Liebherr R 9200 1625 Hydraulic Excavator Operating Manual SN 40083 - PDF DOWNLOAD

MJFCIFSS

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Fig. 1-1

Machine with backhoe attachment

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Fig. 1-2

Machine with 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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Tab. 1-2

Working technical data

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Fig. 2-1

Arrangement of signs on the machine

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Fig. 3-1

Control cab

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Fig. 3-2

Standing position from operator’s point of view

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Fig. 3-3

Switches on the joysticks

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Fig. 3-4

Joysticks right (U22) and left (U21)

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Fig. 3-5

Keyboard

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Fig. 3-6

Cab 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

Control box E1022

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Fig. 3-22

Button S122: Disable of ladder control position

Fig. 3-23

Button S126

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Fig. 3-24

Button S125

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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

Auxiliary seat

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Fig. 3-37

Cab sunshade

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Fig. 3-38

Emergency exit and emergency hammer

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Fig. 3-39

Internal lighting switch button

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Fig. 3-40

Fire extinguisher fixing location

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Fig. 3-41

Container of the windscreen washer fluid

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Fig. 3-42

Heated windscreen

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Fig. 3-43

Field of view

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Fig. 3-44

Configuration of lighting

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Fig. 3-45

Front panel of the heating/air conditioning control unit

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Fig. 3-46

Ignition key S1 on cab control board

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Fig. 3-47

Principal battery switches

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Fig. 3-48

Engine ECM circuit breaker S9_3

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Fig. 3-49

Speed indication on the main menu of the display

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Fig. 3-50

Indicators for Diesel Exhaust Fluid (DEF) and Selective Catalytic Reduction (SCR) system on control board

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Fig. 3-51

Auxiliary start receptacle

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Fig. 3-52

Location of the emergency stop S100_1

Fig. 3-53

Location of the emergency stop S100_2

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Fig. 3-54

Location of the emergency stop S100_3

Fig. 3-55

Location of the emergency stop S100_4

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Fig. 3-56

Location of starter test switches S51_1 and S51_2

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Fig. 3-57

Safety control for the Diesel engine start

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Fig. 3-58

Safety controls for the Diesel engine speed

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Fig. 3-59

Safety control for swing and travel brakes

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Fig. 3-60

Safety controls for hydraulic pumps

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Fig. 3-61

Safety fans control

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Fig. 3-62

Travel straight ahead

Fig. 3-63

Turn on the spot

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Fig. 3-64

Turn with one track chain

Fig. 3-65

Hand levers to operate the travel movements manually

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Fig. 3-66

Turn the uppercarriage

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Fig. 3-67

Working position – machine

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Fig. 3-68

Operating the stick cylinder

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Fig. 3-69

Operating the boom cylinder

Fig. 3-70

Operating the boom down with pressure

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Fig. 3-71

Float position

Fig. 3-72

Operating the bucket cylinder

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Fig. 3-73

Rotary switch for control selection

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Fig. 3-74

Operating the bottom dump shovel bucket

Fig. 3-75

Flap control with the analog stick

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Fig. 3-76

Semi-automatic flap closing

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Fig. 3-77

Deactivation of attachment damping system

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Fig. 3-78

Lowering the attachment when engine is not running

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Fig. 3-79

Working position – machine

Fig. 3-80

Hazard area

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Fig. 3-81

Recommended digging

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Fig. 3-82

Optimal angle for digging

Fig. 3-83

30° forward to the vertical.

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Fig. 3-84

Taking up grab material

Fig. 3-85

45° backward to the vertical

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Fig. 3-86

Emptying grab material

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Fig. 3-87

Digging

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Fig. 3-88

Unloading of the bucket

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Fig. 3-89

Hazard area r

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Fig. 3-90

Sticker for lifting and lashing operations

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Fig. 4-1

LIEBHERR service

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Fig. 4-2

Access door of E1003 electrical box

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Fig. 4-3

Fuses of power electrical box E1003

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Fig. 4-4

Relays of power electrical box E1003

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Fig. 4-5

Fuses of electrical plate E1003_1

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Fig. 4-6

Locations of the electrical plates in E1005

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Fig. 4-7

Fuses and relays of cab connection box E1005

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Fig. 4-8

Electrical box E1091 for the Selective Catalytic Reduction (SCR) system

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Fig. 5-1

Access points for the maintenance

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Fig. 5-2

Horizontal middle bar on handrail (example)

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Fig. 5-3

Welded anchor point (example)

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Fig. 5-4

Drilled anchor point (example)

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Fig. 5-5

R 9200 lubricating chart

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Tab. 5-1

Lubricating chart key

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Tab. 5-2

Lubricant chart

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Tab. 5-3

Operating material chart

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Fig. 5-6

Service trap

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Fig. 5-7

Centralized lubrication system

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Fig. 5-8

Service trap lever

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Fig. 5-9

Lower the service trap

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Fig. 5-10

Close the service trap

Fig. 5-11

Locking hook correct position

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Fig. 5-12

Warning light H68: trap control lock

Fig. 5-13

Button S122: Disable trap control lock

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Fig. 5-14

Grease control box E1043

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Fig. 5-15

Grease warning light H109

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Fig. 5-16

LIEBHERR oils for hydraulic system

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Fig. 5-17

Engine oils for hydraulic system

(ISO VG68)

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(ISO VG100) (ISO VG46)

