Liebherr R 926 Advanced 692 1026 1027 1346 Hydraulic Excavator Operating Manual SN 27692 - PDF

en

Operating manual

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

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

Address

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

4

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

MJFCIFSS

5

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

MJFCIFSS

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

6233

530 560

7000 7100

700 800

7300 7600

1400

9000

6010

9300

6020

9500

6232

9700

MJFCIFSS

1.1.4

Undercarriage

Fig. 1-5

Undercarriage

208

1000

400

4500

1.2 Vibration emissions

Hand-arm vibration

Whole-body vibration

MJFCIFSS

1-5

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

1.3 Sound emission

1-6

MJFCIFSS

1

2

z-axis 3

1

2

3

1.4 EC Declaration of Conformity

Fig. 1-6

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

1.5 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

Sight field

Crack testing

2 - 16

MJFCIFSS

Welding, drilling, firing and grinding work

Process materials

Repair work

MJFCIFSS

2 - 17

Electrical system

2 - 18

MJFCIFSS

Hydraulic accumulator

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

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

2

5

6

MJFCIFSS

3

2 - 29

2 - 30

MJFCIFSS

3 Control and operation 3.1 Operating and control elements 3.1.1

Controls in the operator’s cab

Fig. 3-1

Controls in the cab

3.1.2

1 3

A170 A171

4 5

A172 B500

6

B501

9

E8

87

H1

A168 A169

S1 S497

The joysticks Control of the working movements

Fig. 3-2

Joystick right (3) and left (4)

Standard control system according to ISO 4 4

a

b

4

c

d

3

e

f

3

g

h

3

Special control systems

3-2

MJFCIFSS

Note !

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

Joysticks in standard execution

Fig. 3-3

Tab. 3-1

Arrangement of push buttons and switches in the joysticks in standard execution Left joystick

Right joystick

S5L

S6L

S5M

S6M

S5R

S6R

Functions of push buttons and switches in standard execution

MJFCIFSS

3-3

Left joystick S55

Tab. 3-1

Right joystick S57

Functions of push buttons and switches in standard execution

Caution!

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

Left joystick

Right joystick

S5L

S6L

S5M

S6M

S5R

S6R

S55

Tab. 3-2

3-4

S57

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

MJFCIFSS

Joysticks with proportional function

Fig. 3-4

Arrangement of push buttons, switches and proportional cross in the joysticks with proportional function Left joystick

Right joystick

S5L

S6L

S5R

S6R

S55

S57

X(-)

X(-)

X(+)

X(+)

Y(-)

Y(-)

Y(+)

Y(+)

Tab. 3-3

Functions of the joysticks with proportional function

MJFCIFSS

3-5

Caution!

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

Left joystick

Right joystick

S5L

S6L

S5R

S6R

S55

X(-)

X(-)

X(+)

X(+)

Y(-)

Y(-)

Y(+)

Y(+)

Tab. 3-4

3-6

S57

Functions of the joysticks with proportional function for US version with lifting magnet

MJFCIFSS

3.1.3

Control unit

Fig. 3-5

Excavator control unit

M

MJFCIFSS

3-7

S181 – Normal start / stop of the diesel engine.

Warning! Only the ignition key must be used to stop the Diesel engine in safety mode!

3-8

S20

Engine low idle automatic

S10

Upper carriage lights

S21

Travel speed increase

MJFCIFSS

S17

Preselection of swing brake operating mode

S84

Non-scheduled lubrication

S86 – Working mode

E

ECO

P

POWER

S

SENSITIVE

S148 – Menu 1

S149 – Menu 2

MJFCIFSS

3-9

S90 – "Automatic air conditioning" mode

S91 – Temperature

3 - 10

MJFCIFSS

S92 – Blower

S93 – "Automatic heating" mode

S94 – Defrost mode

S95 – Recirculated air

MJFCIFSS

3 - 11

S46 – Lifting magnet operation (optional equipment)

S85 – Grapple priority when AHS

S19 – Rotating device / rotating grapple

S18 – Overload warning device (optional equipment)

3 - 12

MJFCIFSS

S41 – Rotating beacon (optional equipment)

