waste electrical and electronic equipment

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

Abbreviations The following abbreviations may be used within these instructions:. max. maximum Nm Newtonmeter

6

minimum

incl.

including

min

minutes

i.e.

this means

s

seconds

rh

relative humidity

etc.

and so on

approx. approximately

poss.

possibly

Ø

diameter

e.g.

for example

®

ml

millilitre

registered trademark

ccm

cubic cm

©

Copyright

mm

millimetre

TM

Trademark

°C

degrees Celsius

%

per cent

°F

degrees Fahrenheit

dB (A)

sound pressure level

K

Kelvin

>

greater than

inch

inch

<

less than

etc.

et cetera

kg

kilogram

± SW

plus minus width across flats

l

litre

ESD

Electrostatic Discharge

N/A

not applicable

mbar

millibar

no.

Number

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min.

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Manufacturer and Service addresses Manufacturer

Customer Service

SKF Lubrication Systems Germany GmbH Heinrich-Hertz-Str. 2-8 DE - 69190 Walldorf

SKF Lubrication Systems Germany GmbH Heinrich Hertz Straße 2-8 DE - 69183 Walldorf +49 (0)6227-330

SKF Lubrication Systems Germany GmbH 2. Industriestraße 4 DE - 68766 Hockenheim +49 (0)620527101

SKF Lubrication Systems Germany GmbH Motzener Straße 35-37 DE - 12277 Berlin +49 (0)30-720020

Warranty The installation instructions do not contain any information on the warranty. This can be found in our general terms and conditions.

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

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

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This also includes the creation of training material for internal, non-commercial purposes. Any other use without the written consent of the copyright holder - of whatever kind - is prohibited and is regarded as a violation of copyright.

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

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

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

The manufacturer shall not be held responsible for damages caused by: o non appropriate use, faulty assembly, operation, setting, maintenance, repair or accidents o improper or late response to malfunctions o unauthorized modifications of the product o intent or negligence o Use of non-original SKF spare parts.

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

Emergency stopping of the centralized lubrication system In case of an emergency stop the centralized lubrication system by: switching off the machine, system or vehicle, into which the SKF centralized lubrication system or its components have been integrated. separating the supply of power, compressed air or hydraulic pressure (depending on the system) to the centralized lubrication system or the corresponding components. actuating the emergency-off switch, if any, of the machine, system or vehicle.

Intended use ATTENTION All products may be used only for their intended purpose and in accordance with the instructions.

Intended use is the use of the products to lubricate bearings and friction points with lubricants within the physical limits that can be found in the relevant product documentation, e. g. operating instructions and product descriptions, e. g. technical drawings and catalogues.

Operation of the lubrication system or single components of it All information given in these installation instructions or stated in the referenced documents.

All laws and regulations to be complied with by the user.

Properly and appropriately conducted installation of the system.

Foreseeable misuse Any other use and purpose of the centralized lubrication system or its components than the ones described before are strictly prohibited.

Use is expressly forbidden: 8

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Operation is permitted only, if in compliance with:

Operating Manual in a potentially explosive atmosphere, unless the centralized lubrication system or its components are expressly suitable for it and have been approved accordingly. in a working environment or condition that corresponds to the required protection types IP (International Protection) and Nema (National Electrical Manufacturers Association) only in parts or not at all. to use the CLS to feed, forward, or store hazardous substances and mixtures in accordance with annex I part 2-5 of the CLP regulation (EC 1272/2008).

For the supply, transport, stockpiling of gases, liquefied gases, dissolved gases, vapours, and fluids whose vapour pressure exceeds normal atmospheric pressure (1013 mbar) by more than 0.5 bar at the maximum admissible operating temperature. to use the CLS to feed, forward, or store glycol- or polyglycol based oils and greases. to use inadmissible components or components expressly not suitable for the purpose.

Unauthorised activities The following activities may be carried out by SKF manufacturer specialists or authorized persons only due to potential sources of faults that may not be visible for the user, or due to legal regulations: Removal, replacement or changes to the centralized lubrication system or components integrated or connected to it.

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

Dismantling of individual components of the centralized lubrication system.

Changes to the power supply or to the admissible input voltage.

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

Conversions or modifications Unauthorized conversions or modifications may result in unforeseeable impacts on safety and functionality. Therefore, any unauthorized reconstructions or changes are expressly prohibited.

Inspections

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

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Warning labels on the centralized lubrication pump or system Hand injury warning During operation of the centralized lubrication system, particularly of the pump, never remove the lid or the barrel and reach into the reservoir or the barrel. Risk of trapping or shearing off hands and fingers!

Electric shock Connection of 24 V DC components must be provided by a safe galvanic isolation PELV (Protective Extra Low Voltage) or SELV (Safety Extra Low Voltage) always.

Other applicable documents In addition to these installation instructions, the following documents must be observed by the respective target group: Operational instructions and release provisions by the operator.

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

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

Operating instructions and technical descriptions of purchased parts.

Where appropriate: Project planning documents.

Other relevant documents for the integration of the centralized lubrication system into the superior machine or system.