Fig. 5-18

Hydraulic oil for hydraulic system

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Fig. 5-19

Oil changes at pre-set intervals

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Fig. 5-20

Oil changes at optimized intervals

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Fig. 5-21

Swing gear and travel gear oils

Tab. 5-4

Tab. 5-5

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Tab. 5-5

Tab. 5-6

Tab. 5-7

Fig. 5-22

Gear oils for use as splitterbox oil

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Fig. 5-23

Sampling pump

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Fig. 5-24

Sampling valve 1 for splitterbox oil

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Fig. 5-25

Oil sampling points 1 for travel gear oil

Fig. 5-26

Sampling valve 1 for hydraulic oil

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Fig. 5-27

Sampling valve 1 for Diesel engine oil

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Fig. 5-28

Dipstick location

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Fig. 5-29

Location of the quick coupling on the service trap

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Fig. 5-30

Location of the oil drain plug on the oil pan

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Fig. 5-31

Location of oil filters on the Diesel engine

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Fig. 5-32

Location of the oil filler neck on the Diesel engine

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Fig. 5-33

Engine mounting screws

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Fig. 5-34

Engine elastic bedding

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Fig. 5-35

Splitterbox mounting screws

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Fig. 5-36

Splitterbox mounting screws on engine

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Fig. 5-37

Elastic bedding

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Fig. 5-38

Breather filter on splitterbox

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Fig. 5-39

Check the coupling rubber rollers

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Fig. 5-40

Expansion tank

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Fig. 5-41

Coolant drain

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Fig. 5-42

Coolant filters location

Fig. 5-43

Coolant filters

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Fig. 5-44

Lockable fuel tank cap

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Fig. 5-45

Service trap

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Fig. 5-46

Drain valves of fuel tank

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Fig. 5-47

Fuel filters assembly

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Fig. 5-48

Water separator on the preliminary filter

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Fig. 5-49

Fuel shutoff valve

Fig. 5-50

Filter element on preliminary filter

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Fig. 5-51

Fuel filters

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Fig. 5-52

Dust filter for the vent valve

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Fig. 5-53

Drain plug of the Diesel Exhaust Fluid (DEF) tank

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Fig. 5-54

Coupling on service trap for Diesel Exhaust Fluid (DEF) filling

Fig. 5-55

Button S123 on service trap control box E1043

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Fig. 5-56

Filler neck for Diesel Exhaust Fluid (DEF)

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Fig. 5-57

Diesel Exhaust Fluid (DEF) filters on supply modules

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Fig. 5-58

Coolant shutoff valves

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Fig. 5-59

Air intake system

Fig. 5-60

Vacuum indicator

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Fig. 5-61

Primary filter element

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Fig. 5-62

Safety element

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Fig. 5-63

Precleaner

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Fig. 5-64

Housing of air filter elements

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Fig. 5-65

Air intake hoses, tubes and elbow tubes

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Fig. 5-66

Machine check position for hydraulic oil level check or level adjustment

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Fig. 5-67

Oil level in the hydraulic tank

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Fig. 5-68

Release the hydraulic pressure

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Fig. 5-69

Hydraulic oil change coupling on service trap

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Fig. 5-70

Return filter on the hydraulic tank

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Fig. 5-71

Bleeding valve of the hydraulic tank

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Fig. 5-72

Leak oil filter

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Fig. 5-73

Return filter

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Fig. 5-74

Location of servo oil and replenishing filters

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Fig. 5-75

Servo oil and replenishing filters

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Fig. 5-76

High pressure filters on valve bank

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Fig. 5-77

High pressure filter

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Fig. 5-78

Accumulator on the valve bank

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Fig. 5-79

Pumps intake hoses (aspiration)

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Fig. 5-80

Bleeding of the working pumps

Fig. 5-81

Bleeding of the swing pump

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Fig. 5-82

Bleeding of the cooling pumps

Fig. 5-83

Bleeding of the pump for the air-conditioning system

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Fig. 5-84

Bleeding of valve blocks

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Fig. 5-85

Oil cooler protection filter

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Fig. 5-86

Piston rod mounting

Fig. 5-87

Machine with piston rods retracted

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Fig. 5-88

SAE flanges

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Tab. 5-8

Tightening torques for SAE flanges

Fig. 5-89

Sealing flange 1 and hydraulic block 2

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Fig. 5-90

Criss-cross tightening

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Fig. 5-91

Oil change on the swing gear

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Fig. 5-92

Expansion tank

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Fig. 5-93

Oil change on travel gear

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Fig. 5-94

Oil change on external travel brake

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Fig. 5-95

Oil change on the splitterbox

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Fig. 5-96

Undercarriage components

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Fig. 5-97

Travel gear components (right and left sides)

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Fig. 5-98

Track pad

Fig. 5-99

Carrier roller

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Fig. 5-100 Track roller

Fig. 5-101 Idler and tension unit

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Fig. 5-102 Track guide

Fig. 5-103 Travel motor protection

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Fig. 5-104 Track correctly tensioned

Fig. 5-105 Check of the track tension

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Fig. 5-106 Tightening the track

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Fig. 5-107 Cylinder shutoff valves CVTL and CVTR

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Fig. 5-108 Location of ECM connectors

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Fig. 5-109 Battery care

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Fig. 5-110 Electrical components location

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Fig. 5-111 Aeration device

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Fig. 5-112 Location of the coolant shutoff valves on the Diesel engine

Fig. 5-113 Heater

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Fig. 5-114 Location of the evaporator(s)

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Fig. 5-115 Dryer/receiver unit

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Fig. 5-116 Location of the condenser

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Fig. 5-117 Location of the dryer/receiver unit

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Fig. 5-118 Location of the air-conditioning compressor

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Fig. 5-119 Location of the condenser units

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Fig. 5-120 Components of the condenser unit

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Fig. 5-121 Protection device for bucket cylinders

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Fig. 5-122 Grease nipples for the service trap

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Fig. 5-123 Counterweight bolts

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Fig. 5-124 Swing ring bolts on uppercarriage

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Fig. 5-125 Swing ring bolts on undercarriage

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Fig. 5-126 Fuel tank bolts

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Fig. 5-127 Hydraulic tank bolts

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Fig. 5-128 Bolts of engine cooler box

Fig. 5-129 Bolts of the oil cooler box

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Fig. 5-130 Pumps box bolts

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Fig. 5-131 Bolts of swing gear and swing motor

Fig. 5-132 Cab elevation bolts

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Fig. 5-133 Screws and mounts of the cab

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Fig. 5-134 Service trap bolts

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Fig. 5-135 Hydraulic pumps bolts

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Fig. 5-136 Side frames bolts

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

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Tab. 5-9

Daily maintenance schedule - R9200

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Tab. 5-10 250 Hours maintenance schedule - R9200

