Liebherr R 9200 410 Hydraulic Excavator Operating Manual SN 40001 - PDF DOWNLOAD

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Operating manual Hydraulic excavator R 9200 from serial number 40001

Document identification ORIGINAL MANUAL Order number:

11695477

Edition:

12 / 2020

Valid for:

R 9200 from serial number 40001

Author:

LEC - Technical documentation department

Product identification Manufacturer:

Liebherr-Mining Equipment Colmar SAS

Type:

R 9200

Type no.:

410

Conformity: 0

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Address

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49 rue Frederic Hartmann

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CS 50038, F-68025 Colmar Cedex

copyright© Liebherr-Mining Equipment Colmar SAS 2020

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Operating manual

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

This will also be of use to you when ordering replacement parts.

Vehicle ident. number:

WLHZ . . . . . . . .

Construction year:

First start-up date:

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copyright© Liebherr-Mining Equipment Colmar SAS 2020

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R 9200 / 11695477

Operating manual

Preface

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

They contain: -

the technical data.

-

the safety requirements.

-

the operating instructions.

-

the maintenance instructions.

The operating instructions are to be read and used carefully by all persons who carry out work with or on the machine before putting the machine into service for the first time and later, at regular intervals.

Work with or on the machine includes, for example:

-

Operation including setting up and equipping, rectifying malfunctions during the course of work, resolving production dropouts, care, disposal of operating and process materials.

-

Maintenance, including maintenance, inspection and repair work.

-

Transportation or loading the machine.

The operating instructions allow the machine operator to familiarize himself with the machine more easily and prevent malfunctions occurring due to improper operation.

The observance of the operating and maintenance instructions by maintenance personnel: -

increases reliability in use.

-

extends the service life of your machine.

-

reduces repair costs and downtime.

The operating instructions belong with the machine for the entire lifetime of the machine. Place a copy in an easily reached position on the cab storage shelf. This copy must be replaced immediately if lost, damaged or unreadable.

The operating and maintenance instructions must be completed by information on current national regulations for accident prevention and protection. In addition to the operating instructions and legally binding regulations on accident prevention which apply in the user country and at point of use, authorized specialist rules for safe and correct working procedures are also to be observed.

These operating and maintenance instructions contain all the information required for operating and maintaining your machine.

-

Some illustrations in these operating instructions may depict details and working devices which differ to your machine.

-

In some illustrations, protective devices and covers have been removed in the interests of better presentation.

-

Improvements, which are always being incorporated into our machines, may result in changes to your machine which are not yet indicated in these operating instructions.

However, should you require any further explanations or information, LIEBHERR's

copyright© Liebherr-Mining Equipment Colmar SAS 2020

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Operating manual

technical documentation, sales school and customer service departments are available for your convenience.

You will appreciate that LIEBHERR warranty claims made on the basis of improper operation, unsatisfactory maintenance, use of unauthorized operating materials or non-adherence to safety regulations cannot be recognized.

LIEBHERR will annul any and all obligations incurred by LIEBHERR and/ or its dealerships, such as guarantee commitments, service contracts etc. without prior notice in the event that replacement parts other than original LIEBHERR parts or parts purchased from LIEBHERR are used for maintenance or repair work.

Modifications, conditions, copyright We reserve the right to make modifications without prior notice in the course of technical developments.

The information and illustrations contained in these operating instructions may neither be copied and distributed, nor used for the purposes of competition. All rights are expressly reserved in accordance with copyright laws.

The warranty and liability conditions of LIEBHERR's general business conditions will not be enlarged upon through the above information.

copyright© Liebherr-Mining Equipment Colmar SAS 2020

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Table of contents 1

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

1.1

1.2 1.3 1.4

2

Safety instructions ......................................................................................................................................... 2-1

2.1 2.2 2.3 2.4 2.5

3

3.2

3.3

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Meaning of the symbols in this manual... ............................................................................................... 2-1 Use in accordance with the regulations ................................................................................................. 2-2 Safety Instructions ................................................................................................................................. 2-2 Servicing the machine safely ............................................................................................................... 2-15 Signs on the machine .......................................................................................................................... 2-22 2.5.1 Introduction ............................................................................................................................. 2-22 2.5.2 Arrangement and explanations of signs ................................................................................. 2-23

Control and operation ................................................................................................................................... 3-1

3.1

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Assembly- overview .............................................................................................................................. 1-1 1.1.1 Machine and construction equipment... .................................................................................... 1-1 1.1.2 Uppercarriage ........................................................................................................................... 1-3 1.1.3 Undercarriage ........................................................................................................................... 1-4 Vibration emission ................................................................................................................................. 1-4 EC Declaration of Conformity ................................................................................................................ 1-6 Technical data ....................................................................................................................................... 1-7 1.4.1 Working technical data ............................................................................................................. 1-7 1.4.2 Technical description ................................................................................................................ 1-7

