Liebherr R 924 C Litronic 1066 1067 1068 1069 1136 1174 Hydraulic Excavator Operating Manual 23085

en

Operating instructions

Document identification Order number: Edition: Valid for: Author:

Product identification Manufacturer: Type: Type no.: Conformity:

Address

from serial number

Machine data

Vehicle ident. number:

Construction year:

First start-up date:

MJFCIFSS

Preface

machine operator maintenance personnel

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.

Operation

Maintenance Transportation

The operating instructions belong with the machine. Place a copy in an easily reached position on the cab storage shelf.

MJFCIFSS

Modifications, conditions, copyright

MJFCIFSS

1

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

2

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

3

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

MJFCIFSS

1-1

4

Malfunctions ................................................................................................................................................... 4-1

1-2

MJFCIFSS

5

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

MJFCIFSS

1-3

1-4

MJFCIFSS

MJFCIFSS

1-5

1-6

MJFCIFSS

1 Product description 1.1 Assembly - overview

1.1.1

Machine and construction equipment

Fig. 1-1

Machine with construction equipment

100 200

330 340

300

350

360 370

Fig. 1-2

1-2

Machine with construction equipment

300

330

360

310 320

340 350

370

MJFCIFSS

1.1.2

Machine for transferring material

Fig. 1-3 300 330

Machine for transferring material 340 350

MJFCIFSS

370

1-3

1.1.3

Upper carriage

Fig. 1-4

1-4

Upper carriage

500

7100

530

7300

560

7600

700

8700

800 1400

9000 9300

6000 7000

9500

MJFCIFSS

Fig. 1-5

Upper carriage - cabine

6000

6230

6220

8700

MJFCIFSS

1-5

1.1.4

Undercarriage

Fig. 1-6

Undercarriage

208

1000

400

4500

1.2 Vibration emissions

Hand-arm vibration

Whole-body vibration

1-6

MJFCIFSS

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

Typical working cycles

x-axis 1

2

y-axis 3

1

2

z-axis 3

1

2

3

1.3 Technical data

MJFCIFSS

1-7

1-8

MJFCIFSS

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2 Safety instructions

2.1 Meaning of the symbols in this manual

Danger Caution

Danger!

Caution!

Note!

Note

Following these notes does not relieve you of responsibility for following additional rules and guidelines!

2.2 Use in accordance with the regulations

2.3 Safety Instructions General safety instructions

2-2

MJFCIFSS

MJFCIFSS

2-3

Avoidance of crushing and burns

Avoidance of fire and explosions

2-4

MJFCIFSS

Bringing the machine safely into service

Safely getting up

NOTE

MJFCIFSS

2-5

Adjusting the operator’s standing position

Protection from vibration - seat adjusting

Utilisation in confined spaces

Starting the machine safely

Stopping the machine safely

2-6

MJFCIFSS

Safely getting down

Working safely with the machine

• warn any personnel in the vicinity not to come close to the excavator and not to touch it,

MJFCIFSS

2-7

2-8

MJFCIFSS

Safe use with a hydraulic hammer

Safe use when loading and unloading (particularly when loading and unloading wood)

MJFCIFSS

2-9

Safe use of machines with tower elevation

2 - 10

MJFCIFSS

(Caution! swinging grab)

Protection from vibration

MJFCIFSS

2 - 11

Towing the machine safely

Attaching and removing equipment parts safely

2 - 12

MJFCIFSS

Removing and installing equipment bolts safely

Transporting the machine safely

MJFCIFSS

2 - 13

2.4 Servicing the machine safely General safety instructions

2 - 14

MJFCIFSS

Cleaning

MJFCIFSS

2 - 15

Crack testing

Welding, drilling, firing and grinding work

2 - 16

MJFCIFSS

Process materials

Repair work

MJFCIFSS

2 - 17

Electrical system

Hydraulic accumulator

2 - 18

MJFCIFSS

Hydraulic hoses and sheathed cables.

MJFCIFSS

2 - 19

2.5 Signs on the machine 2.5.1

Introduction the safety plates the information plates the nameplates

Danger! safety plates

2 - 20

MJFCIFSS

2.5.2

Arrangement of signage

Fig. 2-1

Arrangement of standard signage on the machine

MJFCIFSS

2 - 21

Fig. 2-2

Arrangement of North America signage on the machine

4

56

15

60

20 22

65 71

30

73

35

74

36

75

40

76

45

77

47 50

80 101

52

103

54

250

55

2 - 22

MJFCIFSS

Note !

2.5.3

Explanation of signage Serially installed signage

"mociw"

"NA" Plate 4: Machine nameplate LFR (Liebherr France) "CE"

Plate 4: Machine nameplate LFR (Liebherr France)

Plate 4: Machine nameplate LAM (Liebherr America)

MJFCIFSS

2 - 23

"mociw"

"NA" Plate 15: Lubrication chart

Plate 20: Prohibiting sign

Plate 22: Operating symbols

Plate 30: Lubrication chart, engine

Plate 35: Loading and anchoring points

Plate 36: Waxoyl

2 - 24

MJFCIFSS

"mociw"

"NA" Plate 40: Lashing point

Plate 45: Stop-lift point

Plate 47: External starting

Plate 50: Obstruction

Plate 52: Engine-off

MJFCIFSS

2 - 25

"mociw"

"NA" Plate 54: Accident prevention

Plate 55: Safety lever

Plate 56: Equipment

Plate 60: Sound/power level [truck]

*XX

2 - 26

MJFCIFSS

"mociw"

"NA" Plate 65: Load chart

Plate 71: Explosion hazard

Plate 73: High voltage hazard

Plate 74: Hazard of injury due to fluid under high pressure

Plate 75: Hazard of an impact by moving attachment parts

Plate 76: Burning hazard due to hot machine parts

Plate 77: Risk of burning due to hot fluids

MJFCIFSS

2 - 27

"mociw"

"NA" Plate 80: Safety belt

Plate 250: Emergency exit – rear window

Signage relating to optional equipments "mociw"

"NA" Plate 101: Crushing hazard

Plate 103: Hazard of thrown out objects

2 - 28

MJFCIFSS

2.5.4

Nameplates on the machine

Fig. 2-3

Important nameplates on the machine

1

4

2

5

3

6

MJFCIFSS

2 - 29

2 - 30

MJFCIFSS

3 Control and operation 3.1 Operating and control elements 3.1.1

Controls in the operator’s cab

1

S5L or unlocking of cylinder cut-off (NA)

3

S5M

4

S5R or travel alarm on/off (NA)

5

S6L or rotating device left (NA)

6 9

S6M S6R or rotating device right (NA)

10

S55 or lifting magnet (NA)

15

S57

A3

S71 S72

E8 H1

S73 S84-1

H10 P5

U38

S1 S2 * (NA)

This location only for North America

Fig. 3-1

3-2

Controls in the cab

MJFCIFSS

3.1.2

The joysticks Control of the working movements

Fig. 3-2

Joystick right (3) and left (4)

Standard control system according to ISO 4 4 4

a c

b d

3

e

f

3

g

h

3

Special control systems Note !

Liebherr resp. John Deere control system, ....

S 247 H 292

MJFCIFSS

3-3

Push buttons and switches in the joysticks

Fig. 3-3

Arrangement of push buttons and switches in the control levers

Button -Switch

Function

Push button S5L

Rotating device left See in this chapter " control of rotating device (rotating, tilting, locking and unlocking a working tool)".

Push button S5M

Horn

Push button S5R

Rotating device right See in this chapter " control of rotating device (rotating, tilting, locking and unlocking a working tool)".

Push button S6L

Lifting magnet See in this chapter "Lifting magnet (optional equipment)".

Push button S6M

Reserve or Float position of the boom cylinders with shovel attachment See the section "working attachment control", further in this chapter.

Push button S6R

Travel alarm cut-off See in this chapter "Travel alarm (optional equipment)".

Push switch S55

Unlocking of a movement cut-off by end position switch See in this chapter "Attachment movement cut-off by end switch (optional equipment)".

Rocker switch S57

Swing brake control in semi automatic mode See in this chapter "Swing movements and swing brake control".

Tab. 3-1

Functions of push buttons and switches in standard execution

Caution!

3-4

MJFCIFSS

Function of push buttons and switches on US version with lifting magnet

Button -Switch

Function

Push button S5L

Travel alarm cut-off See in this chapter "Travel alarm (optional equipment)".

Push button S5M

Horn

Push button S5R

Unlocking of a movement cut-off by end position switch See in this chapter "Attachment movement cut-off by end switch (optional equipment)".

Push button S6L

Rotating device left See in this chapter " control of rotating device (rotating, tilting, locking and unlocking a working tool)".

Push button S6M

Reserve or Float position of the boom cylinders with shovel attachment See the section "working attachment control", further in this chapter.

Push button S6R

Rotating device right See in this chapter " control of rotating device (rotating, tilting, locking and unlocking a working tool)".

Push switch S55

Lifting magnet See in this chapter "Lifting magnet (optional equipment)"

Rocker switch S57

Swing brake control in semi automatic mode See in this chapter "Swing movements and swing brake control".

Tab. 3-2

Functions of push buttons and switches for US version with lifting magnet

MJFCIFSS

3-5

3.1.3

Control unit

Fig. 3-4 M

3-6

Excavator control unit

The function of the push buttons marked with (M) are memorized when the excavator is stopped.

This means that, when turning on the excavator, the controlled function recovers the previous state (on-off, 1-2, I-C, ...) before the machine had been turned off

MJFCIFSS

S10 Driving light / Equipment headlight

S11

Windshield washer

S14

Windshield wiper

S17

Preselection of swing brake operating mode

MJFCIFSS

3-7

S18

Overload warning device (optional equipment)

S19

Rotating device (optional equipment)

S20

Engine low idle automatic

Adjustment of the time lag for low idle automatic

3-8

MJFCIFSS

S21

Travel speed increase

S22

Auxiliary floodlights (optional equipment)

S36

No function

S41

Rotating beacon (optional equipment)

S56

Working pressure increase (optional equipment)

S85

Grapple operation (optional)

MJFCIFSS

3-9

S86

Operating mode preselection

L F E P

P4

3 - 10

Engine RPM indicator

S228

Engine RPM increase

S229

Engine RPM decrease

S354

Super Finish (quantity reduction)

MJFCIFSS

3.1.4

Monitoring display

Fig. 3-5

Monitoring display

A B

H24 P2

C

P2.1

D

P3

H2

P3.1

H12

S349

H19

S350

H20 H23

S351 S352

MJFCIFSS

3 - 11

Area A : Analog-value display P2 Diesel engine coolant temperature display

P2.1

P2 E 503

E 523

P3

Fuel level display

P3.1

Area B :Indicator lights H2

Indicator light, low engine oil pressure

E 501

3 E 522

3 - 12

MJFCIFSS

H12 Indicator light, battery charge

H19

No function

H20 No function

H23

No function

H24

No function

Area D : Menu control buttons

Fig. 3-6

Menu control buttons

S349 Back S350 Down S351 Up S352 Menu*

Area C: LCD Screen To change the screen contrast: Menu

Up

Down

To alter the brightness of the main screen: Back

MJFCIFSS

Up

Down

3 - 13

Note!