The owner must supplement these documents by the respective valid national or regional regulations laid down by the country in which the centralized lubrication system is to be used.

If the centralized lubrication system is sold or transferred, any associated documents must be passed on to the subsequent operator as well.

Sources of hazard The centralized lubrication system and the components used have been designed, built and tested using state-of-the-art technology.

Depending on their version and necessity, they will have left our company only after having passed stringent safety and reliability tests. Like for all complex machines, also for this system there may still be involved potential sources of hazard.

Moving or rotating parts Drive Tooth wheels

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Stirring paddle Shovel foot Piston Guides Articulations etc.

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Energies Electricity

Temperature (hot or cold surfaces)

Position energy (raised components)

Parts subject to pressure (operating pressure, oil pressure, grease pressure, air pressure, etc.)

Bursting reservoir if filled by a high-performance pump Parts subject to spring tension

Lubricants Greases Oils Transport lifecycle Residual risks Tilting or falling of parts during transport, e.g. over inclines.

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

Dropping of lifted parts or tools.

No people may remain under suspended loads. Keep unauthorized persons away.

Secure suspended loads using suitable hoisting equipment (e.g. tapes, belts, ropes, etc.).

Existing residual risks Installation life cycle

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Residual risks People slipping due to floor contamination with spilled or leaked lubricant

Remedy Take care when filling. Bind and remove leaked or spilled lubricant immediately with a suitable agent.

Follow the operational instructions for handling lubricants and contaminated parts.

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Operating Manual Installation life cycle Residual risks Deviating installation position.

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

Remedy Installation of a suitable protective roof over the air intake.

- Borehole for drainage of condensation water is no longer at the lowest point of the motor.

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

Tearing or damaging of lines when installed on moving machine parts (e.g. pivot arm).

If possible, do not mount onto movable parts. Should this not be possible, use flexible hose lines of sufficient length.

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

Use protective pipes or spring coils.

Falling of parts due to insufficient fixing to the machine.

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

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

Electric shock through reduced insulation resistance.

Literature, see screw manufacturer.

Check the formation of condensation water in the motor regularly.

If applicable, drain off condensation water at the drain plug. Check the insulation resistance regularly.

Prior to connection of electrical components (pump, switch cabinet, valves, etc.) de-energize all affected electrical components. If necessary, please observe discharge times. The electrical connection may be carried out by commissioned and qualified electricians only and in accordance with the connection diagram.

Electric shock when connecting the pump.

Remedy Before installation and start-up check all cables with regard to possible damages.

In case of damage, properly replace affected cable.

Immediately switch off the centralized lubrication system.

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Life cycle - commissioning Residual risks Electrical shock due to defective connection cable

Operating Manual Life cycle - commissioning Residual risks Lubricant spraying out due to incorrect screw connection of components or lines.

Remedy Tighten all parts with appropriate tightening torques.

Use suitable hydraulic screw connections and lines for the stated pressures.

Check these prior to commissioning for correct connection and damage.

Contact with corrosive or toxic substances that may be set free by a defective battery.

Wear protective clothes.

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

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

Ensure sufficient ventilation. Storage and disposal of defective batteries in accordance with the corresponding safety data sheets for lithium.

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

Falling of parts due to insufficient fixing to the machine.

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

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

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Literature, see screw manufacturer.

Bursting reservoir if filled by a high-performance pump

Monitor the filling procedure and stop it when reaching the max marking of the reservoir

Contact with stirring paddle or shovel foot during "test operation" without lubricant reservoir or barrel

Always operate pump with lubricant reservoir or barrel.

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

Tearing or damaging of lines when installed on moving machine parts (e.g. pivot arm).

If possible, do not mount on moveable parts.

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

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Life cycle - operation, maintenance, repair Residual risks Contact to the shovel foot during change of barrel of a pneumatic, hydraulic or electric barrel pump.

Remedy Change barrel only with the centralized lubrication system and pump being de-pressurized.

Contact with the stirring paddle when filling a reservoir pump from the top during pump operation.

Fill preferably via the filling connection.

Switch off the pump before changing the barrel and relieve existing system pressure.

Filling from the top or changing of barrel in case of barrel pumps only while the pump is idle.

When filling, do not reach into the reservoir.

Electrical shock due to defective connection cable

Switch off the centralized lubrication system and check connection cable for damage.

People slipping due to floor contamination with spilled or leaked lubricant

Exercise caution when connecting the system.

Promptly apply suitable binding agents to remove the leaked or spilled lubricant.

Follow the operational instructions for handling lubricants and contaminated parts.

Tearing or damaging of lines

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

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

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

Switch off the pump and system. Let parts cool down, eliminate cause. Replace defective motor or other defective components.

Too strong heating up of hydraulically driven components

Switch of the system or the affected component.

Strong cooling down and formation of ice on sound absorber and air leakage on pneumatically driven pumps or other components

Check the compressor and the drier of the compressed air supply. Reduce the operating speed of the affected pump.

Shortly switch off the system or heat it, if necessary.