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Operating and control elements ............................................................................................................. 3-1 3.1.1 Overview of the control cab ...................................................................................................... 3-1 3.1.2 Arrangement of joysticks .......................................................................................................... 3-4 3.1.3 Keyboard .................................................................................................................................. 3-5 3.1.4 Cab control board ................................................................................................................... 3-11 3.1.5 Monitoring display .................................................................................................................. 3-13 3.1.6 Menus and functions of the display ........................................................................................ 3-13 The access and the outfit of the cab .................................................................................................... 3-39 3.2.1 Enter or leave the cab ............................................................................................................ 3-40 3.2.2 Safety lever ............................................................................................................................ 3-47 3.2.3 Operator's seat ....................................................................................................................... 3-48 3.2.4 Auxiliary seat .......................................................................................................................... 3-55 3.2.5 Sunshade ............................................................................................................................... 3-56 3.2.6 Emergency exit. ...................................................................................................................... 3-57 3.2.7 Internal lighting ....................................................................................................................... 3-58 3.2.8 Fire extinguisher ..................................................................................................................... 3-58 3.2.9 Windscreen ............................................................................................................................ 3-60 3.2.10 Field of view ........................................................................................................................... 3-63 3.2.11 Lighting ................................................................................................................................... 3-64 3.2.12 Heating and air-conditioning system ...................................................................................... 3-66 Setting the machine into operation ...................................................................................................... 3-72 3.3.1 Start and stop the machine .................................................................................................... 3-73 3.3.2 Starting aids (optional) ........................................................................................................... 3-81 3.3.3 Warm-up procedure for Diesel engine and hydraulic circuit... ................................................ 3-95 3.3.4 Jump start procedure ............................................................................................................. 3-97 3.3.5 Emergency and safety operations .......................................................................................... 3-98 3.3.6 Travel movements ................................................................................................................ 3-107 Working with the machine .................................................................................................................. 3-110 3.4.1 Uppercarriage swing movements ......................................................................................... 3-117 3.4.2 Working position ................................................................................................................... 3-119 3.4.3 Joystick functions when setting up the machine .................................................................. 3-119 3.4.4 Lowering the work equipment when the engine is not running ............................................ 3-126 General working methods .................................................................................................................. 3-127

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3.6

4

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

4.3

5

3.5.1 Minimum impact working methods for your machine ............................................................ 3-127 3.5.2 Preparatory activities ............................................................................................................ 3-128 3.5.3 Positioning of the machine ................................................................................................... 3-129 3.5.4 Working with the backhoe bucket... ...................................................................................... 3-129 3.5.5 Working with the Shovel bucket ........................................................................................... 3-132 Transport ............................................................................................................................................ 3-135 3.6.1 Travelling procedures for mining machine ............................................................................ 3-135 3.6.2 Excavator lifting and lashing operations ............................................................................... 3-137

Error code charts ................................................................................................................................... 4-2 4.1.1 Heating and air-conditioning system ........................................................................................ 4-2 Faults and remedies .............................................................................................................................. 4-3 4.2.1 Diesel engine and fuel system .................................................................................................. 4-3 4.2.2 Hydraulic system ...................................................................................................................... 4-4 4.2.3 Transmission ............................................................................................................................ 4-4 4.2.4 Electrical system ....................................................................................................................... 4-5 4.2.5 Heating/air-conditioning system ............................................................................................... 4-5 4.2.6 Work equipment ....................................................................................................................... 4-5 Fuses and relays .................................................................................................................................... 4-6 4.3.1 Power electrical box E1003 ...................................................................................................... 4-6 4.3.2 Cab connection box E1005 ...................................................................................................... 4-9

Maintenance ................................................................................................................................................... 5-1 5.1 5.2 5.3

5.4

5.5

5.6

5.7

5.8

Servicing the machine safely ................................................................................................................. 5-1 Maintenance access doors .................................................................................................................... 5-7 5.2.1 Overview of access doors ........................................................................................................ 5-7 Maintenance anchor points .................................................................................................................... 5-9 5.3.1 Approved anchor points ............................................................................................................ 5-9 5.3.2 Use the anchor points ............................................................................................................. 5-12 Lubricants and operating fluids ............................................................................................................ 5-13 5.4.1 General information on changing lubricants and operating fluids ........................................... 5-13 5.4.2 Lubricating chart ..................................................................................................................... 5-14 5.4.3 Lubricant chart ........................................................................................................................ 5-15 5.4.4 Operating material chart ......................................................................................................... 5-17 5.4.5 Service trap ............................................................................................................................ 5-18 Lubricating and operating material specifications ................................................................................ 5-25 5.5.1 Lubricating oil for the Diesel engine ....................................................................................... 5-25 5.5.2 Fuel ......................................................................................................................................... 5-26 5.5.3 Coolant ................................................................................................................................... 5-26 5.5.4 Hydraulic oil specifications for LIEBHERR Mining excavators ............................................... 5-26 5.5.5 Swing and travel gear oils ...................................................................................................... 5-32 5.5.6 Splitterbox oil .......................................................................................................................... 5-34 5.5.7 Lubricating grease .................................................................................................................. 5-34 5.5.8 Other lubricants ...................................................................................................................... 5-36 Condition monitoring with oil analysis .................................................................................................. 5-37 5.6.1 General information ................................................................................................................ 5-37 5.6.2 Oil sampling ............................................................................................................................ 5-37 5.6.3 Sample processing ................................................................................................................. 5-43 Diesel engine ....................................................................................................................................... 5-47 5.7.1 Check the engine oil level. ...................................................................................................... 5-47 5.7.2 Change the engine oil ............................................................................................................. 5-48 5.7.3 Replace the oil filter elements ................................................................................................ 5-50 5.7.4 Mounting screws ..................................................................................................................... 5-51 5.7.5 Elastic bedding ....................................................................................................................... 5-53 5.7.6 Belts ........................................................................................................................................ 5-53 Splitterbox ............................................................................................................................................ 5-53