To change the brightness and the contrast setting to the initial setting:

Up

3.1.5

Down

Main screen (DISP02 R5.2 Software V4.5.1) Menu

Fig. 3-7

Main screen

EC

SY

INF

TI

Main screen design SY field

Note!

3 - 14

MJFCIFSS

EC field

Up

Down

INF field

TI field

"

Control of the screen at error recognition

MJFCIFSS

3 - 15

Danger!

Back

Warning symbols for operating faults in the SY field

E 502–Coolant low

Caution!

E 503 –Coolant overheat - Warning stage P2

E 504–Hydraulic oil level low

3 - 16

MJFCIFSS

E 505 –Hydraulic oil overheat

E 506 – Splitterbox oil overheat

E 511 – Over voltage for the BBT

E 512 – Under voltage for the Diesel control system

E 513 – Over voltage for the Diesel control system

E 516

Safety shut off for EDC default

E 517 – Safety shut off for injector default

E 518 – Safety shut off for startsynchronisation default startsynchronisation

E 519 – Overspeed of Diesel engine - Warning stage

E 520 – Overspeed of Diesel engine - Safety stage

E 521 – Defect of both engine RPM sensors

MJFCIFSS

3 - 17

E 522 – Low engine oil pressure - Safety stage

E 523 – Coolant overheat - Safety stage

E 524 – Boost air overheat - Safety stage

E 525 – Engine in safety mode

E 526 – Fuel overheat - Warning stage

E 527 – Fuel overheat - Safety stage

E 528 – Water in the fuel filter

E 530 – Centralized symbol - safety limit exceeded

E 532 – Low fuel pressure - Warning stage

E 533 – Low fuel pressure - Safety stage

E 534 – High fuel pressure - Warning stage

E 535 – High fuel pressure - Safety stage

3 - 18

MJFCIFSS

E 536 – Low fuel pressure into Rail 1 - Warning stage

E 537 – Low fuel pressure into Rail 1 - Safety stage

E 538 – Low fuel pressure into Rail 2 - Warning stage

E 539 – Low fuel pressure into Rail 2 - Safety stage

E 597 – Boost air overheat - Warning stage

Quick change adapter (optional equipment)

Information symbols in the INF field Preheating

End of preheating End of preheating Manual Diesel speed adjustment

MJFCIFSS

3 - 19

Service due

Acknowledge error E5xx type error code

back “Increased care required” - servo-control circuit in safety mode S73 Swing brake not operative

Servo control operation changed S73

Overload warning device (optional equipment)

No overload warning device recognized S18

Warm up procedure

3 - 20

MJFCIFSS

Display on the screen of the information provided in menus Menu selection from main screen

Fig. 3-8

Main screen

Menu

Fig. 3-9

List of menus.

To select a menu: Down

Up

Reset daily operating hours Menu Back

Symbol of menu

Denomination of menu

MJFCIFSS

Role of the menu

3 - 21

Symbol of menu

Tab. 3-3

Denomination of menu

Role of the menu

Overview of the possible menus

Menu "Reset Data" - reset of daily operating hours counter

Fig. 3-10

Resetting the daily operating hours counter Up Menu Up

3 - 22

MJFCIFSS

Down

Menu

To exit the menu: Back

Menu "Set Service" - confirmation of the execution of a recurring service work

Fig. 3-11

Menu "Set Service"

Up Menu

Back

Menu "Set option" - selection of the flow and pressure limitations

MJFCIFSS

3 - 23

Caution!

Fig. 3-12

Menu "Set option"

EV1

EV2

EV6

Quota

Up

Down

Menu

To exit the menu: Back

3 - 24

MJFCIFSS

Fig. 3-13

Main screen, the chosen option is displayed

1

2

Note!

Menu "Info Hours" - operating hours of machine components

Fig. 3-14

Menu "Info Hours" - operating hours of Diesel engine

Menu

MJFCIFSS

3 - 25

Fig. 3-15

Menu "Info Hours" - duration of the various movements Menu

Menu

Fig. 3-16

3 - 26

Menu "Info Hours" General Data

MJFCIFSS

Menu

To exit the menu: Back

Menu "Info In/Outputs"- Status of hydraulic pumps and of electrical inputs and outputs

Fig. 3-17

Menu "Info In/Outputs"- flow and pressure limitations

MJFCIFSS

3 - 27

Note!

Menu

Fig. 3-18

Menu "Info In/Outputs"- Currents to the solenoid valves LR and EV5 Menu

Menu

Fig. 3-19

Menu "Info In/Outputs"- Current to the solenoid valve EV3 Menu

3 - 28

MJFCIFSS

Fig. 3-20

Menu "Info In/Outputs"- Status of electrical inputs and outputs

Fig. 3-21

Menu "Info In/Outputs"- Status of electrical inputs and outputs

MJFCIFSS

3 - 29

To exit the menu: Back

Menu "i-errors" - operating faults and electrical system errors

Fig. 3-22

Menu "i-errors" - operating faults and electrical system errors

list Exxx list E-elec list S-Exxx Exxx

list

To select the desired error type: Down

Up

Menu Down

Up

"list Exxx": Operating faults

Fig. 3-23

List of the operating faults (fig. left) and occurrences of a fault (fig. right) list Exxx

3 - 30

MJFCIFSS

Menu

Down

Up

Menu

Back

Notice!

E 5xx

list Exxx

Back Down

Up

Back

"list E-elec." : Errors of the electrical system

Fig. 3-24

List of the electrical errors list E-elec."

Menu

Back Down

MJFCIFSS

Menu

3 - 31

"list S-Exxx" : Operating faults in service mode

Fig. 3-25

List of operating faults appeared in service mode

list S-Exxx Exxx

Menu "set clock"

Fig. 3-26

Clock setting

UP

DOWN

MENU key t

Enter

3 - 32

MJFCIFSS

list

Menu "Purge" - Bleeding of the high pressure fuel system

Fig. 3-27

Menu "Purge"

Note !

MJFCIFSS

3 - 33

3.1.6

Controls and instrumentation for optional equipments

Fig. 3-28

H38-2

3 - 34

Controls for optional equipments

Control light / empty report of centralised greasing system

MJFCIFSS

H90

Control light / Rotation in opposite direction of reversible fan

S160

H292

Control light / Special control system S247

S26

Touch / Fuel preheater

S40

Touch / Frequency commutation for hydraulic hammer

S45

Touch / Priority for special equipment

S45

S46

Touch / Lifting magnet operation

S47

Push button / Quick change adapter

S53

Touch / Special control circuit supply

S54

Rotary switch / Unlocking of cylinder end position

S74

Code key switch / Anti-theft protection system

MJFCIFSS

3 - 35

S76

Touch / Travel parking brake

S77

Touch / Pressurized driver's cab

S78 - Push button / Height adjustable cab - emergency down

S79

S84-1

Touch / Flow divider for special attachment

Touch / Central lubrication

S90 Potentiometer / Intermittent mode of the cab roof window wiper

3 - 36

S98

Touch / Low pressure protection for boom cylinders

S104

Touch / Hydraulic width adjustment of undercarriage

S114

Key switch / Control of a special attachments with the joysticks

MJFCIFSS

S160

Push button / Control of reversible fan in opposite direction

S168 Key switch / Oil flow limitation when operating a super long working attachment

S200

Push button / Height adjustable cab - up

S201

Push button / Height adjustable cab - down

S218

Touch / Cab roof window wiper S218

S232

Control unit / Standstill cab heater

S247

Key switch / Commutation Normalized control system - Special

control system

S275

Touch / Additional floodlight on rear of cab roof

S276

Touch / Additional floodlight on counterweight

S362

Push button / Washer for cab roof window

MJFCIFSS

3 - 37

S422 - Radio muting

3.1.7

Display for LIEBHERR particle filter (optional).

A175

Fig. 3-29

Control unit A175

A

B

C

D

E G

F A175

Use / monitoring of the particle filter system

F

3 - 38

MJFCIFSS

F Following menus could be displayed: – "Exhaust back pressure (mbar)" – "Exhaust back pressure (mbar) / Exhaust temperature 1 (°C)

– "Exhaust back pressure (mbar) / Exhaust temperature 2 (°C)

– "Exhaust back pressure (mbar) / Speed (rpm)

Note:

3.2 The access and the outfit of the cab Safely getting up

NOTE

MJFCIFSS

3 - 39

Safely getting down

3.2.1

Entering or leaving the cab Climbing up Caution!

3 - 40

MJFCIFSS

Cab:

Fig. 3-30

Climb up using the handholds

Getting in

Fig. 3-31

Door - exterior

1

2 11

11 1

2

MJFCIFSS

3 - 41

Getting out Caution!

Fig. 3-32

Door - interior

3

4

3 2

To release the door latch:

4

3 - 42

MJFCIFSS

3.2.2

Height and inclination adjustable cab (optional extra)

Danger!

Danger!

Adjusting the height of the cab S200 S201

Fig. 3-33

S78

Adjusting the height of the cab

To raise the cab: S200 S200 To lower the cab: S201

MJFCIFSS

3 - 43

S201

Emergency operations

Emergency cab lowering from inside the cab: S78 S78 Emergency cab lowering from outside the cab:

Fig. 3-34

Shut off valve for emergency cab lowering.

1

Danger!

1 1

Adjusting the inclination of the cab (3)

3 - 44

MJFCIFSS

Fig. 3-35

Adjusting the inclination of the cab

Repair and maintenance Danger!

3.2.3

The safety lever

Fig. 3-36

Safety lever

Caution !

S17 S17

MJFCIFSS

3 - 45

3.2.4

Operator’s seat

Fig. 3-37

Standard operator’ seat (Fig. left) and air-cushioned (Fig. right, optional extra)

1

4b

7

2

5

8

3

6

10

4a

Setting the armrests

Fig. 3-38

Setting the armrests 3

3 - 46

MJFCIFSS

a

3

b

Setting the seat and backrest

Fig. 3-39

Setting the seat and backrest 4a 4b 10

Setting the horizontal seat position

Fig. 3-40

Setting the horizontal 1 2

MJFCIFSS

3 - 47

Setting the seat springs

Fig. 3-41

Setting the seat springs 5

Options setting (optional extras)

Fig. 3-42

Switch bar on the air-cushioned operator’s seat

To set the vibration damping: 5 +

-

To set the lumbar support: 6 +

-

7 +

-

To set the seat heating: 8

3 - 48

MJFCIFSS

Putting on / releasing the safety belt

Fig. 3-43

Safety belt

2

1 3

Danger!