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Tab. 5-11 500 Hours maintenance schedule - R9200

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Tab. 5-12 1000 hours maintenance schedule - R9200

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Tab. 5-13 2000 hours maintenance schedule - R9200

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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

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Fig. 6-8

Leak oil circuit of working pumps

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Fig. 6-9

High pressure hoses between valves blocks and working pumps

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Fig. 6-10

Intake lines of working pumps

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Fig. 6-11

Leak oil hoses of swing pump

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Fig. 6-12

Leak oil hoses of swing motors

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Fig. 6-13

Working pressure lines

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Fig. 6-14

Intake and replenishing lines

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Fig. 6-15

Return oil lines of fans motors

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Fig. 6-16

Leak oil lines of fan motors

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Fig. 6-17

Leak oil hoses of cooling pumps

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Fig. 6-18

Working pressure lines of fan motors

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Fig. 6-19

Intake line of cooling pumps

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Fig. 6-20

Leak oil circuit of travel motors

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Fig. 6-21

Working pressure circuit on the undercarriage

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Fig. 6-22

Working pressure circuit on the uppercarriage

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Fig. 6-23

Overspeed pressure circuit on the undercarriage

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Fig. 6-24

Overspeed pressure circuit on the uppercarriage

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Fig. 6-25

Hydraulic lines on the uppercarriage

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Fig. 6-26

Hydraulic lines on the attachment

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Fig. 6-27

Hydraulic lines on the uppercarriage

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Fig. 6-28

Hydraulic lines on the boom

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Fig. 6-29

Hydraulic lines on the uppercarriage

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Fig. 6-30

Hydraulic lines on the boom

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Fig. 6-31

Hydraulic lines on the uppercarriage

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Fig. 6-32

Hydraulic lines on the attachment

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Fig. 6-33

Hydraulic lines on the bucket

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Fig. 6-34

Hydraulic lines on the attachment

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Fig. 6-35

Hydraulic lines on the boom

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Fig. 6-36

Hydraulic lines on the boom

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Fig. 6-37

Hydraulic tank cleaning

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Fig. 6-38

Solenoid valves on servo unit

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1. Main Screens and Control Buttons

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

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

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

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

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

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

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

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

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

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

Description of the software menus

makes the pump PX return to

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

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

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

P 3 EM E xe c 2

V1 . 03

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

4 5 6 s e c

O N b a r

S a f e t y 0 s e c

P 3 O N 1 p u l s e

2 0 0 s e c

Right Main Screen : L e v e l

P 1 P 3

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

Description of the software menus

MJFCIFSS!

4. Architecture of Menus

Description of the software menus

MJFCIFSS!

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

f t t t r s

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

t e m r r o r s e t i m e p r e s s s t o r y s e r v

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

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

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

P 3 EM E xe c 2

V1 . 03

Config P1/P2

Config P3

Active Errors : A c t i v e

e r r o r s

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

Description of the software menus

MJFCIFSS!

Set Pause Time : S e t P1 P2 P3

P a u s e

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

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

B a c k

P a u s e

2 4 5

Set max Press : S e t

m a x

2 4 0

Description of the software menus

P r e s s

b a r

t i m e

s e c

P X

MJFCIFSS!

Error History : E r r o r

h i s t o r y

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

E r r o r

h i s t o r y

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

E r r o r

P1 P3 P1 P3 P1

NC NCe f ew f ew l ow

h i s t o r y

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

G34 : G r e a s e

l ev

P3

l ow

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

Safety Function : P

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

B a c k

Description of the software menus

s e r v

MJFCIFSS!

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

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

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

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

3 4 mA 1 2 mA

__________________________________________________________________________________

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

P1

s tay

l ow

G2 : P r e s s

P2

s tay

l ow

G3 : No

f eedba ck

P3 l i ne

G4 : No

pres s

dr op

P1

G5 : No

pres s

dr op

P2

G14 : Le v

sensor

P1

NC

G17 : Lev

sensor

P3

NC

G28 : G r e a s e

l ev

P1

f ew

G29 : G r e a s e

l ev

P3

f ew

G33 : G r e a s e

l ev

P1

l ow

G34 : G r e a s e

l ev

P3

l ow

G36 : P i l o t

pres s

l ow

G3 7 : No

f eedba ckB150

1

G3 8 : No

f eedba ckB150

2

Description of the software menus

MJFCIFSS

...a product of

Central lubrication system

LIEBHERR mining excavator R 9200 Revision 07-2019

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Original operating and assembly manual

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Table of contents

Operating manual_Lubrication system_R9200_07-2019_EN.docx

1.

2.

3.

4.