Inadmissible lubricant leakage on components or lubricant lines of the centralized lubrication system

14

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

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Ensure proper functioning of the oil cooler.

Operating Manual Fault lifecycle Lubricant spraying out due to incorrect screw connection of components or lines.

Tighten all parts with appropriate tightening torques.

Use suitable hydraulic screw connections and lines for the stated pressures.

Check these prior to commissioning for correct connection and damage.

Disposal lifecycle Contamination of the environment with lubricant and wetted parts

Dispose of the parts following the valid legal and company regulations.

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

Exercise caution when disconnecting the lines.

Promptly apply suitable binding agents to remove the leaked or spilled lubricant.

Follow the operational instructions for handling lubricants and contaminated parts.

Dispose of used batteries following the valid legal and company regulations.

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

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Contamination of the environment due to used batteries on control printed circuit boards

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Operating Manual

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

Operator A person who is qualified by training and experience to carry out the functions and activities related to normal operation.

This includes avoiding possible hazards that may arise during pump operation.

Specialist for maintenance and repairs Qualified technical personnel are persons who have been trained, assigned, and instructed by the operator of the final product. Such persons are familiar with the relevant standards, rules, accident prevention regulations, and assembly conditions as a result of their training, experience, and instruction.

They are qualified to carry out the required activities and in doing so recognize and avoid any potential hazards.

Specialist in electrics The definition of qualified personnel and the prohibition against employing non-qualified personnel are laid down in DIN VDE 0105 and IEC 364. Relevant country specific definitions of qualified technical personnel apply for countries outside the scope of DIN VDE 0105 or IEC 364.

Protection of special groups of persons

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The respective legal employment restrictions do apply.

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3 Safety recommendations to be complied with General behaviour when handling the system The centralized lubrication system, pump or single components may be used only in awareness of the potential dangers, in proper technical condition, and according to the information in these installation instructions.

Familiarize yourself with the functions and operation of the product. The specified assembly and operating steps and their sequences must be observed.

Any unclear points regarding proper condition or correct assembly/ operation must be clarified. Operation is prohibited until issues have been clarified.

Keep unauthorized persons away from the centralized lubrication system.

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

Responsibilities for different activities must be clearly defined and observed. Uncertainty seriously endangers safety.

Safety-related protective and emergency devices must not be removed, modified or affected otherwise in their function and are to be checked at regular intervals for completeness and function.

Remedy occurring faults in the frame of responsibilities. Immediately inform your superior in the case of faults beyond your competence.

Do not reach into the system during operation.

Wear personal protective equipment always.

When handling lubricants observe the relevant safety data sheets and operating instructions by the lubricant manufacturer or supplier.

Never use parts of the centralized lubrication system or of the machine as standing or climbing aids.

Explosion protection Always behave so that fire and explosion hazards are avoided.

A written work approval from the operator is required prior to working in potentially explosive areas.

There must be no indications that parts of the explosion protection are missing or are not working. Should such indications become apparent, switch off the machine and inform a superior without delay. Keep unauthorized persons away.

Measures for explosion protection must never be deactivated, modified or bypassed.

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

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Check the machine at regular intervals for damage which may represent an ignition risk.

The ignition temperature of the lubricant must lie at least 50 K over the maximum admissible surface temperature of the components.

Only use tools and clothing which are permitted for use in potentially explosive areas (ESD).

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

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Operating Manual Repairs or modifications to machines which are protected against explosions may be carried out only by the manufacturer or by a workshop recognized by a named institution and confirmed in writing.

If the work is not carried out by the manufacturer, the repairs must be approved by a named expert and confirmed in writing. The repairs are to be marked by a repair sign on the machine, stating the following: o Date o Executing company o Type of repair o If applicable, expert's code Transport damages can result in the loss of the explosion protection. If transport damages can be seen, do not assemble the machine or put it into operation All parts of the earthing concept must be correctly available and connected with the superordinate machine.

If transport lugs are dismantled after set-up, the threaded bores must be permanently sealed in accordance with the protection class.

Handle the materials so that no sparks are generated by tilting, falling, sliding, rubbing, impacting, etc. If needed, cover materials with suitable means.

Never disconnect plug-in connections when energized. Secure plug-in connections against inadvertent manual disconnection with the safety clips included in the delivery.

The operator must check critically whether operation without a low-level signal might lead to a new risk potential (e.g. through heat-up of bearing points on the machine in the area of ignition temperature, poor lubrication or bearing damage). If this cannot be ascertained, provide a low-level signal or suitable organisational measures for monitoring of the bearing point temperature.

Avoid dust accumulation and remove dust immediately. Dust accumulations have a thermally insulating effect and, if whirled up, generate the formation of a potentially explosive atmosphere.

The pump should be integrated into the operator's lightning protection concept.

All parts are to be checked regularly for corrosion. Replace the affected parts.

Terminal boxes must be firmly closed and the cable breakthroughs correctly sealed.

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

Protect the motor with a motor circuit breaker against inadmissible heating up. When reaching their nominal life, the motor bearings have to be replaced or inspected to ensure their suitability for further utilisation.