4 1

3.2.5

Windscreen

Fig. 3-44

Locked positions of the windscreen

a b

MJFCIFSS

3 - 49

Caution!

To change the position of the windscreen 1 2 b

3.2.6

1

Sunshade

Fig. 3-45

Sunshades at windscreen and at cab roof

Maneuvering the sunshade at the windscreen 1 2 Maneuvering the sunshade at the cab roof

3 - 50

MJFCIFSS

a

3.2.7

Emergency exit – rear window

Fig. 3-46

Emergency exit – rear window 2 1

3.2.8

Interior lighting

Fig. 3-47

Dome light for cab interior lighting 1 1 1

2 3

1

3.2.9

Fire extinguisher*

MJFCIFSS

3 - 51

Fig. 3-48

Possible locations for fixing the fire extinguisher

Note!

Caution!

3.2.10

Windscreen wiper Windscreen wiper S14

3 - 52

MJFCIFSS

Setting the interval time for the intermittent switching S14

Windscreen washing system S11

Windscreen washing fluid container

Fig. 3-49

Windscreen washing fluid container

MJFCIFSS

3 - 53

3.2.11

Lighting

Fig. 3-50

Arrangement of lighting

1 2

4 5

3

6

Driving light, equipment headlight S10

Additional headlight (optional extra) S22

3 - 54

MJFCIFSS

Rotating beacon (optional extras) S41

Roof headlights, rear (optional extras) S275

3.2.12

The heater and air conditioner

Control unit of the heating and air conditioning system

Fig. 3-51

Control unit of the airco system

MJFCIFSS

3 - 55

Control keys

Indications at the LCD display

1 – Air conditioning (cooling) 2 – Increase cab temperature 3 – Decrease cab temperature 4 – Control ON / OFF 5 – Evaporator fan speed – manual / automatic 6 – REHEAT operation 7 – Heating – manual / automatic 8 – Fresh air / recirculated air 9 – Air flap to rear wall vent OPEN / CLOSED 10 – Air flap to right control panel (8b) OPEN / CLOSED 11 – Air flap to front window, legroom CENTER / CLOSED 12 – Air flap tofront windshield, legroom CENTER / OPEN

13 – Air circulation 14 – REHEAT operation 15 – Air conditioning (cooling) 16 – Air flap to rear wall OPEN 17 – Air flap to right control panel (8b) OPEN 18 – Air flap to front windshield, legroom CENTER 19 – Air flap to front windshield, legroom OPEN 20 – Automatic operation 21 – Bar graph indicator for fan speed 22 – Symbol, fan speed (in manual operation) 23 – Symbol, heater operation (in manual operation) 24 – Bar graph indicator for heating output 25 – Temperature value or error code 26 – Temperature unit (°)

Note!

F1-F5

Turning the control unit on

Fig. 3-52

Turning the control unit on and setting the cab temperature 4

AUTO

Setting the desired cab temperature 25 2 3

3 - 56

MJFCIFSS

(20)

Manual setting of the heating output

Fig. 3-53

Setting of the heating output and of the fan speed 7

2

3

7

Manual setting of the fan speed

2

3

Air conditioning operation

Fig. 3-54

Air conditioning operation and Reheat-operation 1 15

15

MJFCIFSS

3 - 57

Note!

Reheat-operation

6 14

6 Note!

6

Recirculated air and fresh air operation

Fig. 3-55

Recirculated air and fresh air operation

8

13

3 - 58

MJFCIFSS

13

Note!

The best heating, resp. cooling effect is reached in recirculated air operation!

Air repartition

8a 8b 8c 8d

Fig. 3-56

Air repartition in the cab

MJFCIFSS

3 - 59

heating 8c

8a 8b 10 11

air conditioner operation 8d 8b 12

12 9

Note!

Changing the temperature from °Celsius to °Fahrenheit

Fig. 3-57

Switching over °Celsius - °Fahrenheit 8

3.2.13

3 - 60

Additional standstill heater (Option)

MJFCIFSS

Operating the standstill heater Notice!

SH

Fig. 3-58

Indication of the standstill heater operation on the control unit of the main air conditioner

Notice!

The control unit of the standstill heater

MJFCIFSS

3 - 61

Functioning of the additional standstill heater

Operation of the heater using the mini-clock

Setting functions on the mini-Clock Notice!

Setting-up for the first time:

3 - 62

MJFCIFSS

Setting the current time:

Note!

Setting the heating time:

Setting the preset times:

Operating functions of the Mini-Clock Switching on the heater:

MJFCIFSS

3 - 63

Turning off the heater:

Continuous operation:

Activating / deactivating the preset time:

3.2.14

Pressurized driver’s cab (option)

Note !

S77

S77

3 - 64

MJFCIFSS

Fig. 3-59

Button S77 - Main and safety filter element of installation

Main and safety filter element :

2

3

To clean and change the main and safety filter element : 5 4 2 3 Note!

2

MJFCIFSS

3

3 - 65

Notes : F1

3.3 Setting the machine into operation Bringing the machine safely into service

Adjusting the operator’s standing position

Protection from vibration - seat adjusting

Utilisation in confined spaces

Starting the machine safely

3 - 66

MJFCIFSS

Stopping the machine safely

3.3.1

Starting / stopping the machine General information Note!

LIDEC DC 5-00

MJFCIFSS

3 - 67

Attention !

Activities before starting Caution!

Caution!

3 - 68

MJFCIFSS

Starting the diesel engine Ignition key switching positions

Fig. 3-60

Ignition switch

0 1

2 3

P

Switching on the electrical system

1 1

Note!

S22

MJFCIFSS

3 - 69

Service interval display

Fig. 3-61

3.3.2

Service interval request

Starting the engine Note !

0

Starting procedure 3

Starting procedure for low temperatures

Preheating ON 1 1 Preheating ON

3 - 70

MJFCIFSS

Preheating END

Preheating END 3

Starting procedure for exterior temperature below -18 °C (0 °F).

3.3.3

Speed adjustment and operating modes

Fig. 3-62

Speed adjustment and operating modes selection P4 S86

- orS228

S229

Engine speed and operating mode selection via the mode switch S86 L F E P S86

E

P

MJFCIFSS

L

F

3 - 71

Engine speed adjustment using the arrow keys To increase the speed: S228 P4 To decrease the speed: S229 P4 S228

Fig. 3-63

S229.

Engine speed adjustment via the arrow keys S228 and S229 S86 S86

3 - 72

MJFCIFSS

3.3.4

Notes after starting the engine Danger!

Caution!

3.3.5

Warm-up phase for Diesel engine and hydraulic circuit Diesel engine

P2 Note !

Hydraulic oil

Note !

MJFCIFSS

3 - 73

3.3.6

Switching the Diesel engine off Caution

S229 P4

Emergency stop of the Diesel engine (Option)

Caution!

S2-1

Fig. 3-64

3 - 74

S34

Emergency off switches on keyboard and on uppercarriage structure

MJFCIFSS

Danger!

Diesel engine stop with after running (Option)

S229 P4 0"

Notice !

3.3.7

indicatorStarting aids Cold start device (optional extra)

S210

Fuel preheating S26 (optional extra)

MJFCIFSS

3 - 75

S26

Coolant / engine oil / hydraulic oil preheating (optional extra)

Fig. 3-65

Coolant / motor oil / hydraulic oil preheating

1

5

2

6

3

7

4

8

8 4 1 5 2

3 - 76

MJFCIFSS

6 3 8

3.3.8

Jump start procedure Danger!

Connecting the batteries

Caution!

Disconnecting the batteries

MJFCIFSS

3 - 77

3.3.9

Anti-theft device with code key (option)

Fig. 3-66

Electronic anti-theft device 1

3.3.10

Immobilizer with electronic ignition key (option) System description

Activation of the immobilizer

Note!

Deactivation of the immobilizer

3 - 78

S74

MJFCIFSS

Note!

Master key and operation keys

Fig. 3-67

Ignition switch with immobilizer via electronic operation keys

5

6

Imprinting procedure of an operation key

Note!

MJFCIFSS

3 - 79

Deleting imprinted operating keys

Note!

The code of the master key will not be deleted during the deletion procedure

Operation security

Function security

3.3.11

Travel functions Straight travel

Fig. 3-68

Travelling straight ahead

1 2

5a / 5b 6a / 6b

1 2

3 - 80

MJFCIFSS

Danger If the uppercarriage us turned by 180°, note that all travelling directions (right and left, forward and backward) are reversed when you push the pedals!

Travel forwards: 5a

6a

Travel backwards: Caution!

5b

6b

Counter rotation with both tracks

Fig. 3-69

Counter rotation with both tracks

Counter rotating left (A): 5b 6a Counter rotating right (B): 6b 5a

Turning over one track

Fig. 3-70

Turning with a crawler

Turning ahead to the left (A): 6a

MJFCIFSS

3 - 81

Turning ahead to the right (B): 5a Note!

Manual control of the travelling movements

Fig. 3-71

Hand levers for manual travel control

1

2

Note!

Travel speed increase S21 Normal travel speed

Increased travel speed

S21

3 - 82

MJFCIFSS

S21

The travel brakes Hydraulic braking

Mechanical braking

Caution!

Limit of gradeability Danger!

Note!

MJFCIFSS

3 - 83

Travelling up

Fig. 3-72

Travelling up

Travelling down

Fig. 3-73

3.3.12

Travelling down

Drive warning device (optional extra)

Fig. 3-74

Drive warning device 5

3 - 84

6

MJFCIFSS

Deactivating the drive warning device: S6R

3

S5R

4

Caution!

S6R

Note!

3.4 Operating the excavator in safety modes 3.4.1

Board E52 for safety mode of Diesel engine & servo control

Fig. 3-75

Control board for safety operation E52

E52

S71

H11

S72

H60

S73

Starting the Diesel engine in safety mode

MJFCIFSS

3 - 85

H11 S71a

Safety operation of the Diesel engine

Notice !

Caution!

In case the warning light H60 lights up, the operator must shut the engine down as soon as possible and recognize which error has occurred It's the operator's own responsibility to decide if the machine can be maintained operating or not!

Diesel engine RPM adjustment in safety mode

3 - 86

MJFCIFSS

Fig. 3-76

Emergency control of the engine RPM S72 S72

Notice !

When the engine is switched automatically into safety operation, the current engine speed is maintained as long as the engine is not shutdown.

Safety operation of the servo control circuits

Fig. 3-77

Safety mode of servo circuits - Safety switch and symbols at the display

S73

MJFCIFSS

3 - 87

Danger!