Technical data ................................................................................................................................................................................ 3 Lubricants ....................................................................................................................................................................................... 3 Applicable documents..................................................................................................................................................................... 3 General safety instructions ............................................................................................................................................................. 4 4.1 Safety instructions ..................................................................................................................................................................... 4 4.2 Qualification and training of staff ............................................................................................................................................... 4 4.3 Hazards in case of non-observance of the safety instructions .................................................................................................. 5 4.4 Obligations of the operator / user .............................................................................................................................................. 5 4.5 Safety instructions for maintenance, inspection and assembly ................................................................................................. 5 4.6 Unauthorized modification and production of spare parts ......................................................................................................... 5 4.7 Inadmissible modes of operation ............................................................................................................................................... 6 4.8 Emergency stopping of the centralized lubrication system ........................................................................................................ 6 4.9 Electrostatic discharge............................................................................................................................................................... 6 4.10 General hazard warning – residual risk ..................................................................................................................................... 6 5. Intended use ................................................................................................................................................................................... 7 6. Scope of warranty ........................................................................................................................................................................... 7 7. Transport and storage .................................................................................................................................................................... 7 8. Assembly instructions .....................................................................................................................................................................8 8.1 General ...................................................................................................................................................................................... 8 8.2 Line assembly ............................................................................................................................................................................ 8 8.3 Power connection ...................................................................................................................................................................... 8 9. Start up ........................................................................................................................................................................................... 9 9.1 Filling with lubricant ................................................................................................................................................................... 9 9.2 Filling of the container through service-plate ............................................................................................................................. 9 9.3 Ventilation of the lubrication system .......................................................................................................................................... 9 9.4 Control of direction of rotation of the GIGA PLUS pump ........................................................................................................... 9 10. Functional description ................................................................................................................................................................... 10 10.1 General description of the lubrication system .......................................................................................................................... 10 10.1.1 Systems .......................................................................................................................................................................... 10 10.1.2 Lubrication points backhoe attachment .......................................................................................................................... 10 10.1.3 Lubrication points face shovel attachment ...................................................................................................................... 11 10.1.4 Characteristics of lubrication points ................................................................................................................................ 12 10.2 Description System P1 ............................................................................................................................................................ 13 10.2.1 Configuration single line system ..................................................................................................................................... 13 10.2.2 Lubrication cycle with a cold temperature grease drum configuration ............................................................................ 15 10.2.3 Pump HFP-3UCS ............................................................................................................................................................ 16 10.2.4 Single line injector IV5S .................................................................................................................................................. 17 10.2.5 Single line injector BL-1 .................................................................................................................................................. 18 10.2.6 Progressive distributor SX-5 ........................................................................................................................................... 18 10.3 Description system P3 ............................................................................................................................................................. 19 10.3.1 Configuration progressive system ................................................................................................................................... 19 10.3.2 Lubrication cycle ............................................................................................................................................................. 20 10.3.3 Pump GIGA PLUS .......................................................................................................................................................... 21 10.3.4 Progressive distributor SX-5 ........................................................................................................................................... 22 11. Operation ...................................................................................................................................................................................... 23 11.1 Control panel “Grease control“ ................................................................................................................................................ 23 12. Maintenance ................................................................................................................................................................................. 24 12.1 General maintenance .............................................................................................................................................................. 24 12.2 Lubricant change ..................................................................................................................................................................... 24 12.3 Grease filter ............................................................................................................................................................................. 25 12.4 Filling filter................................................................................................................................................................................ 25 13. Shutdown ...................................................................................................................................................................................... 25 14. Disposal ........................................................................................................................................................................................ 25 15. Troubleshooting ............................................................................................................................................................................ 26 16. Details of the manufacturer........................................................................................................................................................... 27

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The central lubrication system is subsequently called a device.

1.

Technical data

General: Lubricant: ......................................................................................................................... only lubricant acc. to LIEBHERR specifications Standard operating temperature: ................................................................................................................................ -20°C up to +55°C Cold options: ..................................................................................................................................................................... -20°C to -50°C Sound pressure level: ...............................................................................................................................................................<70 dB(A) System P1: Lubrication uppercarriage + attachment: ....................................................................................................................... single line system Uppercarriage + rotating track lubrication: ................................................................. single line system with one progressive distributor Oil cleanness acc. to ISO 4406: .................................................................................................................................................. 17/15/12 Drive oil pressure: .................................................................................................................................................................. 26 to 32 bar System P3: Swing ring teeth lubrication +swing box centering lubrication: ................................................................................... progressive system Drive voltage: ............................................................................................................................................................................... 24V DC Please refer to the operating manual and descriptions of the single components for further technical data. These are listed in chapter 3 “Applicable documents”.

2.

Lubricants

Caution!

3.

Only lubricants which are approved by LIEBHERR may be used. Please pay attention to the approval of lubricants by LIEBHERR!

Applicable documents

This technical documentation of single components of this central lubrication system can be found in separate documents: Component Central lubrication pump GIGA PLUS (progressive) Progressive distributor SX-5 Single line injector IV5S (single line)

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Single line injector BL1 (single line) Hydraulic barrel pump HFP-3UCS (single line) Level switch for hydraulic barrel pump HFP-3UCS Level switch for central lubrication pump GIGA PLUS Pressure switch for hydraulic barrel pump HFP-3UCS Line filter for grease filling

Designation of instruction BAL_GIGA_PLUS_LIEBHERR_0618EN Progressive_distributor_SX5_LIEBHERR_1117EN BAL_4125_IV5S_0719EN REP_4125_IV5S_0719EN BAL_4125_BL1_0118EN REP_4125_BL1_1217EN BAL2395_HFP3UCS_Hydraulic_barrel_pump_Liebherr_0719EN ba_eng_mic_80_I_BK1 ba_eng_pico+xxxui 10107044_2_EK107_Wenglor_en FFAP292 DF-DFF-DFFXEN7501-E7-08-17

Furthermore, all operating instructions and specifications of the mining excavator LIEBHERR R 9200 have to be observed.

This is applicable for documents of LIEBHERR as well as the documentation of further suppliers of single components of the LIEBHERR mining excavator R 9200.

Caution!

Please observe these documents for all work with and at the device!

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4.

General safety instructions

Prior to assembly and commissioning of the device at the machine, everybody who is in charge of the assembly, start-up, maintenance and operation of the device must read these instructions carefully. Furthermore, this manual must always be available at the site of operation!

Basic instructions for setup, operation and maintenance can be found below.

4.1 Safety instructions Please observe the safety instructions within this key chapter as well as the special safety instructions that are included in other parts of this documentation.

Warning of electrical voltage.

Safety instructions, which might cause hazards to persons in case of non-observance, are marked with the general danger symbol.

This symbol warns of hot surfaces.

Warning of suspended loads.

Warning of material damage due to electrostatic discharge! Marks potential risks which may result in material damage, if not avoided.

Caution!

This heading is used if improper or general non-observance of the operating and assembly manual, instructions, prescribed workflows and similar might damage the device.

Notice!

This term is used to point out particular details.

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Instructions and notes directly attached to the device have to be strictly observed and kept in readable condition!

4.2

Qualification and training of staff The staff in charge of operation, maintenance, inspection and assembly have to be qualified accordingly.

Responsibilities for and supervision of staff must be clearly defined by the operator. In case that the staff does not have the necessary knowledge it has to be instructed and trained accordingly. The operator is obliged to ensure that the staff fully understands the contents of this user information.