S47 – Quick change adapter (optional equipment)

MJFCIFSS

3 - 13

3.1.4

Display unit

Fig. 3-6

3 - 14

Touch screen display

1

3

2

4

MJFCIFSS

3.1.5

Main screen

Fig. 3-7

Main screen

1 2

7 8

3 4

9 10

5

11

6

12

MJFCIFSS

3 - 15

E ECO P POWER S SENSITIVE

3.1.6

Main screen with numeric video control

Fig. 3-8

Main screen with numeric video control 1

3 - 16

MJFCIFSS

Fig. 3-9

3.1.7

Display of the camera picture on the whole screen

Status symbols

Servo-pressure control circuit not operative

Swing brake not operative

Diesel engine in safety mode

Overload warning device (optional equipment)

No overload warning device recognized

MJFCIFSS

3 - 17

Quick change adapter (optional equipment)

Quick change adapter (optional equipment)

Service due

Confirmation button

Confirmation button

Engine preheating activated

Emergency stop engaged

Automatic temporized engine stop

3 - 18

MJFCIFSS

3.1.8

Warning symbols

Coolant level low – Safety stage

Coolant overheat – Warning stage

Coolant overheat – Safety stage

Hydraulic oil level low – Safety stage

Hydraulic oil overheat – Warning stage

Hydraulic oil overheat – Safety stage

MJFCIFSS

3 - 19

Under voltage for the Diesel control system

Over voltage for the Diesel control system

Safety shut off for EDC default – Safety stage

Safety shut off for injector default – Safety stage

Safety shut off for startsynchronisation default – Safety stage

Overspeed of Diesel engine – Warning stage

Overspeed of Diesel engine – Safety stage

Defect of both engine RPM sensors – Safety stage

Low engine oil pressure – Warning stage

3 - 20

MJFCIFSS

Low engine oil pressure – Safety stage

Boost air overheat – Warning stage

Boost air overheat – Safety stage

Engine in safety mode

Fuel overheat – Warning stage

Fuel overheat – Safety stage

Fuel level low – Warning stage

Fuel level low – Safety stage

Water in the fuel filter – Warning stage

MJFCIFSS

3 - 21

Centralized symbol – Safety limit exceeded

ASO (ASynchrone Object) error – Safety stage

Error in version number and in software identification number

No grease in grease container

No washer fluid

3.1.9

Menu commands Touch buttons for display and operation

Fig. 3-10

3 - 22

Touch buttons for display and operation

1

5

2

6

3 4

7 8

MJFCIFSS

Heater/air conditioner

Note

Fig. 3-11

Heating/air conditioning mode display and control screen

1

8

2

9

3 4

10 11

5 6

12 13

7

14

Note

MJFCIFSS

3 - 23

Automatic mode touch button

Economic mode touch button

Defrost mode touch button

Recirculated air touch button

Temperature down touch button

Selected inflow temperature display (manual heating and air conditioning)

Selected inflow temperature display (automatic heating and air conditioning)

Temperature up touch button

Head level air distribution touch button

3 - 24

MJFCIFSS

Mid-level air distribution touch button

Footwell air distribution touch button

Increase blower speed touch button

Selected blower speed display

Reduce blower speed touch button

MJFCIFSS

3 - 25

Overview of units

Fig. 3-12

3 - 26

Overview of units display

1 2

6 7

3

8

4 5

9

MJFCIFSS

Settings

Fig. 3-13

Settings screen

1

5

2 3

6 7

4

MJFCIFSS

3 - 27

Clock setting

Fig. 3-14

3 - 28

Clock setting screen

1

4

2 3

5

MJFCIFSS

Time zone setting

Fig. 3-15

Time zone setting screen

1

3

2

MJFCIFSS

3 - 29

Reset daily hour meter

Fig. 3-16

3 - 30

Reset daily hour meter screen

MJFCIFSS

Language setting

Fig. 3-17

Language setting screen

1

2

MJFCIFSS

3 - 31

Setting of the working time in intermittent mode of the windshield wipers

Fig. 3-18

3 - 32

Screen - Setting of the working time in intermittent mode of the windshield wipers