The safety mode must be turned on only temporarily and in order to move the machine for emergency reasons and when, due to a trouble in the normal control circuit, releasing the swing brake or supplying the pilot controls is hindered.

In safety mode, the swing brake will be released as soon as the ignition key is turned to contact position, and the normal brake control is out of function

Note !

3.4.2

Safety operation of the main working pumps

Fig. 3-78

Switching the main pumps in safety operation

1 2 3

3 - 88

MJFCIFSS

Y50

3.5 Recovering, towing the machine Towing the machine safely

3.5.1

Pre-requisite

Notes !

3.5.2

Process preconisations.

MJFCIFSS

3 - 89

Danger !

Caution !

Caution !

Caution !

Fig. 3-79

3 - 90

Towing equipment around the crown base.

MJFCIFSS

Danger !

3.5.3

Other preconisations.

Note !

3.5.4

With clevis type eylet available.

Danger !

Note !

Caution !

MJFCIFSS

3 - 91

Fig. 3-80

Towing the machine

Danger !

3.6 Working with the machine Working safely with the machine

• warn any personnel in the vicinity not to come close to the excavator and not to touch it,

3 - 92

MJFCIFSS

MJFCIFSS

3 - 93

Safe use with a hydraulic hammer

3 - 94

MJFCIFSS

Safe use when loading and unloading (particularly when loading and unloading wood)

Safe use of machines with tower elevation

MJFCIFSS

3 - 95

(Caution! swinging grab)

Protection from vibration

3 - 96

MJFCIFSS

3.6.1

Low idle automatic

S20

To set the time within which the engine is set back to idle after the joystick has been released:

Caution!

MJFCIFSS

3 - 97

3.6.2

The uppercarriage swing movements 4

Fig. 3-81

Rotating the uppercarriage

Caution! normal control, according to ISO-standards

4

c d

Braking the uppercarriage The hydraulic swing brake 4

4 The mechanical swing brake

S17

S17

3 - 98

MJFCIFSS

S57 S57

S57,

Note!

Caution!

Ermergency stop of the uppercarriage swing motion

Caution

To check the mechanical swing gear brake:

S17 4

MJFCIFSS

3 - 99

The positioning swing brake (option)

Fig. 3-82

Positioning swing brake pedal

Note!

10

3.6.3

Working position

Fig. 3-83

Working position of the machine

Note!

3 - 100

MJFCIFSS

3.6.4

Working attachment control Caution! normal control, according to ISO-standards

Control of the stick cylinder 4

Fig. 3-84

Stick cylinder control 4

(a) 4

(b)

Control of the boom cylinders 3

Fig. 3-85

Boom cylinders control 3

(g) 3

(h)

MJFCIFSS

3 - 101

Float position of the boom with shovel attachment

3

h.

S6M

Fig. 3-86

3

Float position of the boom cylinders with a shovel attachment

Note!

3

Control of the bucket or grapple cylinders 3

Fig. 3-87

Operation of the bucket or grapple cylinders 3

3 - 102

e

MJFCIFSS

3

f

Danger Never allow anybody to guide the grapple by hand!

Combined movements

3.6.5

Lowering the working attachment with the engine shut down

Note

Fig. 3-88

Lowering the attachment with shut down engine 1

MJFCIFSS

3 - 103

3.6.6

Turning, rotating, bolting and unbolting the add-on unit S19

Fig. 3-89

Add-on units example

Fig. 3-90

Pushbutton on the joystick

E

F

G

Danger!

S19

L - or - or -

3 - 104

MJFCIFSS

R - or - or -

3.6.7

Control of the swivel rotator (option) Rotation, swivel, locking and unlocking of the swivel rotator :

Fig. 3-91

Swivel rotator

Fig. 3-92

Push buttons on maniopulators 3 and 4 S19

Swivel the rotator : S5L S5R

MJFCIFSS

3 - 105

Turn the rotator : S6R S6R S5L S5R

Remarque !

3.6.8

Lifting magnet control system (optional equipment)

S46 S46

S228 S229

S20

S6L

Fig. 3-93

Lifting magnet control system

Danger!

S6L S6L

3 - 106

MJFCIFSS

S86

S6L

Caution!

S55 S6L

4

S55 S55

Kit conversion S6L / S6M Warning !

S6M 3,

S6L

S6M

S6M

MJFCIFSS

3 - 107

3.6.9

Control of special equipments via the additional pedals

Fig. 3-94

Special equipments controlled by the additional pedals

Fig. 3-95

Disposition of the additional pedals

Danger!

3 - 108

MJFCIFSS

Caution!

Notice!

Control of the hydraulic hammer

m

Fig. 3-96

Control of a hydraulic hammer

Note!

Control of a bottom dump shovel n

MJFCIFSS

3 - 109

p

Fig. 3-97

Control of the flap of a bottom dump shovel

Control of the other special equipments

m

k

3 - 110

MJFCIFSS

3.6.10

Commutation of the controls for an additional user AHS (special equipment)

e

f

3.

Fig. 3-98

Commutation of the control for an AHS add on kit user

Danger!

Caution!

!

S114 S114

joystick

S114 S114

MJFCIFSS

foot pedal

3 - 111

S114

3.6.11

Special control system of the joysticks (Option)

S247

Fig. 3-99

Example for a special control system

Danger!

With switched on special control system, the correspondence between deflection directions at the joystick levers induiced working movements is changed.

There is danger of accident due to possible releasing of an unintentional movement by an not informed excavator driver.

With the key removed from the switch S247, the excavator can be operated only according to ISO-control-system.

It is the responsibility of the owner of the machine to decide which operator must or is approved to operate the excavator with the special control system.

S247 H292

3 - 112

MJFCIFSS

Fig. 3-100 Instruction plate A and warning plate B

Caution!

MJFCIFSS

3 - 113

3.6.12

Special control system of the joysticks (Option, from 1st january 2009)

Fig. 3-101 Location of the switching lever Danger!

With switched on special control system, the correspondence between deflection directions at the joystick levers induiced working movements is changed.

There is danger of accident due to possible releasing of an unintentional movement by an not informed excavator driver.

With the switching lever in PCSA position, the excavator can be operated only according to ISO-control-system.

It is the responsibility of the owner of the machine to decide which operator must or is approved to operate the excavator with the special control system.

3 - 114

MJFCIFSS

Fig. 3-102 Instruction plate A and warning plate B

Caution!

MJFCIFSS

3 - 115

3.6.13

Option oil flow reduction for long working attachment.

S168 Note :

Fig. 3-103 Oil flow reduction for long working equipement Using working equipment with oil flow reduction : S168

Using working equipment with normal oil flow : S168

3 - 116

MJFCIFSS

3.6.14

Dozer blade

Fig. 3-104 Dozer blade

1 Danger !

not

Activating the dozer blade

Fig. 3-105 Dozer blade use Dozer blade height regulation : 87 87

MJFCIFSS

3 - 117

3.6.15

Cut off by end switches of attachment movements (Option) Function

Danger!

The disconnection of a cylinder movement does not constitute a safety device! It must only be considered as an assistance to the driver during actuation of a movement near a zone to be avoided !

Caution!

Danger!

You must keep a safety margin from at least 1.5 m to the dangerous position.

Note!

3 - 118

MJFCIFSS

Adjustment of the cut off point Prerequesite:

Fig. 3-106 Cut off position of an industrial stick Setting Note !

B55 B55 closing proximity switch

opening proximity switch

MJFCIFSS

3 - 119

Case no. 1 : the position of the proximity switch is adjustable on a rail

Fig. 3-107 Example of a proximity switch whose position is adjustable 2

3

B55

2

B55 B55 2

B55

Case no. 2 : the proximity switch is fixed and the position of the reflector is adjustable

Fig. 3-108 Examples of proximity switch whose position is fixed 4

6 4 4 B55 4

3 - 120

MJFCIFSS

Note !

Note !

Unlocking of movements cut off

Fig. 3-109 Switch for the unlocking of attachment movements cut off S54

Danger!

The displacement of attachment parts within a range normally prohibited by a cylinder cut off can bring to a situation presenting a danger for injury of persons and/or damage of material.

The operator is in all the cases responsible for the accidents which can occur when the attachment is working inside the zone of danger while keeping unlocked a cylinder movement cut off.

S54

I S55 S55

MJFCIFSS

3 - 121

Note!

S55

S54

S5L

II S55

S54

0

3.6.16

Mechanical stanchion cylinder shut-down (option) Mode of operation

Fig. 3-110 Sensor stanchion cylinder shut-down Danger! not

3 - 122

MJFCIFSS

Danger!

A minimum safety distance of at least 1.5 m to the danger object should be maintained.

Caution !

The stanchion cylinder shut-down point min. limit

Fig. 3-111 Stanchion cylinder shut-down - shut-down point

MJFCIFSS

3 - 123

Bypassing stanchion cylinder shut-down

Fig. 3-112 Flip switch on left joystick

Danger!

S54

S54

S54 S55 S54

I

0

S55

Caution!

S5L S55

3 - 124

MJFCIFSS

4

3.6.17

Low pressure protection for boom cylinders Mode of operation

Fig. 3-113 Pressure protection for boom cylinders Danger ! not

Caution !

Fig. 3-114 Rocker swich into left joystick handle S98 S98

MJFCIFSS

3 - 125

Notes : F3

3.6.18

Use of the excavator for lifting loads overhead

Danger!

a load hooking system ensuring the safe attaching and removing of the loads (optional equipment)

an overload warning device (optional extra)

a boom lowering control device

a rated lift capacity chart If the points referred to above are not or are only partially fulfilled, the machine may not be used for lifting loads overhead.

3 - 126

MJFCIFSS

Danger!

3.6.19

Overload warning device (Option) General

Note!

Using the overload warning device Danger!

MJFCIFSS

3 - 127

Mode of operation

Starting the overload warning device Danger!

S18

The operator must check the function of the overload warning device before each work shift.

Caution!

Deactivation of the overload warning device Note!

S18

3 - 128

MJFCIFSS

3.6.20

Mowing bucket (option)

Fig. 3-115 Mowing bucket

Danger ! not

Fig. 3-116 Mowing bucket activation Activating the mowing bucket : 9q

Note!

S19

Fig. 3-117 S19

MJFCIFSS

3 - 129

3.7 Attaching and dismounting equipment parts Attaching and removing equipment parts safely

Removing and installing equipment bolts safely

3 - 130

MJFCIFSS

3.7.1

Attaching and dismounting the bucket

Fig. 3-118 Attaching and dismounting the bucket 1

25

2

25.1

3-4 5-6

25.2 25.3

7 222

25.4 25.5

232

MJFCIFSS

3 - 131

Dismounting a bucket

5 3

6 4

25 4

Attaching a new bucket

A 4

25

4

6 7 B

3

25

3

5 3

4

Description and installation of a pin bearing sealing Function description 25 1

2

7

25

3

4

25

25 25.2

25.1 25.2

25.2

25.4

25.1

Installation of a pin bearing sealing 25.4

3 - 132

MJFCIFSS

25 25.2

25.5

Note!