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4.3

Hazards in case of non-observance of the safety instructions Results of non-observance of the safety instructions can be hazards to persons, for the environment and the device. Non-observance of the safety instructions may result in the loss of any liability claims. The non-observance could more specifically result in the following hazards (for example): Failure of important device functions.

Failure of prescribed methods for maintenance and repair.

Danger to persons by electrical, mechanical and chemical effects.

Danger to the environment by leakage of hazardous substances.

4.4

Obligations of the operator / user If movable, rotating, hot or cold parts of the device bear risks, the customer must protect these parts against contact. This protection must not be removed.

Any leakages of hazardous substances must be drained in a way that no risks for persons or the environment arise. For this, the data sheets or safety data sheets of the respective manufacturer have to be observed.

Keep to all legal provisions.

Hazards due to electricity are to be excluded.

Examination of pipes and hoses regarding safe provision, use, proper assembly and function has to be carried out according to regionally applicable directives. Inspection intervals may not be exceeded.

Defective pipes or hoses must be replaced immediately and professionally.

Hydraulic hoses and polyamide pipes are subject to a natural aging-process and thus have to be exchanged in regular intervals according to the manufacturer’s specifications.

A safety data sheet of the currently used lubricant must be provided at the device.

4.5

Safety instructions for maintenance, inspection and assembly All maintenance, inspection and assembly work may only be carried out by qualified personnel, which has thoroughly read the user information and is therefore sufficiently informed.

Any work at the device may generally only be carried out at a complete standstill and in a pressureless as well as disconnected state. Furthermore, appropriate personal protective equipment (among others goggles) is necessary.

The shutdown procedure of the device as described in the manual must be strictly followed

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Secure the device against intentional or unintentional recommissioning during maintenance or repair. All safety and protection arrangements have to be reinserted immediately after completing the work.

Environmentally hazardous media must be disposed of professionally and according to the relevant legal provisions.

Polluted and contaminated surfaces have to be cleaned before maintenance. Please wear protective equipment.

Refer to the lubricant manufacturers’ safety data sheets and the data sheets provided by the manufacturers of auxiliaries and working materials respectively.

Check the surface temperature of the device because a possible heat transfer bears the risk of burns. Wear heat resistant protective gloves!

Open flame and fire are strictly forbidden during maintenance, inspection and repair due to fire hazard.

4.6

Unauthorized modification and production of spare parts Modifications, repairs and alterations of the device can only be accepted as agreed with the manufacturer. Original spare parts and authorized accessories from the manufacturer improve safety. The use of other parts can result in the loss of any liabilities for the resulting consequences. BEKA does not assume liability for parts that are retrofitted by the operator.

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4.7 Inadmissible modes of operation Operational safety of the device is only guaranteed when it is appropriately applied as indicated in the operating and assembly manual.

Never exceed or fall below the limit values, as stated in the technical data.

Use is expressly forbidden: in a potentially explosive atmosphere. 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).

4.8 Emergency stopping of the centralized lubrication system In case of an emergency stop the centralized lubrication system by: switching off the LIEBHERR mining excavator R 9200, into which the centralized lubrication system or its components have been integrated. separating the supply of power 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 LIEBHERR mining excavator R 9200.

4.9

Electrostatic discharge Avoid electrostatic discharge! There are electronic components integrated into the devices which might be destroyed by electrostatic discharge. Observe the safety precautions against electrostatic discharge according to DIN EN 613405-1/-3. Ensure that the environment (persons, workplace and packing) is well grounded when handling these devices.

Operating manual_Lubrication system_R9200_07-2019_EN.docx

4.10 General hazard warning – residual risk All components are designed according to valid regulations of the construction of technical systems in regards to operational safety and accident prevention. Independently from this the use can lead to hazards for the user or third parties as well as for other technical facilities. Therefore, the device may only fulfill its intended use in a technically acceptable and faultless condition. This has to happen in adherence to the according safety regulations and under observance of the operating manual. Inspect the device and its attachment parts regularly and check them for possible damage or leakages. Liquids could escape under high pressure from pressurized components which become leaky.

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5.

Intended use

Caution!

The device is only approved for the use in the LIEBHERR mining excavator R 9200.

The device may only be operated when it is built into this machine and is operated together with it.

The device may only be used for lubricating bearing and friction points of the LIEBHERR mining excavator R 9200.

Only lubricants which comply with the machine manufacturer’s specifications may be conveyed.

The device may only be used according to the technical data (see chapter 1 „technical data”). Never exceed or fall below the mentioned values. Never operate the device without lubricant.

Unauthorized alterations of the device are prohibited. BEKA is not liable for damage of machine or persons that results thereof.

Use according to the regulations means also: paying attention to all chapters and instructions in the operating and assembly manual. carrying out all maintenance work. observing all relevant instructions for work safety, accident prevention and environmental protection during all life cycles of the device. having the necessary professional training and authorization of your company to operate the device and to carry out the necessary work on the device.

Caution!

6.

Another use or a use beyond this is deemed improper.

Scope of warranty

Warranties regarding operational safety, reliability and performance will only be granted by the manufacturer if the device is used according to the regulations and under the following conditions: Assembly, connection and maintenance are carried out by authorized professional staff.

The device is used according to the operating manual.

Never exceed or fall below the limit value indicated in the technical data.

Modifications and repairs at the device may only be carried out by BEKA.

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Caution!

7.

Guarantee and warranty for any damage at the device caused by improper lubricant (e.g. wear of piston, piston jamming, blockades, brittled sealings etc.) will expire.

BEKA will generally not assume guaranty claims for any damage caused by lubricants, although those have been laboratory tested and released by BEKA, because such damage (e.g. by over-stored or incorrectly stored lubricants, batch fluctuations, etc.) cannot be verified or reconstructed later.

Transport and storage

Use suitable lifting devices for transport.

Do not throw the device or impose it to shocks.

Secure the device against toppling down or slipping during transport.

The device may only be transported completely empty.

Observe all valid safety and accident prevention regulations for the transport. Wear suitable protective equipment if necessary. Keep adequate distance to suspended loads. The transport help or the elevating device must have the adequate carrying capacity.

When storing the device make sure that the storage area is cool and dry in order to avoid corrosion of the individual parts of the device.