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

If protective and safety equipment has to be dismantled, it must be reassembled immediately after finishing the work, and then checked for correct function.

Ensure through suitable measures that movable or detached parts are immobilized during the work and that no limbs can be caught in between by inadvertent movements.

Carry out transport using only suitable hoisting equipment.

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Transport / installation / maintenance / repairs / servicing

Operating Manual If transported separately (e. g. repair) lift the motor by means of the transport lugs or eye bolts. Ensure that transport lugs or eye bolts are firmly seated. Do not carry any further load on the transport lugs or eye bolts. Do not transport motors on the fan cover.

Assemble the pumps and other components only outside of the operating range of moving parts, at an adequate distance from sources of heat or cold.

Dry wet, slippery surfaces.

Cover hot or cold surfaces accordingly.

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

Carry out electrical connections only according to the information in the valid wiring diagram and taking into account the relevant regulations, the local connection conditions and legal prescriptions (e.g. DIN, VDE). Electrical connections must be done in such way that no forces are transferred to the product (tension-free connection).

Do not touch cables or electrical components with wet or damp hands.

Maintenance and repair work can be subject to restrictions at low or high temperatures (e.g. changed flow properties of the lubricant). Therefore, where possible, try to carry out maintenance and repair work at room temperature.

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

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

Determine the cause of the failure of the fuse.

Ensure correct earthing of the electrical system.

Undertake drilling at non-critical, non-load bearing parts only. Use any available boreholes. Do not damage lines and cables when drilling. It is essential to observe the machine manufacturer's installation instructions and to consult the machine designer in case of doubts.

Observe possible abrasion points. Protect the parts accordingly.

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

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All components used must be designed for: o

maximum operating pressure

o

lubricant to be supplied

o

maximum/ minimum temperature

o

corresponding supply voltage available on site

o

operating and ambient conditions at the location of use

o

required lubricant volume

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

Check all parts prior to use for contamination and clean, if necessary. Lubricant lines should be primed with lubricant prior to installation. This makes the subsequent ventilation and commissioning of the system easier.

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

When working with heavy parts use suitable lifting tools. If need be, consult the responsible safety officer.

Avoid mixing up or wrong assembly of dismantled parts. Mark these parts accordingly.

Laying of the lubrication lines When laying the lubrication lines, observe the following information in order to warrant troublefree function of the entire centralized lubrication system.

CAUTION Environmental pollution Lubrication lines must be absolutely leakproof. Lubricants may pollute ground and waters. Lubricants have to be handled and disposed of properly. Observe all applicable prescriptions and laws regarding disposal of lubricants as well as the relevant safety data sheets.

Slipping hazard Centralized lubrication systems must be absolutely leakproof. Leaking lubricant is hazardous due to the risk of slipping and injury. During assembly, operation, maintenance and repair of centralized lubrication systems watch out for leaking lubricant. Leaks must be sealed immediately.

Dimension the lubrication line according to the maximum pressure and the output volume of the pump unit used.

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

Mount the lubricant metering devices at the end of the main lubrication line in such way that the outlets of the lubricant metering devices show upwards. If lubricant metering devices have to be mounted below the main lubrication line, then this should not be done at the end of the main lubrication line.

The tube lines, hoses, shut-off and way valves, fittings, etc. have to be laid out according to the maximum operating pressure of the pump unit, the admissible temperatures and the lubricants to be supplied. Furthermore, the lubrication line system must be protected against inadmissibly high pressure.

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

The lubricant flow in the lubrication lines should not be impeded by the installation of sharp elbows, angle valves and check valves. Provide unavoidable changes of the cross sections in the lubrication lines with as smooth transitions as possible. Avoid sudden changes of direction, if possible.

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Lubrication lines shall generally be laid in such way that there can never be created air pockets at any point. Avoid changing the cross sections of the lubrication line from smaller to larger cross sections in the lubricant flow direction. Design cross section transitions as smooth as possible.

Operating Manual

Initial commissioning / daily start-up Ensure that: The machine manufacturer's instructions regarding the lubricants to be used are observed.

All safety devices are completely available and functional.

All connections are correctly connected.

All parts are correctly installed.

All warning labels on the centralized lubrication system are completely available, highly visible and undamaged.

Illegible or missing warning labels are to be replaced without delay.

The system pressure specified for proper operation is adhered to and neither exceeding nor falling below specification.

Cleaning Risk of fire and explosion when using inflammable cleaning agents. Only use nonflammable cleaning agents suitable for the purpose.

Do not use any aggressive cleaning agents.

Do not use steam jet or high pressure cleaners. Otherwise electrical components may be damaged. Observe the protection classes, e.g. IP (International Protection) and NEMA (National Electrical Manufacturers Association), required for proper operation.

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

Do not touch cables or electrical components with wet or damp hands.

LEC / en / Edition: 09/2018

Mark damp areas accordingly.