222

MJFCIFSS

232

3 - 133

3.7.2

Attaching and dismounting the bucket with improved sealing

Fig. 3-119 Attaching and dismounting the bucket 1

7

2 1.1

8 9

2.1 3-4

222 232

5-6

3 - 134

MJFCIFSS

Dismounting a bucket

5

6 8

9

1.1 3

4 4 9

Attaching a new bucket 1 9

1.1 7

A 4

6 7 B

3 2.1

5 9 D

1.1 8 3

4

Note!

222

MJFCIFSS

232

3 - 135

3.7.3

Attaching and dismounting the grab on stick

Fig. 3-120 Attaching and dismounting the grab on the stick 1

11

4

12

6

13

7

14

8

15

9

25

10

3 - 136

MJFCIFSS

Danger!

Attaching the grab

7

9

8

10

1 4 4

25 6 11

12 13

14

Operating the grab

15 A B 15

B

B

Note

15 4

MJFCIFSS

3 - 137

Dismounting the grab

15

A

11

12

A

13

14

6

3 - 138

MJFCIFSS

4

25 4

3.7.4

Attaching and dismounting the grab on stick

Fig. 3-121 Attaching and dismounting the grab on the stick 1

11

4

12

6 7

13 14

8 9

15 25

10

MJFCIFSS

3 - 139

Danger!

Attaching the grab

7

9

8

10

1 4

4

25

6 11

12 13

14

Operating the grab

15 A B 15

B

B

Note LIKUFIX 15 4

Dismounting the grab

3 - 140

MJFCIFSS

15

A

11

12

A

13

14

6

MJFCIFSS

4

25 4

3 - 141

3.7.5

Attaching and dismounting the grab on the industrial stanchion

Fig. 3-122 Attaching and dismounting the grab on the industrial stanchion

Danger!

Attaching the grab

1 4

3 - 142

MJFCIFSS

6

11

12 13

14

Operating the grab

Dismounting the grab

11

12

13

14

6

4

MJFCIFSS

3 - 143

3.7.6

Attaching and dismounting the stick to the boom

Fig. 3-123 Attaching and dismounting the stick to the boom 7 16

20 21

17 18

222

Dismounting the stick Figure A

7

3 - 144

MJFCIFSS

16 17 16

17

Figure B then

17 in the rear bearing of the stick and secure it with the plate, 17 18 21

18 20

20

Attaching the stick (or stick with bucket) Figure B then

17 in the rear bearing of the stick and secure it with the plate, 17 18

20 20 and

20

17 21

18

Figure A 16

17

MJFCIFSS

3 - 145

Note 222

3.7.7

Mechanical quick-change adapter (optional extra) Safety information

Overview

Fig. 3-124

3 - 146

1

3

5

2

4

6

MJFCIFSS

Attaching the work tool To move the equipment into position:

Fig. 3-125 Positioning the equipment

To unlock the quick-change adapter: Danger!

2

3 3

1 1

1 Taking up the work tool:

Fig. 3-126 Taking up the work tool

MJFCIFSS

3 - 147

To lock the quick-change adapter:

Fig. 3-127 Locking the quick-change adapter Danger!

3

1

1 2 Danger!

4 2 2

Caution!

3 - 148

MJFCIFSS

Detaching a work tool To move the equipment into position: Caution!

To unlock the quick-change adapter:

Fig. 3-128 Unlocking the quick-change adapter Danger!

2

3 3

1 1

1 To put down the work tool:

Fig. 3-129 Putting down the work tool

MJFCIFSS

3 - 149

Using the quick-change adapter for hoisting work

Fig. 3-130 Mechanical quick-change adapter

Danger!

6

3.7.8

Hydraulic quick-change adapter (optional extra) Safety information

3 - 150

MJFCIFSS

Overview

Fig. 3-131 Hydraulic quick-change adapter 1

5

MJFCIFSS

6

3 - 151

Operating elements

Fig. 3-132 Operating elements for the hydraulic quick-change adapter

Switch S19 S19

Key switch S47

Pushbuttons L and R L R

Fig. 3-133 Pushbutton on the joystick E

3 - 152

F

MJFCIFSS

Symbol "Quick change adapter"

Two-hand operation S47

L

R

L

R

S47 S47

L

R

Caution !

S47

Attaching the work tool To move the equipment into position:

Fig. 3-134 Positioning the equipment

To unlock the quick-change adapter: S19

S47 R

MJFCIFSS

3 - 153

Taking up the work tool:

Fig. 3-135 Taking up the work tool

To lock the quick-change adapter: S19

S47 L

S47 S19

Caution!

3 - 154

MJFCIFSS

Danger!

Detaching a work tool To move the equipment into position: Caution!

To unlock the quick-change adapter: Danger!

S19

S47 R

MJFCIFSS

3 - 155

To put down the work tool:

Fig. 3-136 Putting down the work tool

Using the quick-change adapter for lifting work

Fig. 3-137 Hydraulic quick-change adapter

Danger!

6

S19 S47

3 - 156

MJFCIFSS

To cancel the buzzer (warning tone)

S349

3.7.9

LIKUFIX – hydraulic coupling system (optional extra)

Overview

Fig. 3-138 LIKUFIX 1

4

2

5

3

MJFCIFSS

3 - 157

Attaching and dismounting work tools

Fig. 3-139 Connecting LIKUFIX

1 2 3

1

3 - 158

2

MJFCIFSS

4

Attaching LIKUFIX work tools to a quick-change adapter without LIKUFIX

Fig. 3-140 LIKUFIX work tool on quick-change adapter without LIKUFIX Caution!

6

4 5

MJFCIFSS

3 - 159

3.7.10

Control of the swivel rotator (option) Rotation, swivel, locking and unlocking of the swivel rotator :

Fig. 3-141 Swivel rotator

Fig. 3-142 Push buttons on maniopulators 3 and 4 S19

Swivel the rotator : S5L S5R

Turn the rotator : S6R S6R S5L

3 - 160

MJFCIFSS

S5R

Remarque !

3.8 General working methods 3.8.1

Minimum impact working methods for your machine

3.8.2

Preparatory activities Danger!

MJFCIFSS

3 - 161

Fig. 3-143 Working position – machine

Danger! not

Fig. 3-144 Safe working Danger! r

Caution!

3 - 162

MJFCIFSS

3.8.3

Using a backhoe bucket Danger!

Fig. 3-145 Aligning the stick and backhoe bucket

Fig. 3-146 Taking up grab material

Fig. 3-147 Raising grab material

MJFCIFSS

3 - 163

3.8.4

Loading a transport vehicle Danger!

Fig. 3-148 Emptying grab material

3.8.5

3 - 164

Skimming

MJFCIFSS

Fig. 3-149 Skimming

Danger!

Caution!

3.8.6

Using a clamshell bucket (earthmoving attachment) Danger!

MJFCIFSS

3 - 165

Fig. 3-150 Straightening the stick

Fig. 3-151 Closing the grab shells

Danger!

Fig. 3-152 Raising grab material

3 - 166

MJFCIFSS

Fig. 3-153 Emptying grab material

3.8.7

Using a multiple tine grapple (industrial attachment)

Fig. 3-154 Taking up the load

MJFCIFSS

3 - 167

Fig. 3-155 Transporting a load

Caution!

3.8.8

3 - 168

Using an hydraulic hammer

MJFCIFSS

Danger!

Fig. 3-156 Hydraulic hammer

MJFCIFSS

3 - 169

Fig. 3-157 Permissible A and not permissible B work areas of the machine with hydraulic hammer Danger!

A

Note!

3.8.9

Working with large and heavy attachments.

Fig. 3-158 Permitted working range for large attachments 1

3 - 170

2

MJFCIFSS

3

4

5

Caution !

3.9 Adjustment of undercarriage width (option) 3.9.1

Hydraulic adjustment of undercarriage width

Preparation for the track gauge adjustment

Caution!

Moving the side frames in and out

MJFCIFSS

3 - 171

Fig. 3-159 Hydraulic adjustment of the tracks width

Fig. 3-160 Moving the side frames in and out

Caution!

3.10 Transport Transporting the machine safely

3 - 172

MJFCIFSS

3.10.1

Transporting the machine on a low loader Hinweis

Preparatory activities

Fig. 3-161 Loading ramp W

MJFCIFSS

3 - 173

Loading the machine onto the low loader To drive the machine up onto the low loader:

Fig. 3-162 Driving up onto the low loader 1

2 1

Danger!

Note

Fig. 3-163 Transport position - machine

3 - 174

MJFCIFSS

To secure the machine:

Fig. 3-164 To secure the machine

Fig. 3-165 To secure the machine with stowage ears (option) Danger!

Transport route Danger!

MJFCIFSS

3 - 175

3.10.2

Loading the machine with a crane

Danger!

Loading a machine with a gooseneck boom:

Fig. 3-166 Suspending the machine with gooseneck boom

Danger!

F1 (daN)

3 - 176

MJFCIFSS

F2 (daN)

Danger!

MJFCIFSS

3 - 177

3 - 178

MJFCIFSS

4 Malfunctions Warning messages and fault messages:

Identifying and rectifying faults and errors:

For each fault, therefore, read the relevant chapter in the operating instructions carefully once more.

Fig. 4-1

LIEBHERR service

If the cause of the fault cannot be recognised or rectified using the error codes and fault charts, please consult LIEBHERR customer service.

4.1 Error code charts Danger!

4.1.1 Error code

Effect

Machine Control system (BST) Cause

Measure / remedy

S71

S72

S71

S72

Y50

Y50

4-2

MJFCIFSS

Error code

Effect

4.1.2 Error code

Effect

Cause

Measure / remedy

Engine control system (PLD-CR) Cause

Measure / remedy

S71

S72

S71

S72

Y50

Y50

MJFCIFSS

4-3

Error code

Effect

Cause

Measure / remedy

S71

S72

S71

S72

S71

S72

Y50

Y50

Y50

4-4

MJFCIFSS

Error code

Effect

Cause

MJFCIFSS

Measure / remedy

4-5

Error code

Effect

4.1.3 Error code

Cause

Measure / remedy

Keypad

Effect

Cause

Measure / remedy

S71 S72 Y50

S73

S71 S72 Y50

4.1.4 Error code

4-6

Effect

Display Cause

MJFCIFSS

Measure / remedy

4.1.5 Error code

Coding error

Effect

Cause

Measure / remedy S71 S72 Y50

4.1.6 Error code

Effect

Other errors Cause

Measure / remedy S20

S20

4.1.7

Error code

Effect

Error due to warning symbols in SY field

Cause

MJFCIFSS

Measure / remedy

4-7

Error code

Effect

Cause

Measure / remedy -

4-8

MJFCIFSS

Error code

Effect

Cause

Measure / remedy

4.2 Faults and remedies 4.2.1 Fault / error

Diesel engine and fuel system Cause

MJFCIFSS

Solution

4-9

Fault / error

Cause

Solution

Note!