copyright© Liebherr-Mining Equipment Colmar SAS 2020

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5.9 5.10

5.11

5.12

5.13

5.14

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5.8.1 Splitterbox mounting screws .................................................................................................. 5-53 5.8.2 Elastic bedding ....................................................................................................................... 5-56 5.8.3 Breather filter .......................................................................................................................... 5-57 Coupling ............................................................................................................................................... 5-58 5.9.1 Check the coupling rubber rollers ........................................................................................... 5-58 Cooling system .................................................................................................................................... 5-58 5.10.1 Check and clean the cooling system ...................................................................................... 5-58 5.10.2 Check the coolant level .......................................................................................................... 5-59 5.10.3 Coolant antifreeze and anti-corrosion fluid ............................................................................. 5-60 5.10.4 Change the coolant ................................................................................................................ 5-60 5.10.5 Replace the coolant filters ...................................................................................................... 5-61 Fuel system ......................................................................................................................................... 5-63 5.11.1 Refuel ..................................................................................................................................... 5-63 5.11.2 Drain the fuel tank .................................................................................................................. 5-65 5.11.3 Clean the fuel tank ................................................................................................................. 5-66 5.11.4 Fuel filtering system ............................................................................................................... 5-66 5.11.5 Replace the dust filter for the vent valve ................................................................................ 5-71 Dry air filter .......................................................................................................................................... 5-71 5.12.1 Replace the primary filter element... ....................................................................................... 5-73 5.12.2 Replace the safety element .................................................................................................... 5-74 5.12.3 Clean the precleaner .............................................................................................................. 5-75 5.12.4 Clean the housing of the air filter elements ............................................................................ 5-76 5.12.5 Check the air intake system, hoses, elbow tubes, clamps ..................................................... 5-77 Hydraulic system ................................................................................................................................. 5-78 5.13.1 Preparatory activities .............................................................................................................. 5-78 5.13.2 Check the oil level in the hydraulic tank ................................................................................. 5-79 5.13.3 Release the pressure from the hydraulic system ................................................................... 5-80 5.13.4 Drain and fill the hydraulic tank .............................................................................................. 5-81 5.13.5 Hydraulic oil coolers ............................................................................................................... 5-85 5.13.6 Leak oil filter and return filter .................................................................................................. 5-85 5.13. 7 Servo oil and replenishing filters ............................................................................................ 5-87 5.13.8 High pressure filters in working circuit... ................................................................................. 5-88 5.13.9 Servo oil circuit ....................................................................................................................... 5-91 5.13.10 Remove the pumps intake hoses ........................................................................................... 5-92 5.13.11 Bleed the hydraulic pumps ..................................................................................................... 5-92 5.13.12 Bleed the hydraulic cylinders .................................................................................................. 5-95 5.13.13 Bleed the valve blocks ............................................................................................................ 5-95 5.13.14 Oil cooler protection filters (optional) ...................................................................................... 5-96 5.13.15 Servicing the hydraulic cylinder .............................................................................................. 5-97 5.13.16 Replacement of the hydraulic hoses ...................................................................................... 5-98 5.13.17 Progressive criss-cross tightening procedure ....................................................................... 5-102 Oil changes on components .............................................................................................................. 5-103 5.14.1 General information .............................................................................................................. 5-103 5.14.2 Swing gear-Oil change ...................................................................................................... 5-103 5.14.3 Travel gear and Lifetime travel gear (optional)- Oil change ................................................ 5-105 5.14.4 Swing gears and travel gears flushing ................................................................................. 5-111 5.14.5 Splitterbox- Oil change ....................................................................................................... 5-112 Track components ............................................................................................................................. 5-113 5.15.1 Check the track components mounting ................................................................................ 5-113 5.15.2 Check the track tension ........................................................................................................ 5-119 5.15.3 Increase the track tension .................................................................................................... 5-120 5.15.4 Decrease the track tension ................................................................................................... 5-121 5.15.5 Clean the travel gear ............................................................................................................ 5-122 Electrical system ................................................................................................................................ 5-122 5.16.1 Notes on the electrical system ............................................................................................. 5-122 5.16.2 Batteries switches and ECM connectors .............................................................................. 5-122 5.16.3 Battery care .......................................................................................................................... 5-124 5.16.4 Electrical components location ............................................................................................. 5-126