1

4

2

5

3

6

MJFCIFSS

Test system

Fig. 3-19

Test system screen 1

MJFCIFSS

3 - 33

Functions

Fig. 3-20

Functions screen

1 2

5 6

3 4

7

Note

3 - 34

MJFCIFSS

Tools configuration

Fig. 3-21

Tools configuration screen

1

5

2

6

3

7

4

MJFCIFSS

3 - 35

LIEBHERR automatic lubrication system

Fig. 3-22

Central lubrication system screen

1

4

2

5

3

Note

3 - 36

MJFCIFSS

Engine bleeding function

Fig. 3-23

Engine bleeding button screen

Note

MJFCIFSS

3 - 37

Maintenance

Fig. 3-24

3 - 38

Maintenance screen

1

6

2 3

7 8

4

9

5

10

MJFCIFSS

Timing set of automatic low idling

Fig. 3-25

Timing set of automatic low idling screen

1

3

2

MJFCIFSS

3 - 39

Informations

Fig. 3-26

Informations screen

1

3

2

3 - 40

MJFCIFSS

Operating hours of the differents movements

Fig. 3-27

Display - operating hours of the differents movements

1

5

2

6

3

7

4

8

MJFCIFSS

3 - 41

Fuel consumption

Fig. 3-28

3 - 42

Fuel consumption

1

4

2

5

3

6

MJFCIFSS

Messages

Fig. 3-29

Display - messages (service codes)

1

3

2

4

MJFCIFSS

3 - 43

3.1.10

Secondary and options keyboards

Fig. 3-30

3 - 44

Secondary and options keyboards

MJFCIFSS

Secondary keyboard A169

Fig. 3-31

Secondary keyboard A169

M

S276 – Equipment headlights

S22 – Front roof headlight (optional extra)

S275 – Roof headlights, rear (optional extra)

MJFCIFSS

3 - 45

S11 – Front windshield wiper

S218 – Cab roof windshield wiper

3 - 46

MJFCIFSS

S362 – Rear windshield wiper

MJFCIFSS

3 - 47

Secondary keyboard A170

Fig. 3-32

Secondary keyboard A170

M

S114 – Commutation of the controls for an additional user AHS (special equipment)

S247

S104 – Hydraulic width adjustment of undercarriage

3 - 48

MJFCIFSS

S160 – Control of reversible fan in opposite direction (optional equipment)

S26 – Fuel preheater (optional extra)

S422 – Mute function (optional equipment)

MJFCIFSS

3 - 49

Options keyboard A171

Fig. 3-33

Options keyboard A171

M

S54 – Unlocking of boom cylinder movement limitation

3 - 50

MJFCIFSS

S524 – Unlocking of stanchion cylinder shut-down

S98 – Protection for boom cylinders (optional equipment)

Automatic protection

Manual protection

MJFCIFSS

3 - 51

S124 – Mowing bucket (optional equipment)

S57 S124

S168 – Oil flow limitation when operating a super long working attachment (optional equipment)

S354

3 - 52

MJFCIFSS

3.1.11

Display for LIEBHERR particle filter (optional).

A175

Fig. 3-34

Control unit A175

A

B

C E

D F

G

A175

Use / monitoring of the particle filter system

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

MJFCIFSS

3 - 53

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

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

Note:

3.2 Access and equipment of the cab Safely getting up

NOTE

3 - 54

MJFCIFSS

Safely getting down

3.2.1

Entering or leaving the cab Climbing up Caution!

Cab:

Fig. 3-35

Climb up using the handholds

MJFCIFSS

3 - 55

Getting in

Fig. 3-36

Door - exterior

1

2 11 2

Getting out Caution!

3 - 56

MJFCIFSS

11 1

Fig. 3-37

Door - interior

3

4

3 2

To release the door latch:

4

3.2.2

Safety lever

Fig. 3-38

Safety lever

MJFCIFSS

3 - 57

Caution !