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8.

Assembly instructions

Check the device for possible transport damage and for completeness prior to assembly. Installed equipment for transportation safety has to be removed.

Comply with the following conditions for assembly of the device in order to obtain a properly built together machine of all parts without compromising safety or health of persons: Assemble the device in balance on the site of installation in order to ensure safe operation. Observe the information on the fastening holes given in the dimensional drawing. When the set-up location is selected the device should be protected against ambient impact and mechanical influences if possible. Full access has to be ensured. The assembly of the single components may only be implemented at the positions specified by LIEBHERR. The type of fastening must also be approved of by LIEBHERR. All components have to be cleaned before assembly in order to prevent soiling in the system.

Special measures concerning noise prevention or oscillation reduction do not have to be taken.

Grease drum „P3“

Grease drum „P1“

Fig. 1: Mounting position of the pumps for the lubrication systems „P1“ and „P3“.

Operating manual_Lubrication system_R9200_07-2019_EN.docx

8.1 General All used components must have the following characteristics: Authorization for the maximum operating pressure.

Suitable for the lubricant and quantity of lubricant which is to be delivered.

Designed for the operating temperature and the ambient conditions at the site of use.

8.2

Line assembly Professional layout!

When using pipes, observe that they are clean, seamless and of precision steel!

Assemble the hoses professionally and torsion-free!

Pay attention to pressure tightness of fittings!

If no pre-filled hose lines are used, the main line has to be preferably mounted rising to the lubrication point.

8.3

Power connection Power supply must be done by a professional electrician!

Electrical device components must be wired professionally!

Compare voltage details with the existing mains voltage!

Equipotential bonding must be done professionally by the operator via a corresponding ground connection!

Wire the device according to the electrical connection diagram in the applicable documentation!

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9.

Start up

Prior to putting the device into operation, it has to be checked that all safety devices are completely available and functional. All connections have to be correctly linked and professionally assembled.

9.1

Filling with lubricant

Caution!

9.2

The lubricant filling only takes place via the maintenance flap of the LIEBHERR mining excavator R 9200. The separate operating instruction of LIEBHERR has to be observed for this! As soon as the service station displays that the pump reservoirs are full, the filling operation has to be ended immediately. Otherwise, grease will leak out from the grease drums.

Filling of the container through service-plate Remove dust protective cap at the filling coupling and the dust protective cap at the filling nipple.

Couple the filling hose for P1 resp. P3 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 (P1) or the reservoir (P3). The solenoid valve for overfill protection will be closed.

When the filling pump is switched off, disconnect the filling coupling and reinstall the dust protective caps.

Lines are pressurized. Be careful when decoupling!

Collect leaking lubricant in a suitable reservoir and dispose it professionally!

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.

Observe the machine manufacturer’s lubricant details! Only use lubricants according to machine manufacturer’s specifications!

Observe the safety data sheet of the lubricant manufacturer!

Observe the operating manual and specifications of the mining excavator LIEBHERR R 9200.

Caution!

The entire central lubrication system has to be emptied, in case that a lubricant, which does not correspond to the LIEBHERR specifications, has been filled in by accident. Afterwards a lubricant according to the specifications has to be filled in and the entire system has to be ventilated.

9.3 Ventilation of the lubrication system Ventilation can be achieved with a first filling of all hoses/pipes/lines prior to installation

Operating manual_Lubrication system_R9200_07-2019_EN.docx

9.4

Control of direction of rotation of the GIGA PLUS pump Compare the direction of rotation of the agitator blade with the directional arrow on the adhesive label of the reservoir!

If the direction of rotation is wrong, check the connection to the terminal box and change it, as necessary!

Caution!

Longer operation with the wrong direction of rotation will cause motor and pump damage!

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10. Functional description 10.1 General description of the lubrication system 10.1.1 Systems The lubrication system of the LIEBHERR mining excavator R 9200, which provides lubricant to the lubrication points, is supplied by two independent centralized lubrication systems: System P1 is used for to lubricate Lubrication uppercarriage + attachment and for rotating track lubrication.

System P3 is used for swing ring teeth lubrication +swing box centering lubrication.

10.1.2 Lubrication points backhoe attachment

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Fig. 2: Position of the lubrication points backhoe attachment

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10.1.3 Lubrication points face shovel attachment

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Fig. 3: Position of the lubrication points shovel attachment

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10.1.4 Characteristics of lubrication points

Fig. 4: lubrication points 1

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Fig. 5: lubrication points 2

Fig. 6: lubrication points 3 All necessary information regarding the lubricating points and quantities are available in chapter 21 of the LIEBHERR Service Manual

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10.2 Description System P1 The central lubrication pump HFP-3UCS supplies lubricant to the connected single line injectors IV5S and BL-1. These either provide the lubricant directly to the lubrication point (bearing) or to a connected progressive distributor SX-5.

10.2.1 Configuration single line system

Attachment:

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Uppercarriage:

———— ————

Fig. 7: Lubrication scheme backhoe attachment Page 13

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Attachment:

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Uppercarriage:

———— ————

Fig. 8: Lubrication scheme shovel attachment

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Operating manual_Lubrication system_R9200_07-2019_EN.docx

10.2.2 Lubrication cycle with a cold temperature grease drum configuration When the pause time has expired, the pump HFP-3UCS starts operating and supplies the lubricant via the main line to the single line injectors IV5S and BL-1.

After all single line injectors IV5S and BL-1 have operated, the pressure rises in the main line until the preset pressure is reached at the pump (between 180 - 220 bar according the control unit setup), the control unit receives a signal from the pressure switch B69 and stops the pump, but does not release the pressure (dump valve remains closed with Y79). The control unit will monitor the grease pressure during 15 seconds and within this time. If the grease pressure drops by more than 40 bar, the pump will re-charge the grease line to the preset pressure and the monitoring time will start again.

If the pressure drop stays below 40 bar during the 15 seconds monitoring time, we assume that all injectors have fully worked, the control unit switches the Y79 solenoid valve. The pressure will immediately be released through the hydraulic dump valve.