copyright© Liebherr-Mining Equipment Colmar SAS 2020 R 9200 / 11695477

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Operating manual

5.16.5 Cab pressurization ................................................................................................................ 5-128 5.17 Heating and air-conditioning system .................................................................................................. 5-128 5.17.1 Possible configurations ......................................................................................................... 5-128 5.17 .2 Heating system ..................................................................................................................... 5-129 5.17.3 Air-conditioning system ........................................................................................................ 5-131 5.17.4 Additional maintenance work ................................................................................................ 5-139 5.17.5 Additional cab heater (optional) ............................................................................................ 5-139 5.18 Greasing the machine ........................................................................................................................ 5-139 5.18.1 Lubrication of attachment bearing points .............................................................................. 5-139 5.18.2 Grease the service trap ........................................................................................................ 5-140 5.19 Check mounting bolts for tightness .................................................................................................... 5-141 5.19.1 Counterweight mounting bolts .............................................................................................. 5-142 5.19.2 Mounting bolts of the swing ring ........................................................................................... 5-143 5.19.3 Mounting bolts of the fuel tank .............................................................................................. 5-145 5.19.4 Mounting bolts of the hydraulic tank ..................................................................................... 5-146 5.19.5 Mounting bolts of the engine cooler box ............................................................................... 5-147 5.19.6 Mounting bolts of the oil cooler box ...................................................................................... 5-14 7 5.19.7 Mounting bolts of the pumps box .......................................................................................... 5-148 5.19.8 Mounting bolts of swing gear and swing motor .................................................................... 5-149 5.19.9 Mounting bolts of the cab elevation ...................................................................................... 5-149 5.19.10 Mounting bolts of the cab ..................................................................................................... 5-150 5.19.11 Mounting bolts of the service trap ......................................................................................... 5-151 5.19.12 Mounting bolts of hydraulic pumps ....................................................................................... 5-152 5.19.13 Mounting bolts of side frames ............................................................................................... 5-153 5.20 Drive unit brakes and swing gear brakes ........................................................................................... 5-153 5.21 Starting aids (option) .......................................................................................................................... 5-153 5.21.1 Coolant heater (basic equipment) ........................................................................................ 5-153 5.21.2 Bleed the water system ........................................................................................................ 5-155 5.21.3 Starting fluid system (basic equipment) ................................................................................ 5-156 5.21.4 Circulating heating system (if installed) ................................................................................ 5-157 5.22 General maintenance points .............................................................................................................. 5-158 5.22.1 Replacing working parts ....................................................................................................... 5-158 5.22.2 Welding work on the machine .............................................................................................. 5-158 5.23 Control and maintenance chart .......................................................................................................... 5-159 5.23.1 General information .............................................................................................................. 5-159 5.23.2 How to use the maintenance chart ....................................................................................... 5-160 5.23.3 Daily Maintenance Schedule - R9200 .................................................................................. 5-161 5.23.4 250 Hours Maintenance Schedule - R9200 .......................................................................... 5-167 5.23.5 500 Hours Maintenance Schedule - R9200 .......................................................................... 5-173 5.23.6 1000 Hours Maintenance Schedule - R9200 ........................................................................ 5-180 5.23.7 2000 Hours Maintenance Schedule - R9200 ........................................................................ 5-188

6

Appendix ......................................................................................................................................................... 6-1 6.1

6.2

Visual check of the hydraulic hoses ....................................................................................................... 6-1 6.1.1 Preface ..................................................................................................................................... 6-1 6.1.2 General information .................................................................................................................. 6-2 6.1.3 Components functions .............................................................................................................. 6-4 6.1.4 Recommendations for hose assembly maintenance ................................................................ 6-5 Cleaning procedure for hydraulic circuits ............................................................................................... 6-9 6.2.1 Preface ..................................................................................................................................... 6-9 6.2.2 General information about hydraulic oil contamination ............................................................. 6-9 6.2.3 General cleaning procedure ................................................................................................... 6-11 6.2.4 Location of the hydraulic tank filters ....................................................................................... 6-11 6.2.5 Working pumps circuit ............................................................................................................ 6-12 6.2.6 Swing circuit ........................................................................................................................... 6-16 6.2.7 Cooling pumps circuit ............................................................................................................. 6-20 6.2.8 Travel motors circuit ............................................................................................................... 6-25 6.2.9 Backhoe cylinders lines .......................................................................................................... 6-30

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6.3

6.2.10 Shovel cylinders lines ............................................................................................................. 6-36 6.2.11 Clean the hydraulic tank ......................................................................................................... 6-42 6.2.12 Restart the machine ............................................................................................................... 6-42 6.2.13 Monitor the restarted machine ................................................................................................ 6-44 Centralized lubrication system ............................................................................................................. 6-44

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copyright© Liebherr-Mining Equipment Colmar SAS 2020

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R 9200 / 11695477

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

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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

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

Additional cab heater

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Fig. 3-47

Foot heating zones

Fig. 3-48

Foot heater

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Fig. 3-49

Ignition key S1 on cab control board

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Fig. 3-50

Principal battery switches

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Fig. 3-51

Engine ECM circuit breaker S9_3

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Fig. 3-52

Speed indication on the main menu of the display

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Fig. 3-53

Backhoe (up) and shovel (down) attachments position

Fig. 3-54

Additional tarpaulins, louvers and covers (if installed)

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Fig. 3-55

Circuit breakers of the special preheating batteries

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Fig. 3-56

Voltmeter of special preheating batteries

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Fig. 3-57

Devices for coolant preheating

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Fig. 3-58

Control unit U106 of the coolant heater

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Fig. 3-59

Warning lights of coolant preheating

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Fig. 3-60

Circulating heating system (if installed)

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Fig. 3-61

Control box of the circulating heating system (if installed)

Fig. 3-62

External socket (if installed)

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Fig. 3-63

Warning light H68: external Gen-Set connected

Fig. 3-64

Additional connection for warm air duct (if installed)