S17 S17

3.2.3

Operator’s seat

Fig. 3-39

3 - 58

Air suspension seat

MJFCIFSS

1 2

8 9

3 4

10 11

5

12

6

13

7

14

Weight adjustment

Height adjustment

MJFCIFSS

3 - 59

Seat pan angle adjustment

Seat depth adjustment

Absorber

1 2 3

Armrest adjustment

3 - 60

MJFCIFSS

Armrests

Head rest * ***

Backrest adjustment

Lumbar support

MJFCIFSS

3 - 61

Lumbar support * **

Fore/aft isolator

1 2 1

3 - 62

MJFCIFSS

Fore/aft adjustment **

Swivel *

Seat heater

0 1

MJFCIFSS

3 - 63

Putting on / releasing the safety belt

Fig. 3-40

Safety belt

2

1 3

Danger!

4 1

Cleaning the operator’s seat

Attention!

Take care with the backrest - it may jerk forward and cause injury!

3 - 64

MJFCIFSS

3.2.4

Windscreen Lower part

Fig. 3-41

Windscreen lower part

1 2 2 1

MJFCIFSS

3 - 65

Upper part

Fig. 3-42

Windscrenn upper part

1 2

Caution!

Whole windscreen

3 - 66

MJFCIFSS

3.2.5

Sunshade

Fig. 3-43

Sunshades at windscreen and at cab roof

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

MJFCIFSS

3 - 67

3.2.6

Emergency exit – rear window

Using the emergency hammer Warning!

Fig. 3-44

Emergency hammer for emergency exit

Note

3 - 68

MJFCIFSS

3.2.7

Fire extinguisher*

Fig. 3-45

Location for fixing the fire extinguisher

Note!

Caution!

MJFCIFSS

3 - 69

3.2.8

Windscreen wiper Front windshield wiper S11

Cab roof windshield wiper S218

Rear windshield wiper S362

3 - 70

MJFCIFSS

Windscreen washing fluid container

Fig. 3-46

Windscreen washing fluid container

MJFCIFSS

3 - 71

3.2.9

Lighting

Fig. 3-47

Arrangement of lighting

1 2

4 5

3

6

Equipment headlights S276

Front roof headlight S22

3 - 72

MJFCIFSS

Rotating beacon (optional extras) S41

Roof headlights, rear S275

3.2.10

Heating and air conditioning system

Manual functioning

"Automatic air conditioning" mode

Temperature setting

Blower speed setting

MJFCIFSS

3 - 73

"Automatic heating" mode

"Automatic defrosting" mode

Automatic functioning

"Automatic air conditioning" mode

Temperature setting

Blower speed setting

3 - 74

MJFCIFSS

"Automatic heating" mode

"Automatic defrosting" mode

"Automatic air conditioning" mode

"Semi-automatic air conditioning" mode

MJFCIFSS

3 - 75

"Automatic heating" mode

"Semi-automatic heating" mode

"Automatic defrosting" mode

3 - 76

MJFCIFSS

Recapitulatory of the mode changes

Fig. 3-48

Recapitulatory of the mode changes

1

4

2

5

3

6

MJFCIFSS

3 - 77

3.2.11

Additional standstill heater (Option)

Operating the standstill heater Notice!

The control unit of the standstill heater

Functioning of the additional standstill heater

3 - 78

MJFCIFSS

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

MJFCIFSS

3 - 79

Stopping the machine safely

3.3.1

Starting / stopping the machine General information Note!

LIDEC DC 5-00

3 - 80

MJFCIFSS

Attention !

Activities before starting Caution!

Caution!

MJFCIFSS

3 - 81

Starting the diesel engine Ignition key switching positions

Fig. 3-49 0 1

Ignition switch 2 3

P

Switching on the electrical system

1 1

3 - 82

MJFCIFSS

3.3.2

Starting the Diesel engine Note!

Starting procedure S181 1

Note!

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

3.3.3

Speed adjustment and operating modes selection

MJFCIFSS

3 - 83

Fig. 3-50

Speed adjustment and operating modes

1

Fig. 3-51

2

Control knob B500 for setting of the Diesel engine speed

Engine speed adjustment using the control knob

3 - 84

MJFCIFSS

Engine speed and operating mode selection via the mode switch E

ECO

P

POWER

S

SENSITIVE

P+

S86

3.3.4

Notes after starting the engine Danger!