When the pressure has fallen below 80 bar, the pistons in the single line injectors IV5S and BL-1 return to their initial position via spring force and recharge the adjustable amount of lubricant by this action. The pause time can start and the system is now ready for another lubrication cycle.

When the pressure switch B69 does not determine the entire pressure within a preset time, the control panel “Grease control” sends an alarm signal.

The indicator pins in the single line injectors IV5S and BL-1 move up and down once per lubrication cycle. This signals that the lubricant was delivered.

Fig. 9: Generic lubrication cycle P1 with Hold Time function (Y114 not installed on R9200) The pause time is preset to 10 minutes and can be changed via the control panel “Grease control”. The control panel “Grease control” includes the timer function with a monitoring and alarm function.

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10.2.3 Pump HFP-3UCS 1 Level monitoring (mechanical) 2 Grease filter 3 Pump 4 Terminal box 5 Lubrication filter (filling) 6 Solenoid valve overfill protection 7 Grease reservoir 213 liter 8 Level sensor minimum 9 Solenoid valve Y79 10 Solenoid valve Y34_1 (pump control) 11 Pressure switch P69 12 Overfill protection 13 Hydraulic relief valve/dump valve 14 Level sensor overfill protection 3 2 1

4 7

8

6 5

Operating manual_Lubrication system_R9200_07-2019_EN.docx

9 10 14 13

Fig. 10: Pump HFP-3UCS in front

11 12 3 3 Fig. 11: Pump HFP-3UCS above

Delivery volume grease at 20°C per double stroke: ....................................................................................................................... 26 cm³ Operating pressure (hydraulic): .............................................................................................................................................. 25 to 55 bar Control voltage: ........................................................................................................................................................................... 24V DC Max. oil flow rate: .................................................................................................................................................................. 312 cm³/min Please refer to the operating manual „BAL2395_HFP3UCS_Hydraulic_barrel_pump_Liebherr_0719EN“ for further information about the technical data and operating principles.

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10.2.4 Single line injector IV5S 1 Protective cap 2 Single-line injector 3 Manifold 1

2

3

Fig. 12: Single line injector IV5S Pressure connection: ......................................................................................................................................................................... G1/4 Connection of manifold: ........................................................................................................................................................ G1/4 or G1/2 Operating pressure:............................................................................................................................................................ 130 to 250 bar Relief pressure: ........................................................................................................................................................................ 0 to 90 bar Delivery rate: ............................................................................................................................................. adjustable from 1,0 to 5,0 cm³

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Please refer to the operating manual „BAL_4125_IV5S_0719EN“ and “REP_4125_IV5S_0719EN“ for further information about the technical data and operating principles.

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10.2.5 Single line injector BL-1 1 Protective cap 2 Single-line injector 3 Manifold 1

2

3

Fig. 13: Single line injector BL-1 Pressure connection: ............................................................................................................................................................ 1/8-27 NPTF Connection of manifold: ........................................................................................................................................................ 3/8-27 NPTF Operating pressure: ............................................................................................................................................................ 140 to 240 bar Relief pressure: ........................................................................................................................................................................ 0 to 50 bar Delivery rate: ............................................................................................................................................. adjustable from 0,2 to 1,2 cm³

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Please refer to the operating manual „BAL_4125_BL1_0118EN“ and “REP_4125_BL1_1217EN“ for further information about the technical data and operating principles.

10.2.6 Progressive distributor SX-5 See chapter 10.3.4

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10.3 Description system P3 The central lubrication pump GIGA PLUS supplies lubricant to each lubrication point via the connected progressive distributors SX-5.

10.3.1 Configuration progressive system

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Fig. 14: Scheme toothed ring lubrication

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10.3.2 Lubrication cycle When the pause time has expired, the pump GIGA PLUS starts operating and delivers the lubricant via the main line to the progressive distributor SX-5. This is operated by the lubricant pressure and supplies lubricant to all connected lubrication points in each distributor cycle. A proximity switch B51, which is attached to the progressive distributor SX-5, monitors the distributor cycles. The control unit stops the pump after having received two switching impulses from the proximity switch B51.

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

When the proximity switch B51 does not determine the required two distributor cycles within a required time, the control panel “Grease control” sends an alarm signal.

Fig. 15: Generic lubrication cycle P3 (Y93 for hydraulic pump, M21 for electric pump)

Operating manual_Lubrication system_R9200_07-2019_EN.docx

The pause time is preset to 8 minutes and can be changed via the control panel “Grease control”. The control panel “Grease control” includes the timer function with a monitoring and alarm function.

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10.3.3 Pump GIGA PLUS 1 Reservoir 24 liter 2 Level switch min.

3 Level switch max.(overfill protection) 4 Pressure limiting valve 5 Connecting plug motor 6 Pump housing with integrated motor

3

2

1

4

6

5

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Fig. 16: GIGA PLUS pump Operating pressure:.............................................................................................................................................................. max. 300 bar Reservoir volume / effective volume: ...................................................................................................................................... 24 / 20 liter Delivery rate per pump element: ................................................................................................................................................. 250 mm³ Numbers of pump elements: ................................................................................................................................................................... 2 Operating voltage: ........................................................................................................................................................................ 24V DC Please refer to the operating manual „BAL_GIGA_PLUS_LIEBHERR_0618EN“ for further information about the technical data and operating principles.

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10.3.4 Progressive distributor SX-5 End element Middle element

Metering code no.

Initial element

Inlet

Outlet

Fig.17: Progressive distributor SX-5 Operating pressure inlet: ...................................................................................................................................................... max. 300 bar Amount of circulations: ..................................................................................................................................... max. 180 circulations/min Outlet thread:..................................................................................................................................................................................... G1/4 Inlet thread: ....................................................................................................................................................................................... G3/8 Operating voltage proximity switch: ...................................................................................................................................... 10 – 60V DC

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Please refer to the operating manual „Progressive_distributor_SX5_LIEBHERR_1117EN„ for further information about the technical data and operating principles.

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11. Operation 11.1 Control panel “Grease control“ Instructions on how to operate the control panel can be found in the instructions for the LIEBHERR mining excavator R 9200.