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Fig. 3-65

Diagnostic unit system

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Fig. 3-66

Auxiliary start receptacle

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Fig. 3-67

Location of the emergency stop S100_1

Fig. 3-68

Location of the emergency stop S100_2

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Fig. 3-69

Location of the emergency stop S100_3

Fig. 3-70

Location of the emergency stop S100_4

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Fig. 3-71

Location of starter test switches S51_1 and S51_2

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Fig. 3-72

Safety control for the Diesel engine start

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Fig. 3-73

Safety controls for the Diesel engine speed

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Fig. 3-74

Safety control for swing and travel brakes

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Fig. 3-75

Safety controls for hydraulic pumps

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Fig. 3-76

Safety fans control

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Fig. 3-77

Travel straight ahead

Fig. 3-78

Turn on the spot

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Fig. 3-79

Turn with one track chain

Fig. 3-80

Hand levers to operate the travel movements manually

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MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 3-81

Turn the uppercarriage

MJFCIFSS

MJFCIFSS

Fig. 3-82

Working position – machine

MJFCIFSS

Fig. 3-83

Operating the stick cylinder

MJFCIFSS

Fig. 3-84

Operating the boom cylinder

Fig. 3-85

Operating the boom down with pressure

MJFCIFSS

Fig. 3-86

Float position

Fig. 3-87

Operating the bucket cylinder

MJFCIFSS

Fig. 3-88

Rotary switch for control selection

MJFCIFSS

Fig. 3-89

Operating the bottom dump shovel bucket

Fig. 3-90

Flap control with the analog stick

MJFCIFSS

Fig. 3-91

Semi-automatic flap closing

MJFCIFSS

Fig. 3-92

Deactivation of attachment damping system

MJFCIFSS

Fig. 3-93

Lowering the attachment when engine is not running

MJFCIFSS

Fig. 3-94

Working position – machine

Fig. 3-95

Hazard area

MJFCIFSS

Fig. 3-96

Recommended digging

MJFCIFSS

Fig. 3-97

Optimal angle for digging

Fig. 3-98

30° forward to the vertical.

MJFCIFSS

Fig. 3-99

Taking up grab material

Fig. 3-100 45° backward to the vertical

MJFCIFSS

Fig. 3-101 Emptying grab material

MJFCIFSS

Fig. 3-102 Digging

MJFCIFSS

Fig. 3-103 Unloading of the bucket

MJFCIFSS

MJFCIFSS

Fig. 3-104 Hazard area r

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 3-105 Sticker for lifting and lashing operations

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 4-1

LIEBHERR service

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 4-2

Access door of E1003 electrical box

MJFCIFSS

Fig. 4-3

Fuses of power electrical box E1003

MJFCIFSS

Fig. 4-4

Relays of power electrical box E1003

MJFCIFSS

Fig. 4-5

Locations of the electrical plates in E1005

MJFCIFSS

Fig. 4-6

Fuses and relays of cab connection box E1005

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 5-1

Access doors and covering

MJFCIFSS

MJFCIFSS

Fig. 5-2

Horizontal middle bar on handrail (example)

MJFCIFSS

Fig. 5-3

Welded anchor point (example)

MJFCIFSS

Fig. 5-4

Drilled anchor point (example)

MJFCIFSS

MJFCIFSS

Fig. 5-5

R9200 lubricating chart

MJFCIFSS

Tab. 5-1

Lubricating chart key

MJFCIFSS

Tab. 5-2

Lubricant chart

MJFCIFSS

Tab. 5-3

Operating material chart

MJFCIFSS

Fig. 5-6

Service trap

MJFCIFSS

Fig. 5-7

Configurations A and B of centralized lubrication systems

MJFCIFSS

Fig. 5-8

Service trap lever

MJFCIFSS

Fig. 5-9

Lower the service trap

MJFCIFSS

Fig. 5-10

Close the service trap

Fig. 5-11

Locking hook correct position

MJFCIFSS

Fig. 5-12

Warning light H68: trap control lock

Fig. 5-13

Button S122: Disable trap control lock

MJFCIFSS

Fig. 5-14

Grease control box E1043

MJFCIFSS

Fig. 5-15

Grease warning light H109

MJFCIFSS

MJFCIFSS

Fig. 5-16

LIEBHERR oils for hydraulic system

Fig. 5-17

Engine oils for hydraulic system

MJFCIFSS

(ISO VG68)

(ISO VG100) (ISO VG46)