Caution!

MJFCIFSS

3 - 85

3.3.5

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

Note !

Hydraulic oil

3.3.6

Switching the Diesel engine off S181

0

Caution!

0

Diesel engine delayed stop (option) S181

0

Remarque!

3 - 86

MJFCIFSS

Caution!

0

Diesel engine emergency stop switch (Option)

Caution!

S2-1

Fig. 3-52

S34-2

Emergency off switches in the cab and on uppercarriage structure

Danger!

MJFCIFSS

3 - 87

3.3.7

indicatorStarting aids Fuel preheating S26 (optional extra)

S26

S26

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

Fig. 3-53

3 - 88

Coolant / motor oil / hydraulic oil preheating

1

5

2

6

3

7

4

8

MJFCIFSS

8 4 1 5 2 6 3 8

3.3.8

Jump start procedure Danger!

Connecting the batteries

Caution!

Disconnecting the batteries

MJFCIFSS

3 - 89

3.3.9

Immobilizer with electronic ignition key (option) System description

Activation of the immobilizer

Note!

Deactivation of the immobilizer

Note!

Master key and operation keys

Fig. 3-54

Ignition switch with immobilizer via electronic operation keys

5

3 - 90

6

MJFCIFSS

Imprinting procedure of an operation key

Note!

Deleting imprinted operating keys

Note!

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

Operation security

Function security

MJFCIFSS

3 - 91

3.3.10

Travel functions Straight travel

Fig. 3-55

Travelling straight ahead

1 2

5a / 5b 6a / 6b

1 2 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

Counter rotation with both tracks

Fig. 3-56

3 - 92

Counter rotation with both tracks

MJFCIFSS

6b

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

Turning over one track

Fig. 3-57

Turning with a crawler

Turning ahead to the left (A): 6a Turning ahead to the right (B): 5a Note!

MJFCIFSS

3 - 93

Manual control of the travelling movements

Fig. 3-58

Hand levers for manual travel control

1

2

Note!

Travel speed increase S21 Normal travel speed

Increased travel speed

S21

S21

3 - 94

MJFCIFSS

The travel brakes Hydraulic braking

Mechanical braking

Caution!

Limit of gradeability Danger!

Note!

MJFCIFSS

3 - 95

Travelling up

Fig. 3-59

Travelling up

Travelling down

Fig. 3-60

3 - 96

Travelling down

MJFCIFSS

3.3.11

Drive warning device (optional extra)

Fig. 3-61

Drive warning device 5

6

Deactivating the drive warning device: S6R

3

S5R

4

Caution!

S6R

Note!

MJFCIFSS

3 - 97

3.4 Operating the excavator in safety modes

Fig. 3-62

Central electrical plate - Switches S1 and S2 S1

3 - 98

MJFCIFSS

Notice !

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 (with the security lever tilted down), and the normal brake control is out of function

MJFCIFSS

3 - 99

3.5 Recovering, towing the machine Towing the machine safely

3.5.1

Pre-requisite

Notes !

3.5.2

Process preconisations.

Danger !

3 - 100

MJFCIFSS

Caution !

Caution !

Caution !

Caution !

Fig. 3-63

Towing equipment around the crown base.

MJFCIFSS

3 - 101

Danger !

3.5.3

Other preconisations.

Note !

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 - 102

MJFCIFSS

MJFCIFSS

3 - 103

Safe use with a hydraulic hammer

3 - 104

MJFCIFSS

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

Safe use of machines with tower elevation

MJFCIFSS

3 - 105

(Caution! swinging grab)

Protection from vibration

3 - 106

MJFCIFSS

3.6.1

Low idle automatic

S20

1

MJFCIFSS

2

3 - 107

Note !

S20

Caution!

S20

3.6.2

3 - 108

Automatic motorstop after low idle (option)

MJFCIFSS

3.6.3

The uppercarriage swing movements 4

Fig. 3-64

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

Caution!

MJFCIFSS

3 - 109

S17

Remarque !

Note!

S17

Caution!