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Operating Manual

4 Operator obligations Determination of hazards The operator must determine all hazards resulting from the integration of the pump into the superordinate machine and the hazards at the location of operation of the machine, and carry out the measures necessary to ensure safety and health protection.

Provision of necessary information The operator must make the installation instructions required for the respective activity accessible to all people commissioned with operation, maintenance and repairs.

He must ensure that these people have read and understood the necessary installation instructions.

The same applies for all relevant safety data sheets, company instructions, accident prevention regulations, instructions from suppliers of purchase parts and utilities.

Depending on the business organization, the relevant installation instructions may have to be made accessible to other people and departments.

Inspection for correct use The operator must check at regular intervals through suitable measures that the centralized lubrication system is being used according to its intended purpose, that no conversions or manipulations have been made to the centralized lubrication system or to single components and that all parts are fully functional.

Briefing of external technicians Prior to commencing the activities, external technicians must be informed by the operator of the company safety provisions, the applicable accident prevention regulations to be maintained, and the functions of the centralized lubrication system and protective devices.

Provision of personal protective equipment The operator must provide suitable personal protective equipment for the respective location of operation and the purpose of operation.

Training courses

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In order to provide a maximum of safety and economic viability, SKF carries out detailed product training courses. It is recommended that the training courses are attended. Please contact SKF Customer Service for information.

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Inspection of the delivery / returns The delivery must be inspected for completeness based on the delivery papers. Transport damages must be reported to the forwarder immediately. Keep the packaging material until any discrepancies are resolved.

Returns Clean all parts and pack them properly, i.e. following the regulations of the recipient country, before returning them. Mark returns on the packaging as follows; Do not burden / this side up!

Protect against moisture!

Handle with care!

Fragile, do not throw!

Disposal

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

In case of a final shutdown follow the applicable rules and regulations on the disposal of contaminated parts or means of operation. The product can also be returned to SKF for proper disposal, in which case the customer is responsible for reimbursing the costs incurred. The parts are recyclable.

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

LEC / en / Edition: 09/2018

Observe the instructions by the machine manufacturer regarding the lubricants to be used.

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Operating Manual

5 Lubricant

LEC / en / Edition: 09/2018

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

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Operating Manual

Filling of the reservoir

WARNING Risk of hand injuries caused by the stirring paddle or shovel foot Never reach into the reservoir or grease barrel while the pump is running.

Lines are pressurized. Be careful when decoupling.

Observe extreme cleanliness when topping up the grease reservoirs.

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

Clean surroundings before exchanging or topping up Switch off centralized lubrication system Remove dust protective cap at the filling coupling and the dust protective cap at the filling nipple Couple the filling hose for P1 resp. P2 and switch on the filling pump When the reservoir is full, the sensor transmits an electric signal to the control unit. Visual control is possible by using the dipstick When the filling pump is switched off Disconnect the filling coupling and reinstall the dust protective caps

Inadvertent filling with incorrect lubricant Should incorrect lubricant have been filled, please proceed as follows: Switch off the pump or centralized lubrication system and secure it against being switched on.

Remove lubricant.

Clean the entire centralized lubrication system (lubricant reservoir, pump housing, metering devices and line systems).

Fill in lubricant of correct specification.

Switch the system or pump on.

Vent lubrication system.

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

Inspections prior to initial start-up ATTENTION

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Risk of damage to the machine Fill the feed lines and bearing housings with lubricant to specification and lubricate the lubrication points by hand. Otherwise the bearing points may become damaged due to a lack of lubricant.

Check the entire system for accordance with the intended purpose and the planning documentation. Ensure that all parameters, characteristic values and means of operation are present and have been correctly adjusted. If deviations are detected, they must be remedied without delay.

In order to warrant safety and function, a person assigned by the operator must inspect certain areas of the central lubrication system prior to initial commissioning. Report any detected deficiencies immediately to your superior and remedy them. Deficiencies may be remedied by an authorized and qualified specialist only.

Check the following points prior to initial commissioning.

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Operating Manual

Electrics: Electrical connections carried out correctly.

Cable entries sealed correctly.

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

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

All parts such as lines, cables, metering devices, etc. have been correctly installed and are undamaged.

Mechanics: No loose or missing parts remaining (e.g. pressure relief valves, feed lines).

No damages, deformations, cracks, burnt and smoky points.

No discolorations, contaminations and/or corrosion.

No unusual humidity accumulations, odours, vibrations, or sounds.

No leakages of lubricant at connections and from lines.

Activation of the pump

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Depending on the version the centralized lubrication system or pump is activated: By installing it into a machine By switching on the machine contact By a control provided by the customer By manual activation

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Operating Manual

6 Standard operation Daily start-up Below find the activities to be carried out in case of standard operation.

Inspections With regard to the actions listed below "Inspections prior to commissioning" the operator has to determine adequate control intervals depending on the respective operating situation of the pump or centralized lubrication system.

Filling of the reservoir during operation Fill the reservoir as described in chapter "Installation and commissioning".

Cleaning Execution, required protective clothes, cleaning agents and devices following the valid operational regulations of the operator.