4.2.2 Fault / error

Hydraulic system Cause

Note!

4 - 10

MJFCIFSS

Solution

Fault / error

Cause

4.2.3 Fault / error

Fault / error

Transmission Cause

4.2.4

Solution

Solution

Electrical system Cause

MJFCIFSS

Solution

4 - 11

Fault / error

Cause

4.2.5 Fault / error

Fault / error

4 - 12

Work equipment Cause

4.2.6

Solution

Solution

Heating/air-conditioning system Cause

MJFCIFSS

Solution

Fault / error

Cause

Solution

Error code “F0“ faulty room temperature gauge:

Cause of gauge error:

Error code “F1“ faulty blow-out temperature gauge:

Cause of gauge error:

MJFCIFSS

4 - 13

Error code “F2“ faulty reserve temperature gauge:

Cause of gauge error:

Error code “F3“ faulty vent flap foot room area and front window:

Cause of flap fault:

Error code “F4“ pressure fault and faulty magnetic coupling:

Cause of flap fault:

4 - 14

MJFCIFSS

Error code “F5“ faulty data transmission operating feature / control unit:

Cause of the fault:

4.2.7

LIEBHERR particles filter system

LCD display message

LED

Cause

Remedy

"Themo element 1 (or 2) is defective"

E

"ERROR idling / Temp. ignition block active"

E

"Error interrupt. Terminal W"

E

"Pre-loading pressure achieved"

"Main load pressure achieved."

E

"Filter breakage or pressure line clogged"

E

"Call service"

E

MJFCIFSS

4 - 15

4.3 Fuses and relays 4.3.1

Fuse box E50

Fig. 4-2

Fuse box E50

F19

4 - 16

MJFCIFSS

F20 F22 F31 F33 F34 F35 F36 F36-2 F37 F109 F110 F115 F116 F117 F122 F133 F253 K10-1 K56 K66-1 K66-2 K127 K128 K288 K302 K359 K415

4.3.2

A1010 Plate

Danger

MJFCIFSS

4 - 17

Fig. 4-3

Fuses and relays, A1010 plate Fuses on terminal 15 (Kl15)

F1 F2 F3 F4

F5 F6 F7 F8 F9 Fuses on terminal 30 (Kl30) F10 F11

4 - 18

MJFCIFSS

F12 F13 F14 F15 Relays on printplate A1010 K5 K6 K7 K8 K9

MJFCIFSS

4 - 19

4 - 20

MJFCIFSS

5 Maintenance 5.1 Servicing the machine safely General safety instructions

Cleaning

Crack testing

5-2

MJFCIFSS

Welding, drilling, firing and grinding work

Process materials

MJFCIFSS

5-3

Repair work

Electrical system

5-4

MJFCIFSS

Hydraulic accumulator

Hydraulic hoses and sheathed cables.

MJFCIFSS

5-5

5-6

MJFCIFSS

5.2 Maintenance access doors 5.2.1

Overview of access doors

Fig. 5-1

Access doors on the machine

10

70

30

90.

50

110

60

145

MJFCIFSS

5-7

Caution!

Access door

Lock

Tab. 5-1 Tab. 5-2

5.2.2

Door lock

Fig. 5-2

5-8

Access doors

Door lock

MJFCIFSS

Access to:

5.2.3

Engine hood lock 17

Caution!

145

5.3 Lubricants and operating fluids 5.3.1

General information on changing lubricants and operating fluids Note

Note!

Note!

MJFCIFSS

5-9

Danger!

0

5 - 10

MJFCIFSS

5.3.2

Lubrication chart

Fig. 5-3

Lubrication chart - R 924 C-Litronic

MJFCIFSS

5 - 11

Symbol

Tab. 5-3

5 - 12

Lubrication chart key

MJFCIFSS

Display

5.3.3 Designation

Lubricant chart

Medium

Tab. 5-4

Symbol

Classification

Viscosity

Quantities* Liter / (USgal)

Lubricant chart

MJFCIFSS

5 - 13

5.3.4 Designation

Operating material chart Medium

Tab. 5-5

Symbol

Quantities* Liter / (USgal)

Operating material chart

5.4 Lubricants and operating fluids specification 5.4.1

Diesel fuel Specifications

Sulphur content of diesel fuel

5 - 14

MJFCIFSS

Note!

ASTM D 975 fuels must have a cetane number of minimum 45

Diesel fuels for operation at low temperatures (winter)

Caution!

Diesel fuels with the LIEBHERR Particles filter Caution!

5.4.2

Lubricating oil for the Diesel engine

Classification

MJFCIFSS

Specification

5 - 15

Classification

Tab. 5-6

Specification

Lubricating oil for the Diesel engine - specifications

Caution !

Viscosity

Fig. 5-4

Temperature-based selection of the SAE class

Liebherr Motoroil 10W-40 Liebherr Motoroil 10W-40 low ash

Liebherr Motoroil 5W-30

Lubricating oil change intervals

5 - 16

MJFCIFSS

adverse factors

Operating conditions

Tab. 5-7

5.4.3

Oil change interval dependent on oil quality:

Oil change intervals for the Diesel engine

Coolant for the diesel engine

General recommandations

Note!

MJFCIFSS

5 - 17

Water quality

Do not use sea water, brackish water, brine or industrial wastewater.

Contents

Tab. 5-8

Quantity

Fresh water quality

Fresh water quality when using coolant with DCA 4 Contents

Tab. 5-9

Quantity

Fresh water quality with use of DCA 4

Mixting ratio for coolant all times of the year Outside temperature up to

Mixing ratio

°C

Water %

°F

A%

Tab. 5-10 Mixture ratio (for all seasons)

Fig. 5-5

5 - 18

Temperature-based mixing ratio of water + corrosion inhibitor and antifreeze agent

MJFCIFSS

A

Permitted corrosion inhibitors / antifreeze agent Note!

Product description

MJFCIFSS

Manufacturer

Country

5 - 19

Permitted premixed coolants Note!

Product description

Manufacturer

Checking and replacing the coolant Note!

5 - 20

MJFCIFSS

Country

Fig. 5-6

Select the anti-freeze concentration level

Determining the top-up quantity - example -15 °C:

3

Correct the mixing ratio

Permitted corrosion inhibitors without antifreeze agent exceptional circumstances freezing

at temperatures which are continually above no anti-corrosion / anti-

MJFCIFSS

5 - 21

freeze fluid available coolant

water and water soluble anti-corrosion fluid

Chart of approved water soluble anti-corrosion fluids Product description

Manufacturer

Country

Note!

Using DCA 4 without anti-corrosion / anti-freeze fluid

Note! annually 0.6

1.06

Using other water soluble anti-corrosion fluids

Note! annually 7.5 %

5 - 22

MJFCIFSS

92.5 %

Use a refractometer to check the mixing ratio

Fig. 5-7

Refractometer Gefo 2710

Refractometer:

Measurement procedure:

Conversion diagram: Note!

y

x

Fig. 5-8

Conversion diagram

x y

MJFCIFSS

5 - 23

5.4.4

Hydraulic liquids

Hydraulic oil

Fig. 5-9

Hydraulic oil for use as hydraulic oil (ISO classes)*.

A B C

Engine oil

Single-grade oils (1): Multigrade oils (2):

Tab. 5-11 Engine oils for use as hydraulic oil

5 - 24

MJFCIFSS

Fig. 5-10

Engine oils for use as hydraulic oil (SAE classes)*

A

1

B C

2

Warm-up instruction B C B 1.

2.

1

Biodegradable hydraulic oils Note!

Liebherr Hydraulic Plus

Liebherr Hydraulic Plus Arctic

MJFCIFSS

5 - 25

Fully saturated synthetic ester-based oils, HEES

Monitoring, filter change and oil change Note!

Biodegradable hydraulic oils

mineral oils .

Symbol

Signification

Tab. 5-12 Key to figures

Hydraulic oil in normal use

Fig. 5-11

5 - 26

Oil sampling and filters change in normal use

MJFCIFSS

Hydraulic oil used in dust intensive applications

Fig. 5-12

Taking oil samples and changing return filters in heavy dust environments

Instructions for the reduction of the contamination of the hydraulic oil in machines used for dust intensive applications

MJFCIFSS

5 - 27

Note!

5.4.5

Lubricating grease and other lubricants Lubricant

Description / manufacturer KP2k

For use in central lubrication systems for the temperature range +60° C to -10° C Multi service grease RPL

if ambient temperatures are expected to remain under -10° C

Tab. 5-13 Grease and other process chemicals

5 - 28

MJFCIFSS

5.5 Diesel engine Danger !

5.5.1

Checking the oil level in the diesel engine Danger !

Fig. 5-13

Oil level markings on the dipstick min

MJFCIFSS

max

5 - 29

5.5.2

Changing the diesel engine oil Note !

Fig. 5-14

Drain valve on the oil sump, oil filter cartridges, oil filler cap

To drain the oil (A): 1

To change the oil filter cartridges (B):

Danger !

by hand

5 - 30

MJFCIFSS

To add the oil (C):

5.5.3

Belt for the A/C compressor and alternator installation

Fig. 5-15

Replacing the belt

To replace the belt:

MJFCIFSS

5 - 31

5.5.4

Lubricating starter ring gear

Fig. 5-16

Starte ring gear

1 2

3 4

5

Note!

3

1 4 4 2

5 4 1

5 - 32

MJFCIFSS

5.5.5

Vibration damper

Fig. 5-17

5.5.6

Vibration damper

Checking mounting screws

Fig. 5-18

Checking mounting screws

2 3 7

MJFCIFSS

5 - 33

5.5.7

Oil separator

Fig. 5-19

5 - 34

Replacing the oil separator

MJFCIFSS

To replace the oil separator filter element:

5.5.8

Heater flange

Fig. 5-20

5.5.9

Heater flange

Checking and adjustment of valve clearance Preparation

Note !

MJFCIFSS

5 - 35

Fig. 5-21

Valves location

Valves - cylinder for engine D934

Valves - cylinder for engine D936

Checking and adjustment of valve clearance

Fig. 5-22

Clearance value for intake valves on the engine type identification plate.