4 4

Ermergency stop of the uppercarriage swing motion S17 Caution S17

To check the mechanical swing gear brake:

S17

3 - 110

MJFCIFSS

4

The positioning swing brake (option)

Fig. 3-65

Positioning swing brake pedal

Note!

10

MJFCIFSS

3 - 111

3.6.4

Working position

Fig. 3-66

Working position of the machine

Note!

3.6.5

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

Control of the stick cylinder 4

Fig. 3-67

3 - 112

Stick cylinder control

MJFCIFSS

4

(a) 4

(b)

Control of the boom cylinders 3

Fig. 3-68

Boom cylinders control 3

(g) 3

(h)

Control of the bucket or grapple cylinders 3

Fig. 3-69

Operation of the bucket or grapple cylinders 3 3

e f

Danger Never allow anybody to guide the grapple by hand!

MJFCIFSS

3 - 113

Combined movements

3.6.6

Lowering the working attachment with the engine shut down

Note

Fig. 3-70

Lowering the attachment with shut down engine 1

3 - 114

MJFCIFSS

3.6.7

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

Fig. 3-71

Add-on units example

S19

Danger!

Digital controls S5L

S5R S19

S5L

S19

Fig. 3-72

S5L

S5R S5R

Pushbuttons of the left joystick S19

S5L - or -

MJFCIFSS

3 - 115

- or S5R - or - or S19

Proportional controls (option) X(-)

X(+)

S19 S19

X(-)

X(+)

Fig. 3-73

Joystick left with proportional cross S19

X(-) - or - or -

3 - 116

MJFCIFSS

X(+) - or - or S19

3.6.8

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

Fig. 3-74

Swivel rotator

Fig. 3-75

Push buttons on maniopulators 3 and 4 S19

MJFCIFSS

3 - 117

Swivel the rotator : S5L S5R

Turn the rotator : S6R S6R S5L S5R

Remarque !

3.6.9

Lifting magnet control system (optional equipment)

S46

Fig. 3-76

Lifting magnet control system S46

B500

3 - 118

MJFCIFSS

S20 S6L

Danger!

S6L S6L

S6L

Caution!

S55 S6L S55 S55

Kit conversion S6L / S6M Warning !

S6M 3,

S6L

S6M

S6M

MJFCIFSS

3 - 119

3.6.10

3 - 120

Control of special equipments via the additional pedals

Fig. 3-77

Special equipments controlled by the additional pedals

Fig. 3-78

Disposition of the additional pedals

MJFCIFSS

Danger!

Control of the hydraulic hammer m

Fig. 3-79

Control of a hydraulic hammer

Note!

Control of a bottom dump shovel n p

Fig. 3-80

Control of the flap of a bottom dump shovel

MJFCIFSS

3 - 121

Control of the other special equipments

m

k

3 - 122

MJFCIFSS

3.6.11

AHS11 proportional control (in option)

X(-)

Fig. 3-81

X(+)

Proportional cross of the right joystick

Danger!

X(-)

X(+)

MJFCIFSS

3 - 123

3.6.12

AHS11 control commutation on bucket control (in option)

e

f

3 mk

S114

Fig. 3-82

A170

Commutation of the control for an AHS add on kit userl

Danger!

S114

Caution!

!

S114 A170 S114

3 - 124

MJFCIFSS

mk S114 mk

3.6.13

AHS11 proportional control commutation on bucket control (in option)

e

S114

MJFCIFSS

f

3

A170

3 - 125

Fig. 3-83

Commutation of the control for an AHS add on kit userl

Danger!

S114

Caution!

!

S114 A170 S114

S114

X(-)

3 - 126

MJFCIFSS

X(+)

3.6.14

Special control system of the joysticks

Fig. 3-84

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.

MJFCIFSS

3 - 127

Fig. 3-85

Instruction plate A and warning plate B

Caution!

3 - 128

MJFCIFSS

3.6.15

Option oil flow reduction for long working attachment.

S168

Fig. 3-86

Oil flow reduction for long working equipement S168

S168

3.6.16

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

MJFCIFSS

3 - 129

Danger!

The cylinder movement cut off 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 - 130

MJFCIFSS

Adjustment of the cut off point Prerequesite:

Fig. 3-87

Cut off position of an industrial stick

Setting Note !