MJFCIFSS

Fig. 5-18

Hydraulic oil for hydraulic system

MJFCIFSS

MJFCIFSS

Fig. 5-19

Oil changes at pre-set intervals

Fig. 5-20

Oil changes at optimized intervals

MJFCIFSS

Fig. 5-21

Swing gear and travel gear oils

MJFCIFSS

Tab. 5-4

Tab. 5-5

Tab. 5-6

MJFCIFSS

Tab. 5-7

Fig. 5-22

Gear oils for use as splitterbox oil

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 5-23

Sampling pump

MJFCIFSS

MJFCIFSS

Fig. 5-24

Sampling valve 1 for splitterbox oil

MJFCIFSS

Fig. 5-25

Oil sampling points 1 for travel gear oil

Fig. 5-26

Sampling valve 1 for hydraulic oil

MJFCIFSS

Fig. 5-27

Sampling valve 1 for Diesel engine oil

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 5-28

Dipstick for indication of engine oil level

MJFCIFSS

Fig. 5-29

Engine oil drain coupling on service trap

MJFCIFSS

Fig. 5-30

Engine oil pan

MJFCIFSS

Fig. 5-31

Oil filler neck of the Diesel engine

MJFCIFSS

Fig. 5-32

Oil filters on Diesel engine

MJFCIFSS

Fig. 5-33

Engine mounting screws

MJFCIFSS

Fig. 5-34

Engine elastic bedding

MJFCIFSS

Fig. 5-35

Splitterbox mounting screws

MJFCIFSS

Fig. 5-36

Splitterbox mounting screws on engine

MJFCIFSS

Fig. 5-37

Elastic bedding

MJFCIFSS

Fig. 5-38

Breather filter on splitterbox

MJFCIFSS

Fig. 5-39

Check the coupling rubber rollers

MJFCIFSS

Fig. 5-40

Expansion tank

MJFCIFSS

MJFCIFSS

Fig. 5-41

Coolant drain

MJFCIFSS

Fig. 5-42

Coolant filters location

Fig. 5-43

Coolant filters

MJFCIFSS

Fig. 5-44

Lockable fuel tank cap

MJFCIFSS

Fig. 5-45

Service trap

MJFCIFSS

Fig. 5-46

Drain valves of fuel tank

MJFCIFSS

Fig. 5-47

Fuel filters assembly

MJFCIFSS

Fig. 5-48

Water separator on the preliminary filter

MJFCIFSS

Fig. 5-49

Fuel shutoff valve

Fig. 5-50

Filter element on preliminary filter

MJFCIFSS

Fig. 5-51

Fuel filters

MJFCIFSS

MJFCIFSS

Fig. 5-52

Dust filter for the vent valve

MJFCIFSS

Fig. 5-53

Air intake system

Fig. 5-54

Vacuum indicator

MJFCIFSS

Fig. 5-55

Primary filter element

MJFCIFSS

Fig. 5-56

Safety element

MJFCIFSS

Fig. 5-57

Precleaner

MJFCIFSS

Fig. 5-58

Housing of air filter elements

MJFCIFSS

Fig. 5-59

Air intake hoses, tubes and elbow tubes

MJFCIFSS

Fig. 5-60

Machine check position for hydraulic oil level check or level adjustment

MJFCIFSS

Fig. 5-61

Oil level in the hydraulic tank

MJFCIFSS

MJFCIFSS

Fig. 5-62

Release the hydraulic pressure

MJFCIFSS

Fig. 5-63

Hydraulic oil change coupling on service trap

MJFCIFSS

Fig. 5-64

Return filter on the hydraulic tank

MJFCIFSS

Fig. 5-65

Bleeding valve of the hydraulic tank

MJFCIFSS

Fig. 5-66

Leak oil filter

MJFCIFSS

Fig. 5-67

Return filter

MJFCIFSS

Fig. 5-68

Location of servo oil and replenishing filters

MJFCIFSS

Fig. 5-69

Servo oil and replenishing filters

MJFCIFSS

Fig. 5-70

High pressure filters on valve bank

MJFCIFSS

Fig. 5-71

High pressure filter

MJFCIFSS

Fig. 5-72

Accumulator on the valve bank

MJFCIFSS

Fig. 5-73

Pumps intake hoses (aspiration)

MJFCIFSS

Fig. 5-74

Bleeding of the working pumps

Fig. 5-75

Bleeding of the swing pump

MJFCIFSS

Fig. 5-76

Bleeding of the cooling pumps

Fig. 5-77

Bleeding of the pump for the air-conditioning system

MJFCIFSS

Fig. 5-78

Bleeding of valve blocks

MJFCIFSS

Fig. 5-79

Oil cooler protection filter

MJFCIFSS

Fig. 5-80

Piston rod mounting

Fig. 5-81

Machine with piston rods retracted

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 5-82

SAE flanges

MJFCIFSS

Tab. 5-8

Tightening torques for SAE flanges

Fig. 5-83

Sealing flange 1 and hydraulic block 2

MJFCIFSS

Fig. 5-84

Criss-cross tightening

MJFCIFSS

Fig. 5-85

Oil change on the swing gear

MJFCIFSS

Fig. 5-86

Expansion tank

MJFCIFSS

MJFCIFSS

Fig. 5-87

Oil change on travel gear

MJFCIFSS

Fig. 5-88

Special expansion tank of the Lifetime interspace

Fig. 5-89

Oil change on the Lifetime interspace

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 5-90

Oil change on external travel brake

MJFCIFSS

MJFCIFSS

Fig. 5-91

Oil change on the splitterbox

MJFCIFSS

MJFCIFSS

Fig. 5-92

Undercarriage components

MJFCIFSS

Fig. 5-93

Travel gear components (right and left sides)