DANGER Danger to life Risk of fire and explosion when using inflammable cleaning agents.

Do not use steam jet or high pressure cleaners. Electrical components may be damaged. Do not touch cables or electrical components with wet or damp hands. Cleaning work on energized components may be carried out by electrical specialists only. Wear personal protective equipment always.

Exterior cleaning Thorough cleaning of all surfaces.

Mark and secure wet areas.

Interior cleaning Normally, interior cleaning is not required.

ATTENTION

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Risk of damage to the machine If using solvents for cleaning, ensure compatibility with plastic parts and painting. Do not use polar organic solvents such as alcohol, methanol or acetone.

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Operating Manual

7 Maintenance and repairs Safety instructions for maintenance and repairs

WARNING Electric shock Make sure to disconnect the pump from the power supply before carrying out works on electrical parts.

Risk of injury Before carrying out any maintenance or repair work, take at least the following safety measures: o

Keep unauthorized persons away.

o

Mark and secure work area.

o

Depressurize the product.

o

Disconnect the product from the power supply and secure it against being switched on.

o

Verify that no power is being applied.

o

Earth and short-circuit the product.

o

Where needed, cover neighbouring units that are live.

Maintenance of the system Depending on the version our centralized lubrication systems require virtually no maintenance.

However, the following parts should be inspected and, if necessary, replaced by new parts at regular intervals: Pressure relief valves Check valves Pump elements

LEC / en / Edition: 09/2018

Pressure relief valve tolerance +5 %/ -10 % If this tolerance is exceeded, the pressure relief valves must be replaced.

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8 Technical data and operating instructions Operating pressure / operating temperature All system components must be designed for the maximum operating pressure and must be secured by an adequate pressure relief valve against too high system pressures. For details see operating or installation instructions and data sheets of the respective product.

Installation position, sound pressure level, weight, dimensions For details see operating or installation instructions and data sheets of the respective product.

Tightening torques For details see operating or installation instructions and data sheets of the respective product.

Output / connections For details see operating or installation instructions and data sheets of the respective product.

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

Filling possibilities For details see operating or installation instructions and data sheets of the respective product.

Electrical connection (electrically driven products) Following the respective applicable installation prescriptions for electrical systems. For details see operating or installation instructions and data sheets of the respective product.

IP type of protection Motor and system: For IP or NEMA protective class see type identification plate of motor or system respectively the Technical Data chapter of the individual components. For details see operating or installation instructions and data sheets of the respective product.

Air pressure and air quality (air-operated products)

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Filtered and oiled air according to DIN ISO 8573-1 not higher than class 5 Inlet air pressure

5.5 – 7 bar

Maximum particle density

10 mg / m3

Water content (pressure dew point)

+ 7 °C

Oil content (maximum oil concentration) 25 mg / m3 Please follow the instructions of the respective product.

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Operating Manual

9 Lubrication System: Description General design 9.1.1

Systems

The lubrication system of the R9100 excavator which provide lubricant to the lubrication points are supplied by two independent centralized lubrication systems: System P1, to lubricate the swing gear bearing and the attachment bushes (and options) System P3, to lubricate the swing ring teeth and the swing gear centering seat 9.1.2

Allocation of the lubrication points

The lubrication points of the R9100 excavator described below are dispatched as follows: Backhoe attachment:

Position of lubrication points

LEC / en / Edition: 09/2018

Fig. 10-1

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Operating Manual Shovel attachment:

Position of lubrication points

LEC / en / Edition: 09/2018

Fig. 10-2

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Operating Manual Characteristics of lubrication points on the excavator (This section must only be available inside the SKF service Manual)

All the necessary information regarding the greasing points and quantities are available in chapter 21 of the Liebherr Service Manual.

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9.1.3

Operating Manual

System P1: Automatic lubrication In the automatic system, a central lubrication pump provides lubricant to each lubrication point through a single line via injectors model LM5 and subsequent metering devices model SSV. 9.2.1

Configuration

LEC / en / Edition: 09/2018

Injector model LM5 supplies lubricant to the progressive metering devices model SSV which distributes the lubricant to each lubrication point evenly. A control unit U4-1 commands and monitors the entire system.

Legend: Equipment: Uppercarriage:

Fig. 10-3

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Operating Manual

Automatically operated single-line system with LM5 and subsequent progressive divider valve for shovel attachment

LEC / en / Edition: 09/2018

Fig. 10-4

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Greasing cycle

When the pause time has lapsed, the pump starts operating and supplies the lubricant via the main line to the LM5 injectors. The pistons inside the injectors are operated via lubricant pressure. A premetered amount of lubricant is dispensed to the connected SSV. After all injectors have operated, the pressure in the main line rises until the preset pressure on the pump is reached 240 bar. The control unit stops the pump via the pressure switch B69. The pump stops running and relief valve (see Fig. 10-6, item 3) is deactivated at the same time. The compressed lubricant in the main line can flow back into the reservoir, the pressure drops. When the pressure has fallen below 80 bar the pistons inside the LM5 injectors return to their initial positions by means of spring force and reload the adjustable amount of lubricant by this action.