Set-up of the control panel on the dashboard.

Fig.18: Control panel Malfunctions of the central lubrication system, which are displayed on the control panel, have to be fixed as soon as possible. When the pumps are in operation, the power supply must not be interrupted.

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Caution!

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12. Maintenance Disconnect the device from the power supply before maintenance or repair.

Maintenance and repair may only be carried out at complete standstill and under pressureless condition. When the system is under pressure, lubricant may spurt out.

Grease: The system has to be entirely relieved from pressure by carefully opening a fitting of the grease line or by unscrewing both ventilation screws at the grease filter of the HFP3-UCS until the pressure is built up. For further information see the manuals of the central lubrication pump GIGA PLUS and the hydraulic barrel pump HFP-3UCS. Hydraulic oil: Relieve the hydraulic oil system from pressure as indicated in the operating manual of the mining excavator LIEBHERR R 9200.

Soiled or contaminated surfaces have to be cleaned before maintenance, wear protective equipment to this purpose, if necessary! Protect the device against recommissioning during maintenance/repairs!

Check the surface temperature of the device, as there is the risk of burns by radiant heat. Wear heat-resistant gloves and safety goggles!

Further information and technical details regarding the components can be found in the enclosed operating manuals of the components.

12.1 General maintenance Retighten all fittings 6 weeks after start up!

Check all components for leakages and damage at least once per week!

Only use non-flammable cleaning agents suitable for the purpose.

Do not use any aggressive cleaning agents.

Do not use steam jet or high pressure cleaners. Otherwise, components may be damaged.

If leakages are not repaired, lubricant might leak out under high pressure. Remove possible puddles of lubricant immediately. There is a risk of fire and explosion when using inflammable cleaning agents.

12.2 Lubricant change

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Caution!

Observe utmost cleanliness when refilling lubricant!

Check the level regularly and refill clean lubricant as necessary, see chapter start up.

Lubricant change has to be done according to the specifications of the lubricant manufacturer. Environmental influences like increased temperature or pollution may make it necessary to shorten these intervals!

Please make sure to only use lubricants that are suitable for the device as well as the lubricated machine and that they comply with the requirements of the particular operating conditions.

In case of different lubricant manufacturers, ensure that the lubricant quality corresponds to the quality of the previously used one! As a precautionary measure, drain the lubricant reservoir professionally and clean it!

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12.3 Grease filter The filter element of the grease filter has to be renewed in regular intervals, however, at the latest after 1000 operating hours.

Caution!

Perform assembly and disassembly only in a pressureless state of the device!

12.4 Filling filter The filter element of the filling filter has to be renewed in regular intervals, however, at the latest after one year.

Caution!

Perform assembly and disassembly only in a pressureless state of the device! Also observe the operating instructions “DF-DFF-DFFXEN7501-E7-08-17”of the filter manufacturer.

13. Shutdown Relieve the device from pressure!

Switch off power supply!

Have the device disconnected from power supply by a qualified electrician!

Remove all pipes and hoses from the device and loosen all fastenings for disassembly!

14. Disposal

Notice!

Observe the disposal instructions of the lubricant manufacturer when lubricant is changed!

Lubricants or cloths contaminated with lubricant or similar must be collected in specially marked reservoirs and disposed of accordingly.

Disposal of the central lubrication pump must be done properly and professionally and according to the national and international laws and regulations.

Operating manual_Lubrication system_R9200_07-2019_EN.docx

Moreover, BEKA devices could contain batteries. Professionally and properly disposed batteries will be recycled. They contain important raw materials.

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15. Troubleshooting In the following, only malfunctions of the complete system are described. Detailed instructions for troubleshooting can be found in the single documentations of the components.

Malfunction

Possible cause

Possible remedy

Malfunction of the pump

See troubleshooting of the respective pump

Leakage in the main line

Check main lines and eliminate leakages

Defective fitting

Check fittings and eliminate leakages

Entrapped air in the main line

Ventilate line

Single line injectors leaky

Replace affected single line injector

No pressure relief or

Pressure control device defective

Replace pressure control device

too slow pressure

Pressure relief valve in valve block

Replace pressure relief valve

relief in the main

defective

No pressure build-up in the system

line (only system P1)

Pump does not operate

Lubricant with incorrect specification

Fill in lubricant according to the specifications for

used or too low temperatures

the corresponding temperatures

No application of voltage of

Check electrical lines and superordinate control

superordinate control unit

units, replace them if necessary

Motor protection switch has triggered

Check electrical lines, reset motor protection switch

Pump operates, but does not supply lubricant

Strong wear of the pump

Renew pump

Air entrapped in lubricant

Ventilate pump

Pressure safety valve does not close

Replace pressure safety valve

Pump element defective

Replace pump element

Pressure relief valve in valve block

Replace pressure relief valve

Operating manual_Lubrication system_R9200_07-2019_EN.docx

defective Blockade of a lubrication point

Repair lubrication point

(progressive system) Error codes, which are displayed at the control panel “Grease control”, can be seen in the instructions for the LIEBHERR mining excavator R 9200.

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16. Details of the manufacturer

BEKA BAIER + KÖPPEL GmbH + Co. KG Beethovenstraße 14 91257 PEGNITZ / Bayern Germany Tel. FAX

+49 9241 729-0 +49 9241 729-50

POSTFACH 1320 91253 PEGNITZ / Bayern Germany

Operating manual_Lubrication system_R9200_07-2019_EN.docx

http://www.beka-lube.de E-Mail: beka@beka-lube.de beka@beka-max.de

Our range of supply: Gear pumps Multi-line oil pumps Multi-line grease pumps Single-line central lubrication systems Dual line central lubrication systems Oil circulation central lubrication systems Oil-air and spray lubrication Wheel flange central lubrication systems Rolling mill central lubrication systems Commercial vehicle lubrication Progressive distributors Control and monitoring units Subject to alterations!

We do not accept liability for errors, technical mistakes and misprints!

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Conversion factors Pressure:

Length:

Volume:

Torque:

Weight:

Temperature:

MJFCIFSS