MJFCIFSS

Fig. 5-94

Track pad

Fig. 5-95

Carrier roller

MJFCIFSS

Fig. 5-96

Track roller

Fig. 5-97

Idler and tension unit

MJFCIFSS

Fig. 5-98

Track guide

Fig. 5-99

Travel motor protection

MJFCIFSS

Fig. 5-100 Track correctly tensioned

Fig. 5-101 Check of the track tension

MJFCIFSS

Fig. 5-102 Tightening the track

MJFCIFSS

Fig. 5-103 Cylinder shutoff valves CVTL and CVTR

MJFCIFSS

MJFCIFSS

Fig. 5-104 Connectors on engine

MJFCIFSS

MJFCIFSS

Fig. 5-105 Battery care

MJFCIFSS

Fig. 5-106 Electrical components location

MJFCIFSS

MJFCIFSS

Fig. 5-107 Aeration device

MJFCIFSS

MJFCIFSS

Fig. 5-108 Location of the coolant shutoff valves on the Diesel engine

Fig. 5-109 Heater

MJFCIFSS

MJFCIFSS

Fig. 5-110 Location of the evaporator(s)

MJFCIFSS

Fig. 5-111 Dryer/receiver unit

MJFCIFSS

Fig. 5-112 Location of the condenser

MJFCIFSS

Fig. 5-113 Location of the dryer/receiver unit

MJFCIFSS

Fig. 5-114 Location of the air-conditioning compressor

MJFCIFSS

Fig. 5-115 Location of the condenser units

MJFCIFSS

Fig. 5-116 Components of the condenser unit

MJFCIFSS

MJFCIFSS

Fig. 5-117 Protection device for bucket cylinders

MJFCIFSS

Fig. 5-118 Grease nipples for the service trap

MJFCIFSS

Fig. 5-119 Counterweight bolts

MJFCIFSS

Fig. 5-120 Swing ring bolts on uppercarriage

MJFCIFSS

Fig. 5-121 Swing ring bolts on undercarriage

MJFCIFSS

Fig. 5-122 Fuel tank bolts

MJFCIFSS

Fig. 5-123 Hydraulic tank bolts

MJFCIFSS

Fig. 5-124 Bolts of engine cooler box

Fig. 5-125 Bolts of the oil cooler box

MJFCIFSS

Fig. 5-126 Pumps box bolts

MJFCIFSS

Fig. 5-127 Bolts of swing gear and swing motor

Fig. 5-128 Cab elevation bolts

MJFCIFSS

Fig. 5-129 Screws and mounts of the cab

MJFCIFSS

Fig. 5-130 Service trap bolts

MJFCIFSS

Fig. 5-131 Hydraulic pumps bolts

MJFCIFSS

Fig. 5-132 Side frames bolts

MJFCIFSS

Fig. 5-133 Preheating devices for Diesel engine coolant

MJFCIFSS

Fig. 5-134 Water system of coolant heater

MJFCIFSS

Fig. 5-135 Bleed valve of additional cab heater (if installed)

MJFCIFSS

Fig. 5-136 Starting fluid system (if installed)

Fig. 5-137 Overview of circulating heating device (if installed)

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 5-138 How to use the check lists (in addition to the daily maintenance)