The pause time can start and the system is now ready for another lubrication cycle.

Cycle (factory setting): Equipment and uppercarriage

LEC / en / Edition: 09/2018

Fig. 10-5

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Operating Manual 9.2.3

Single-line system

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

The lubrication cycle is initiated by an automated pump. The injectors have indicator stems, which move in and out to indicate that they have been cycled.

A controller will control the automated system.

The time between on cycles and the length of off cycles is adjustable. The controller includes the timer function above with a monitor function and alarm capability. A pressure switch is used to indicate when system pressure has been reached to turn off the pump and verify that a lube cycle has been completed. If the pressure switch does not detect full pressure within a preset period of time, the controller goes into alarm state.

9.2.4

Pump station 27L

Fig. 10-6

1

Dip stick

2

Pump P1 – Model FlowMaster II

3

Hydaulic relief (vent) valve

4

Contact rod – B96 (low level control) + B185_1 (highlevel control)

5

Overflow pipe

6

Grease reservoir 27L for FlowMaster II-pump

7

Strainer assembly, pressure line

8

Lubricant filter, refilling

9

Optical high-level control

10

Solenoid Y34_1 (pump control)

Central lubrication pump 27L

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For information and descriptions of the components, refer to chapter 13.

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Cabin greasing module U4-1

Fig. 10-7

Module U4-1

The control unit controls and monitors the central lubrication system. It allows the adjustment of the operating and pause time and reports the current operating status of the lubrication system into the cabin. It indicates if the grease reservoir is full or empty. Furthermore, certain errors in the lubrication system are signaled via an error code. You can also trigger additional lubrication impulses.

Technical data Operating temperature Voltage Switching current Safety extra-low voltage Connection Outputs

- 25 °C to + 70 °C 10 - 32 VDC ± 10 % (max.) 3 A SELV 2-pole plug AMP Mate-N-Lok for E/A 2 x semiconductor 3 A

Factory settings Pause time* Monitoring time

15 min, variable 15 min, fixed

*The pause time can be set variably between 4 min and 40 min

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Display elements

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Operating Manual Fault indications (error codes)

Pause-time setting

Press keys Press key

and simultaneously. to set the pause time.

Note!

By holding down key , the pause time can be adjusted more quickly. After reaching the maximum pause time the display jumps to the minimum possible pause time (continuous speedy display).

Trigger additional lubrication cycle Press key

(> 2 seconds)

Query pause time Press key shortly. The projected pause time (PP) and the remaining pause time (rP) will be shown twice alternately.

Reset low-level and fault indications Press key to acknowledge a low-level or fault indication. (Precondition: Lubricant was refilled and cause of fault was remedied).

Note!

If lubricant was refilled up to the high-level indication, the low-level indication is acknowledged automatically. to deactivate the acoustic fault signal.

LEC / en / Edition: 09/2018

Press key

For more details: Operating elements Functions Refer to Manual 4.4DE_EN-68610-xxx

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System P3: Swing ring and swing gear lubrication In the automatic system P3, the central lubrication pump provides lubricant to the Progressive Metering Device (Progressive System) which distributes the lubricant to each lubrication point evenly (swing ring teeth and the swing gear centering seat).

Fig. 10-8

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9.3.1

Schematic of lubrication: Swing ring teeth and swing box centering

Grease cycle

Fig. 10-9

Grease cycle (factory setting)

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

The pause time can be set variably between 4 min and 30 min.

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Operating Manual 9.3.2

Pump P3 - Multi-line pump type P203

Fig. 10-10

Option P203-8XBF-1K6-24-2A8.XX-M05 (with internal control B185_2 (high level) and B51_2 (low level)

The pump is a compact multiline pump consisting of the following components: · Housing with integrated motor · Reservoir with stirring paddle · Printed circuit board · Pump element · Pressure relief valve · Filling nipple · Electrical connection parts · Operates according to lubrication cycles (pause and operating times) · Designed for the delivery of greases up to NLGI 2 · Can be used at low temperatures down to -40 °C. · During the operating time the pump dispenses lubricant to the connected lubrication points via one device.

Number of outlets: Piston diameter: Lubricant output: Reservoir capacity:

1 6 mm approx. 2.8 cm³/min 8

For more details:

LEC / en / Edition: 09/2018

Description Mode of operation Maintenance Troubleshooting Technical data Refer to Technical Description: 21EN-30001-xxx; 20EN-20003-xxx; 26A-20003-xxx For information and descriptions of the components, refer to chapter 13.

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10 Operation Greasing system – Cabin Location

Fig. 10-11

Cabin location

For more details: Information regarding the operation of U4-1 module are available in chapter 9.2.5 Cabin greasing module U4-1

LEC / en / Edition: 09/2018

Refer to Data Sheet 93A-20014-xxx.

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System P1: Automatic lubrication CAUTION! Operation by authorized and instructed personnel only!

Never exceed the admissible system pressures!

Refill clean lubricant on time!

CAUTION! Do not interrupt the power supply (main switch of battery) while the pump is operating.