1 4

5 - 36

MJFCIFSS

3

2

Fig. 5-23

Check and adjust intake valve clearance - cold

Fig. 5-24

Check and adjust exhaust valve clearance of 0,40 mm - cold

2

3

MJFCIFSS

4

F

5 - 37

5.6 LIEBHERR particles filter (In option)

Fig. 5-25

5.6.1

Water separator

Drain the condensation water: 203 203

5.6.2

Water separator maintenance: 201 105 Notice!

103

5 - 38

MJFCIFSS

101 to 104 130 101 to 104 105 201

202

5.7 Cooling system 5.7.1

Checking and cleaning the cooling system

Fig. 5-26

Cooling system

90

MJFCIFSS

5 - 39

5.7.2

Checking the coolant level Danger!

5.7.3

Coolant antifreeze and anti-corrosion fluid

5.7.4

Changing the coolant Danger!

1

5 - 40

MJFCIFSS

Note!

Fig. 5-27

Shutoff valves for the heating circuit

MJFCIFSS

5 - 41

Draining the coolant

Fig. 5-28

Draining the coolant

9a

9c

9b

Fig. 5-29

Draining the engine

2

5 - 42

MJFCIFSS

Shutoff valves for the heating circuit must be closed.

To drain the coolant at the cooler: 90

9a

To drain the coolant at the diesel engine: 2

Refilling the coolant and bleeding the coolant circuit Shutoff valves for the heating circuit must be closed.

9a 2 90

90

Caution!

MJFCIFSS

5 - 43

5.7.5

Reversible fan drive (option).

Fig. 5-30

Reversible fan drive Reversible fan drive

S160

H90

S160

H90 S160

S160 H90

Danger !

5 - 44

MJFCIFSS

5.8 Fuel system Danger!

5.8.1

Refuelling Fuel filler cap

Fig. 5-31

Fuel filler cap 15 20

MJFCIFSS

5 - 45

5.8.2

Electrical refuelling pump (optional extra)

Fig. 5-32

Electrical refuelling pump

1

15

2 3

S25 S59

3 Proceed as follows when refuelling and stowing the hoses : 15 1 2

B

S25

S59 Caution!

2

A 1 1

5 - 46

MJFCIFSS

15

5.8.3

Draining the fuel tank

Fig. 5-33

Draining the fuel tank

15

20

36

To drain the fuel tank and the fuel system daily:

36

36

Note!

P3 P3.1

MJFCIFSS

5 - 47

5.8.4

Emptying and cleaning the fuel tank 36

36

15

36

20 20

5.8.5

Draining the fuel prefilter

Fig. 5-34

Fuel filter cartridges

3

5

11

The water separator of the fuel pre-filter must be drained each time the symbol E528 appears in the display:

5

5 - 48

MJFCIFSS

3

5.8.6

Changing fuel filter cartridges Danger !

Changing the fuel pre-filter

Fig. 5-35

Changing the fuel pre-filter

1 3

2 4

5

6

7

8

9

10 3

6

5

3 4

3

4 9 3 9

MJFCIFSS

5 - 49

4 5 1

10

3 3

10

1 3 6

Changing the fuel fine filter

Fig. 5-36

Changing the fuel fine filter

11

12 11 11 11 11

12

11

Warning

11

5 - 50

MJFCIFSS

12

11

5.8.7

Bleeding the fuel system

Bleeding the low pressure fuel system

Fig. 5-37

Bleeding the low pressure fuel system

2

14

6

15

13

16

To bleed the fuel pre-filter 6 2 6 2

MJFCIFSS

5 - 51

To bleed the fuel fine filter 13 2 13 2 To bleed the fuel canal on the crankcase 14 2 14 2

Bleeding the high pressure fuel system

A) Since the software version 36 of the engine control unit

Notice!

Notice!

5 - 52

MJFCIFSS

B) up to the software version 35 of the engine control unit 15

16

Fig. 5-38

Bleeding the injection lines

2

16

15

17

Notice !

2 15

16

17

2

MJFCIFSS

5 - 53

Notice !

5.9 Dry air filter

Fig. 5-39

Dry air filter

3

5 - 54

MJFCIFSS

4

Fig. 5-40

Vacuum gauge, dust discharge valve, engine intake pipe

9

20

10

21

11

22 9 10

11

5.9.1

Changing the main element Caution!

MJFCIFSS

5 - 55

Fig. 5-41

Changing the filter cartridges

1

3

2

4 1 3

2

5.9.2

1

Changing the safety element Note!

3 4

Caution!

5 - 56

MJFCIFSS

4 3 2

5.9.3

1

Monitoring the filtered air line 20 21

5.9.4

22

Spark catcher (option)

Fig. 5-42

Pare-étincelles avec bouchon de vidange C

A B

Note !

MJFCIFSS

5 - 57

5.10 Hydraulic system

Note!

5.10.1

Depressurizing the hydraulic system

Danger!

To depressurize the high pressure system

To depressurize the servo oil system

5 - 58

MJFCIFSS

Fig. 5-43

Depressurizing the hydraulic system

To depressurize the hydraulic tank 1

maximum

1

2

Note!

2

Danger!

MJFCIFSS

5 - 59

5.10.2

Checking the oil level, emptying and refilling the hydraulic tank Machine position

Fig. 5-44

Machine position for checking the oil level of the hydraulic system

Checking the oil level in the hydraulic tank

Fig. 5-45

Hydraulic tank oil level

MAXI

5 - 60

MJFCIFSS

MINI MINI

Emptying and refilling the hydraulic tank

Fig. 5-46

Draining and refilling the hydraulic oil

1 2

6

3

7 R

To drain the oil:

1 2 5

MJFCIFSS

5 - 61

6

To refill the hydraulic oil: 1 2 2 1 2 R

7

2 Caution!

To drain off condensate water

5

Note!

5 - 62

MJFCIFSS

6

5.10.3

Return-line filter

Fig. 5-47

Return-line filter

1 2

4 5

3 4 5 Note

To clean the magnetic rod and replace the filter element:

1

4

5

Caution!

8

MJFCIFSS

5 - 63

5 3

5.10.4

Leak oil filter

Fig. 5-48

Filtre de retour de fuite

1 2

5 6

3 4

7

36

Note!

To clean the filter: 1 3

5 - 64

MJFCIFSS

7

To install the new or cleaned filter element

7 3 1

5.10.5

Control oil filter 11

Fig. 5-49

1

Control oil unit

1

12

2 10

13 14

11

15

Note!

To replace the filter element:

14

11

12

14 14 13

1

15 12

14

MJFCIFSS

2 1/4

5 - 65

5.10.6

Control circuit

Danger!

10

5.10.7

Bleeding the hydraulic pumps

Fig. 5-50

Hydraulic pumps

T T T

5 - 66

MJFCIFSS

Fig. 5-51

Pompe d’entrainement du ventilateur

60

62

61 61a

62a

60

5.10.8

61a

61 61a

61

Removing the intake hose to the pumps

MJFCIFSS

5 - 67

Fig. 5-52

Shut off valve on the hydraulic tank

27

29

28

a b

b 27

27 a

5.10.9

5 - 68

Bleeding the hydraulic cylinders

MJFCIFSS

Fig. 5-53

Hydraulic cylinder

2

3 2

Procedure 1 2 3

3 2

Procedure 2

Danger!

MJFCIFSS

5 - 69

5.10.10

Replacement of the vent filter on the hydraulic tank

Fig. 5-54

Hydraulic tank vent filter

1

2

Note!

2

5.10.11

Bypass oil filter for hydraulic system (Special equipment)

Note!

5 - 70

MJFCIFSS

Fig. 5-55

Bypass oil filter for hydraulic system

1

2

3

4

1

Checking filter contamination:

Replacing filter element:

2 4

4 3,

MJFCIFSS

2

5 - 71

5.10.12

Return oil filter for hydraulic hammer (option)

Fig. 5-56

Return oil filter for hydraulic hammer

1 2

3 4

5 6

5

Replacement of the filter cartridge

1

2 4

3

4 3

2 6

1

5 - 72

MJFCIFSS

5.10.13

Servicing the hydraulic cylinder Checking the condition of the piston rod mount

Fig. 5-57

Piston rod mount

Note

Protecting the piston rods

Fig. 5-58

Machine with piston rods drawn in

MJFCIFSS

5 - 73

5.10.14

Replacing hydraulic hoses

Fig. 5-59

High pressure hose with SAE fitting

Danger!

Size of screw 4

Torque value in Nm - Quality 10.9 Half flanges 5a

Flat flange 5b

Tab. 5-14 Tightening torques for SAE fittings - Quality 10.9 Size of screw 4

Torque value in Nm - Quality 8.8 Half flanges 5a

Tab. 5-15 Tightening torques for SAE fittings - Quality 8.8

5 - 74

MJFCIFSS

Conical flange 5c

Size of screw 4

Torque value in Nm - Quality 8.8 Half flanges 5a

Tab. 5-15 Tightening torques for SAE fittings - Quality 8.8

5.11 Oil changes on components 5.11.1

General information

MJFCIFSS

5 - 75

5.11.2

Slewing gear transmission – oil change

Fig. 5-60

Changing the oil on the slewing gear transmission

1

3

2

4 5

To drain the oil: 4 1 5 5 1 To add the oil: 3 2 4

5 - 76

MJFCIFSS

5.11.3

Splitterbox - Oil change

Fig. 5-61

Changing oil in splitterbox

5

6 7

Oil draining : 5 6

7

6 7 Oil fulling : 5 5 5

Check oil level :

5 5

5

MJFCIFSS

5 - 77

5.11.4

Travel gear oil change

Fig. 5-62

Travel gear - Oil level plugs 1 and oil drain plug 2

To drain the oil:

1 2

To add the oil: 2 1 1 Note!

5 - 78

MJFCIFSS

5.12 The track components

5.12.1

Checking the track components

Fig. 5-63

Track components setup

7 Track pads

Screws

Tightening torques (Nm) / screws quality 11.9

12.9

13.9

Tab. 5-16

MJFCIFSS

5 - 79

Fig. 5-64

Tightening the screws of the track pads 8 9 10

560 Nm 560 Nm 280 Nm

Note !

5.12.2

Monitoring the track chain tension

Fig. 5-65

Monitoring the track chain tension

1 A 15 to 20 mm

5 - 80

MJFCIFSS

5.12.3

Retensioning the track chain

Fig. 5-66

Track chain when insufficient (A) and correctly (B) tensioned

Fig. 5-67

Retensioning the chain - R904, R914, R924, R924 Compact

Fig. 5-68

Retensioning the chain - R916 / R926 6 2

1

5 3

2 4

MJFCIFSS

5 - 81

5.12.4

Releasing the track chain tension

Fig. 5-69

Releasing the track - Hands of from part 3.

Danger!

7

Danger!