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

Tab. 5-9

Daily maintenance schedule - R9200

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

Tab. 5-10 250 Hours maintenance schedule - R9200

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

Tab. 5-11 500 Hours maintenance schedule - R9200

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

Tab. 5-12 1000 hours maintenance schedule - R9200

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

MJFCIFSS

or

Tab. 5-13 2000 hours maintenance schedule - R9200

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 6-1

Hydraulic tube and hose assembly

MJFCIFSS

Fig. 6-2

Marking of hose

Fig. 6-3

Marking of hose assembly

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

MJFCIFSS

Fig. 6-4

Clean magnetic rod

Fig. 6-5

Magnetic rod with metal collection

MJFCIFSS

Fig. 6-6

Filters on the hydraulic tank

MJFCIFSS

Fig. 6-7

Return lines

MJFCIFSS

Fig. 6-8

Leak oil circuit of working pumps

MJFCIFSS

Fig. 6-9

High pressure hoses between valves blocks and working pumps

MJFCIFSS

Fig. 6-10

Intake lines of working pumps

MJFCIFSS

Fig. 6-11

Leak oil hoses of swing pump

MJFCIFSS

Fig. 6-12

Leak oil hoses of swing motors

MJFCIFSS

Fig. 6-13

Working pressure lines

MJFCIFSS

Fig. 6-14

Intake and replenishing lines

MJFCIFSS

Fig. 6-15

Return oil lines of fans motors

MJFCIFSS

Fig. 6-16

Leak oil lines of fan motors

MJFCIFSS

Fig. 6-17

Leak oil hose of cooling pumps

MJFCIFSS

Fig. 6-18

Working pressure lines of fan motors

MJFCIFSS

Fig. 6-19

Intake line of cooling pumps

MJFCIFSS

Fig. 6-20

Leak oil circuit of travel motors

MJFCIFSS

Fig. 6-21

Working pressure circuit on the undercarriage

MJFCIFSS

Fig. 6-22

Working pressure circuit on the uppercarriage

MJFCIFSS

Fig. 6-23

Overspeed pressure circuit on the undercarriage

MJFCIFSS

Fig. 6-24

Overspeed pressure circuit on the uppercarriage

MJFCIFSS

Fig. 6-25

Hydraulic lines on the uppercarriage

MJFCIFSS

Fig. 6-26

Hydraulic lines on the attachment

MJFCIFSS

Fig. 6-27

Hydraulic lines on the uppercarriage

MJFCIFSS

Fig. 6-28

Hydraulic lines on the boom

MJFCIFSS

Fig. 6-29

Hydraulic lines on the uppercarriage

MJFCIFSS

Fig. 6-30

Hydraulic lines on the boom

MJFCIFSS

Fig. 6-31

Hydraulic lines on the uppercarriage

MJFCIFSS

Fig. 6-32

Hydraulic lines on the attachment

MJFCIFSS

Fig. 6-33

Hydraulic lines on the bucket

MJFCIFSS

Fig. 6-34

Hydraulic lines on the attachment

MJFCIFSS

Fig. 6-35

Hydraulic lines on the boom

MJFCIFSS

Fig. 6-36

Hydraulic lines on the boom

MJFCIFSS

Fig. 6-37

Hydraulic tank cleaning

MJFCIFSS

Fig. 6-38

Solenoid valves on servo unit

MJFCIFSS

MJFCIFSS

MJFCIFSS!

1. Main Screens and Control Buttons

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

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

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

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

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

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

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

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

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

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

Description of the software menus

makes the pump PX return to

MJFCIFSS!

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

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

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

P 3 EM E xe c 2

V1 . 03

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

4 5 6 s e c

O N b a r

S a f e t y 0 s e c

P 3 O N 1 p u l s e

2 0 0 s e c

Right Main Screen : L e v e l

P 1 P 3

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

Description of the software menus

MJFCIFSS!

4. Architecture of Menus

Description of the software menus

MJFCIFSS!

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

f t t t r s

o s y s 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

MJFCIFSS!

MJFCIFSS!

MJFCIFSS!

o

DANGER WARNING CAUTION ATTENTION

MJFCIFSS!

Symbol

Meaning

Symbol

Meaning

MJFCIFSS!

MJFCIFSS!

MJFCIFSS!

o o o o o

ATTENTION

MJFCIFSS!

MJFCIFSS!

MJFCIFSS!

MJFCIFSS!

MJFCIFSS!

MJFCIFSS!

MJFCIFSS!

MJFCIFSS!

MJFCIFSS!

MJFCIFSS!

o o o o

MJFCIFSS!

o o o o o o

MJFCIFSS!

CAUTION

MJFCIFSS!

MJFCIFSS!

MJFCIFSS!

CAUTION

MJFCIFSS!

MJFCIFSS!

WARNING

ATTENTION

MJFCIFSS!

MJFCIFSS!

DANGER

ATTENTION

MJFCIFSS!

WARNING

o o o o o o o

MJFCIFSS!

Motor and system:

MJFCIFSS!

Fig. 1

Position of lubrication points

MJFCIFSS!

Fig. 2

Position of lubrication points

MJFCIFSS!

MJFCIFSS!

Legend

Fig. 3

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

MJFCIFSS!

Fig. 4

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

MJFCIFSS!

MJFCIFSS!

Fig. 5

Cycle: Equipment and uppercarriage

MJFCIFSS!

MJFCIFSS!

MJFCIFSS!

MJFCIFSS!

MJFCIFSS!

MJFCIFSS!

MJFCIFSS!

Fig. 6

Schematic of lubrication: Swing ring teeth and swing box centering

Fig. 7

Grease cycle

MJFCIFSS!

Fig. 8 P203-15XYB

MJFCIFSS!

Fig. 9

Cabin location

MJFCIFSS!

CAUTION!

CAUTION!

MJFCIFSS!

CAUTION!

CAUTION!

NOTE!

MJFCIFSS!

DANGER!

NOTE!

MJFCIFSS!

MJFCIFSS!

MJFCIFSS!

User Manual EC

Error Codes G

Fault

Cause

Displ ay E__

Display G__ to:

Signalisation

Lubrication

01

02

03

04

05

06

07

08

09

10

11

12

13

IMPORTANT NOTE Codings “B…“, “H…“, “S…“, “X…“, and “Y…“ refer to t he wiring diag ram (se e annex).

User Manual EC

Error Codes, continuation G

Fault

Cause

14

15

16

17

18

19

20

21

22

23

24

25

26

27 IMPORTANT NOTE C odings “B…“, “H…“, “S…“, “X… “, and “Y…“ refer to the wiring d iagram (see annex).

Displ ay E__

Display G__ to:

Signalisation

Lubrication

User Manual EC

Error Codes, continuation G

Fault

Caus e

28

29

30

31

32

33

34

35

36

37

38

39 40 41 42 43 44 45

IMPORTANT NOTE Codings “B…“, “H…“, “S…“, “X…“, and “Y…“ refer to the wiring diagram (see annex).

Display Display E_ _ G__ to:

Signal isation

Lubrication

User Manual EC

Error Codes, continuation G

Fault

Cause

46

47

48

49

50

51

52 53 54

55

56

57 58 59 60

61

81

82

IMPORTANT NOTE C odings “B…“, “H…“, “S…“, “X… “, and “Y…“ refer to the wiring d iagram (see annex).

Displ ay E__

Display G__ to:

Signalisations

Lubrication

User Manual EC

Error Codes, continuation G

Fault

Cause

83

84

85

86

87

88

89

90

IMPORTANT NOTE C odings “B…“, “H…“, “S…“, “X… “, and “Y…“ refer to the wiring d iagram (see annex).

Displ ay E__

Display G__ to:

Signalis ation

Lubrication

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