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

The pause time is factory-set to 15 minutes. This corresponds to an approximate grease consumption of 120 g/h at a pump runtime of about 6 min/cycle.

The pump P1 delivers lubricant via a single-line system to the lubrication points according to Chapter 9.2.1 Configuration.

Regarding the control and monitoring of the system refer to: Chapter 9.2.5 Cabin greasing module U41 If required, the operator can force the greasing cycle by pushing the button S84-1 on the cab control board: Trigger additional lubrication cycle See the characteristics of each lubrication points: Characteristics of lubrication points on the excavator.

For more details:

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Chapter 9.2.2 Greasing cycle

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Pump P3: CAUTION! Operation by authorized and instructed personnel only!

Never exceed the admissible system pressures!

Refill clean lubricant on time!

CAUTION! Do not interrupt the power supply (main switch of battery) while the pump is operating.

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

The pause time is factory-set to 6 minutes. This corresponds to an approximate grease consumption of 7 g/h at a pump runtime of about 25 sec/cycle.

In normal working condition, no actions are required from the operator.

The only useful information is the low level quantity of the pump P3 reservoir.

If required, the operator can force the greasing cycle buy pushing the button S84-2 (see Chapter 10.1 Greasing system – Cabin Location) on the cab control board.

NOTE! DAILY:

DO A VISUAL CHECK OF THE RESERVOIR FOR GREASE LEVEL

For more details:

LEC / en / Edition: 09/2018

Chapter 9.3.1 Grease cycle

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Operating Manual

11 Inspection and Maintenance DANGER! DANGER! – Do not carry out any repair works while the system is pressurized – Grease: Relieve system from pressure by carefully opening a fitting and/or the manual vent valve(s) if installed (option) – Hydraulic Oil: Relieve hydraulic system from pressure as described in the Operator Manual – Warning: Lubricant may spurt out while system is under pressure.

NOTE! Regular inspection and maintenance intervals are prerequisites for the proper functioning of the centralized lubrication system over a longer period of time. Any claim for warranty or liability will be null and void, if the prescribed maintenance intervals are not adhered to.

Please observe the following regular inspections and maintenance works: Daily: Visually check the lubrication points with regard to leaking lubricant Visually check the hose connections with regard to leaks and abrasions Check movement of indicator pins: During the lubrication time the pins have to retract, in the pause time all pins have to be extracted.

Weekly: Visually check of tube fittings with regard to leaks Determine the time required for one lubrication cycle. If the determined time deviates much from the usual lubrication time, check each single component (pumps, metering devices, tube lines).

Every 1000 operating hours: Clean or replace strainer assembly (Erreur ! Source du renvoi introuvable.)

Clean or replace lubricant filter (refilling) (Erreur ! Source du renvoi introuvable.)

Check the oil level in the crankcase of the pump model FlowMaster at the dip stick (Erreur !

Source du renvoi introuvable.)

Change the oil in the crankcase of the pump model FlowMaster.

Use SAE 10W30 motor oil in all units used in an ambient temperature between –40° to 65°C. For ambient temperatures between 10° to 21°C uses Mobil Aero HFA low temperature oil.

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Every 2000 operating hours:

Operating Manual

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

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

Remedy:

Malfunctions of the pump

See Troubleshooting: Pump

Leakage in the main line

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

Air trapped in the main line

De-aerate the line

Injectors leaky or worn

See Troubleshooting: Injectors

Malfunction: No pressure relief or too slow pressure relief in the main line (automatic option only) Cause:

Remedy:

Pressure control device faulty

Replace pressure control device, check electric cable

Hydraulic vent valve faulty

Replace valve, check fluid supply

Grease too hard or not suitable for low temperatures

Change lubricant

Motor of pump does not run Possible cause

Visible

Remedy

Fault in the superior machine or external control unit.

No pump noise

Check the electrical lines and the external control unit

Check the motor circuit breaker

Motor circuit breaker has tripped

LEC / en / Edition: 09/2018

Motor runs, but pump does not supply lubricant

R 9100

Possible cause

Visible

Remedy

Reservoir empty

Visual check

Refill

Air pockets in the lubricant

Air bubbles in the lubricant

Vent

Suction bore of pump element is clogged.

After disassembling the pump element

Disassemble and clean the pump elements.

Defective or dirty system check valve

After disassembly of the check valve

Replace check valve.

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Operating Manual

Worn pump element

Little pressurization

Defective pressure relief valve or fault at the lubrication point

Lubricant leaking from the pressure relief valve

Blockade in the downstream lubrication system

Grease leaking from the pressure relief valve

Check pump element and replace, if necessary.

Determine cause.

Replace pressure relief valve Determine cause and eliminate it.

If the fault cannot be determined and remedied, contact our Customer Service.

Please follow the instructions of the respective product.

For more details: Regarding error codes (fault indications) Refer to Chapter 9.2.5

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Fault indications (error codes)

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Conversion factors Pressure:

Length:

Volume:

Torque:

Weight:

Temperature:

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