3

7

5.12.5

Greaser extension replacement

7

5 - 82

MJFCIFSS

3 7

5.12.6

7

Cleaning the running carriage

Caution!

Fig. 5-70

Raising the machine

Caution!

MJFCIFSS

5 - 83

5.12.7

5 - 84

Undercarriage with adjustable track gauge (Typ VH-HD)

Fig. 5-71

Undercarriage with hydraulically adjustable track gauge

Fig. 5-72

CVC undercarriage type

Fig. 5-73

CVT undercarriage type

MJFCIFSS

Models

Types

Undercarria ge variant

Stud bolts for the setting of the clearance

CVC

Size

Tightening torque of stud bolts (Nm)

Tightening torque of counter nuts (Nm)

M24 - 10.9

960

960

M24 - 10.9

960

960

M24 - 10.9

960

960

M33 - 10.9

2600

2600

M33 - 10.9

2600

2600

M33 - 10.9

2600

2600

CVT

Possible track gauges (mm)

Adjusting the track gauge of the undercarriage Danger !

Operating organs in the operator’s cab for track width adjustment

Fig. 5-74

Push-button S104 - preselection of width adjustment

MJFCIFSS

5 - 85

Fig. 5-75

Retraction and extension of side frames

Caution !

Track width adjustment for CVC undercarriages

5 - 86

MJFCIFSS

Note !

Special recommendations - Track width adjustment on machine with demolition attachment Danger !

MJFCIFSS

5 - 87

Danger !

Modification of the tracks width

Fig. 5-76

Extension and retraction of the side frames

Caution !

Track width adjustment for CVT undercarriage

Note !

5 - 88

MJFCIFSS

Caution !

Fig. 5-77

CVT undercarriage - Position for width adjustment

Fig. 5-78

Removal of the mechanical locking pins

Note !

MJFCIFSS

5 - 89

Caution !

Fig. 5-79

Replacement of the locking pins

Caution !

Fig. 5-80

5 - 90

Storage of the unused shackles

MJFCIFSS

Lubrication of the undercarriage Lubrication of accessories on the undercarriage Quality of the grease to be employed

Caution !

MJFCIFSS

5 - 91

Lubrication of the connecting links of the track width adjustment Note !

Lubrication of the sliding parts of the CVC undercarriage

Fig. 5-81

5 - 92

Grease nipples location at CVC undercarriage

MJFCIFSS

Note !

Lubricating of the sliding parts of the CVT undercarriage

Fig. 5-82

Grease nipples location at CVT undercarriage

MJFCIFSS

5 - 93

Note !

Setting the slide clearance on the track width adjustment Note !

Setting the clearances on the CVC undercarriages Caution !

Hinweis !

1. Prior modification in the "Track gauge widened" position 1.1 Undercarriages with stop pins for track gauge limitation

Fig. 5-83

5 - 94

Undercarriage with stop pins for track gauge limitation

MJFCIFSS

Notice !

1.2 Undercarriages without stop pin for track gauge limitation (with arrows)

Fig. 5-84

Undercarriage with arrows to indicate track gauge limitation

2. Clearance adjustment

Fig. 5-85

Clearance adjustment at CVC undercarriages

MJFCIFSS

5 - 95

Setting the clearance on the CVT undercarriage

Setting the middle stud bolts

Fig. 5-86

Setting the middle stud bolts

Setting the side stud bolts

Fig. 5-87

5 - 96

Setting the side stud bolts

MJFCIFSS

5.13 Electrical system 5.13.1

Notes on the electrical system Danger!

Danger!

5.13.2

Main battery switch Caution!

MJFCIFSS

5 - 97

Fig. 5-88

Main battery switch 0

Note!

0

5.13.3

Battery care A

Danger!

B

5 - 98

MJFCIFSS

Fig. 5-89

Battery care C unit weight is 1.28 kg/l (31.5° Bé)

5.13.4

Slip ring assembly (optional extra)

Fig. 5-90

Slip ring assembly

1 2

1

MJFCIFSS

5 - 99

1

2

5.14 Heating/air-conditioning system

5.14.1

Recirculated and fresh air filters

Fig. 5-91

Recirculated air filter

Fig. 5-92

Fresh air filter

1

6 To clean and change the recirculated and fresh air filters: 1 2 1 4

5 - 100

MJFCIFSS

3

3 Note!

1

5.14.2

3

Heating system

Fig. 5-93

Heating unit with solenoid valve

To vent the heating system: A

To clean solenoid valve 5: 5

To check the heat exchanger: 6

MJFCIFSS

5 - 101

5.14.3

Air-conditioning system

Fig. 5-94

A/C compressor and capacitor

2

7

To check the capacitor: 2 2

To check the A/C compressor: 7

5 - 102

MJFCIFSS

Fig. 5-95

Dryer-accumulator unit

To check the dryer-accumulator unit: 10

9

Note!

11

9 12

9 9 9 9

9

Fig. 5-96

Fan motor on the heating/air-conditioning device

MJFCIFSS

5 - 103

Additional maintenance work:

13

14 B44

9

5.15 Greasing the machine 5.15.1

Centralized lubrication system

Construction and operation of the centralized lubrication system .

6 7, 8, 9, U4 13

Fig. 5-97

14

Centralized lubrication system

6

5 - 104

15

7

MJFCIFSS

8

13

14

15

U4

LP LP

Lube points connected to the central lubrication system:

Lube points which are not connected to the central lubrication system: Caution!

Notice!

MJFCIFSS

5 - 105

5.15.2

Semi automatic and full automatic systems

Fig. 5-98 Semi automatic system

Full automatic system 16

5.15.3

Operation of the semi automatic system S84

S84

Fig. 5-99

Centralized lubrication S84

5 - 106

MJFCIFSS

Note!

27.2

27

2

27.1

Lubrication intervals.

5.15.4

Operation of the full automatic system Function of the lubrication system S84 17

16

B51

2

MJFCIFSS

5 - 107

Fig. 5-100 Full automatic lubrication system 2 14

13 15

16 18

17 19

26 CD

B51 NS

S84

U4

B51 16

Starting an additional lubrication procedure S84 19

Monitoring of the automatic lubrication system 2 S84

17

B51

17

18

S84

26 B51

5 - 108

MJFCIFSS

13 14

Adjustments at the automatic system and grease consumption CD

NS

5.15.5

Emergency lubrication with defective lubrication system 15 25 25

Fig. 5-101 Emergency lubrication 15

25

MJFCIFSS

5 - 109

5.15.6

To refill a grease container 13

21 Note!

13

23 15 31 21 13

31 13

22

Fig. 5-102 Refilling the grease container

5 - 110

13

15

21

22

23

31

MJFCIFSS

5.15.7

Changes in the lubrication circuit

Fig. 5-103 Main and secondary distributor

5.15.8

Greasing the grab (optional extra)

Fig. 5-104 Greasing the grab

MJFCIFSS

5 - 111

5.16 Quick-change systems 5.16.1

Greasing the mechanical quick-change adapter (optional extra)

Fig. 5-105 Greasing the mechanical quick-change adapter

Note!

5 - 112

MJFCIFSS

5.16.2

Hydraulic quick-change adapter (optional extra) Greasing the quick-change adapter

Fig. 5-106 Greasing the quick-change adapter 1 Note!

Cleaning the sieve filter

Fig. 5-107 Cleaning the sieve filter 12

20

21 10 13 12

12

MJFCIFSS

11

5 - 113

13

20

5.16.3

21

LIKUFIX (optional extra) Cleaning LIKUFIX

Replacing the sealing ring

Fig. 5-108 Replacing the sealing ring A

B C

5 - 114

MJFCIFSS

D E F

5.16.4

Checking and maintenance of quick change coupler Functional check out of quick change coupler

Fig. 5-109 Functional check out of quick change coupler

Opening the quick change coupler :

S19 S47 S47

S5R

S47

MJFCIFSS

5 - 115

Closing the quick change coupler : S47 S5L

S19

Daily visual check out

Fig. 5-110 Functional check out of quick change adapter

A B C

5.17 Check mounting bolts for tightness

Caution!

Notice :

5 - 116

MJFCIFSS

5.17.1

Mounting bolts of the counterweight

Fig. 5-111 Counterweight mounting bolts 1

MJFCIFSS

5 - 117

5.17.2

Mounting screws of the swing ring

Fig. 5-112 Swing ring mounting bolts 3 4

5.17.3

Mounting screws of the hydraulic oil and fuel tank

Fig. 5-113 Hydraulic oil tank and fuel tank mounting bolts 5

5 - 118

MJFCIFSS

5.17.4

Mounting screws of the swing gear and motor

Fig. 5-114 Swing gear and swing motor mounting bolts 6 7

5.18 Drive unit brakes and swing gear brakes

5.19 General maintenance points 5.19.1

Replacing working parts

MJFCIFSS

5 - 119

5.19.2

Checking or replacing the teeth on the bucket Note!

To attach and dismount the teeth: Liebherr teeth system with flat locking wedge:

Fig. 5-115 Replacing the teeth 1

2 A

3

B

2 C

5 - 120

MJFCIFSS

(New) Liebherr teeth system with tooth locking bolt round: To remove an old tooth

1 3

2 4

5

10 5 3 10

3 A

3 2

1

4

To install a new tooth

Note!

3

4

4

1 2

1

3

MJFCIFSS

5 - 121

10 3 3a

4a 5 3

5.19.3

Welding work on the machine

Caution!

5.20 Control and maintenance chart Caution!

Note

5 - 122

MJFCIFSS

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 924 C Litronic By maintenance personnel (machine owner)

By authorized specialist personnel

Note

DIESEL ENGINE AND SPLITTERBOX

MJFCIFSS

5 - 123

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 924 C Litronic By maintenance personnel (machine owner)

By authorized specialist personnel

HYDRAULIC SYSTEM

5 - 124

MJFCIFSS

Note

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 924 C Litronic By maintenance personnel (machine owner)

By authorized specialist personnel

Note

ELECTRICAL SYSTEM

SWING GEAR TRANSMISSION

BALL SWING RING

TRAVEL GEAR

TRACKS

MJFCIFSS

5 - 125

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 924 C Litronic By maintenance personnel (machine owner)

By authorized specialist personnel

CAB + HEATING

AIR-CONDITIONING SYSTEM

5 - 126

MJFCIFSS

Note

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 924 C Litronic By maintenance personnel (machine owner)

By authorized specialist personnel

Note

UNDERCARRIAGE + UPPERCARRIAGE + ATTACHMENT

HYDRAULIC QUICK-CHANGE ADAPTER

MECHANICAL QUICK-CHANGE ADAPTER

Tab. 5-17 Control and maintenance chart 1 2

MJFCIFSS

5 - 127

3 4

5 - 128

MJFCIFSS