B55 B55 closing proximity sensor

opening proximity sensor

MJFCIFSS

3 - 131

The position of the proximity switch is adjustable on a rail

Fig. 3-88

Example of a proximity switch whose position is adjustable

2

3 2

B55 B55

B55 2

Note !

Note !

Danger !

3 - 132

MJFCIFSS

B55

Note!

Unlocking of movements cut off

Fig. 3-89

Toggle switch S55 on the left joystick, touches S54 and S524, confirmation button S497

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.

Unlocking of the boom movement cut off S54 S497

MJFCIFSS

3 - 133

S55 S55

S54

Unlocking of the stick movement cut off S524 S497 S55 S55

S524

Note!

S55

3.6.17

S5L

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

3 - 134

MJFCIFSS

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.

Danger!

3.6.18

Overload warning device (Option) General

Note!

MJFCIFSS

3 - 135

Using the overload warning device Danger!

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!

3 - 136

MJFCIFSS

S18

S497

S497

3.6.19

Mowing bucket (option)

Fig. 3-90

Mowing bucket

Danger !

Activating the mowing bucket : S124

Operating the mowing bucket : S57 S124

MJFCIFSS

3 - 137

3.6.20

Float position of the boom (option)

Fig. 3-91

Push buttons S6L and S6M, classical right joystick 3 and touch S98 S98 S6M

S98

Note!

Danger!

3 - 138

MJFCIFSS

3

S6L

3.6.21

Preparation for swivel rotator (option) S224

Fig. 3-92

Switch S224

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

MJFCIFSS

3 - 139

Removing and installing equipment bolts safely

3 - 140

MJFCIFSS

3.7.1

Attaching and dismounting the bucket

Fig. 3-93

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 - 141

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 - 142

MJFCIFSS

25 25.2

25.5

Note!

222

MJFCIFSS

232

3 - 143

3.7.2

Attaching and dismounting the bucket with improved sealing

Fig. 3-94

Attaching and dismounting the bucket

1

7

2 1.1

8 9

2.1 3-4

222 232

5-6

3 - 144

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 - 145

3.7.3

Attaching and dismounting the grab on stick

Fig. 3-95

Attaching and dismounting the grab on the stick

1

11

4

12

6

13

7

14

8

15

9

25

10

3 - 146

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 - 147

Dismounting the grab

15

A

11

12

A

13

14

6

3 - 148

MJFCIFSS

4

25 4

3.7.4

Attaching and dismounting the grab on the industrial stanchion

Fig. 3-96

Attaching and dismounting the grab on the industrial stanchion

Danger!

Attaching the grab

1 4

MJFCIFSS

6

3 - 149

11

12 13

14

Operating the grab

Dismounting the grab

11

12

14

6

3 - 150

4

MJFCIFSS

13

3.7.5

Attaching and dismounting the stick to the boom

Fig. 3-97

Attaching and dismounting the stick to the boom

7 16

20 21

17 18

222

Dismounting the stick Figure A

7

MJFCIFSS

3 - 151

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

3 - 152

MJFCIFSS

Note 222

3.7.6

Mechanical quick-change adapter (optional extra) Safety information

Overview

Fig. 3-98 1

3

5

2

4

6

MJFCIFSS

3 - 153

Attaching the work tool To move the equipment into position:

Fig. 3-99

Positioning the equipment

To unlock the quick-change adapter: Danger!

2

3 3 1

Taking up the work tool:

Fig. 3-100 Taking up the work tool

3 - 154

MJFCIFSS

1 1

To lock the quick-change adapter:

Fig. 3-101 Locking the quick-change adapter Danger!

3

1

1 2 Danger!

4 2 2

Caution!

MJFCIFSS

3 - 155

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

To unlock the quick-change adapter:

Fig. 3-102 Unlocking the quick-change adapter Danger!

2

3 3

1 1

1 To put down the work tool:

Fig. 3-103 Putting down the work tool

3 - 156

MJFCIFSS

Using the quick-change adapter for hoisting work

Fig. 3-104 Mechanical quick-change adapter

Danger!

6

3.7.7

Hydraulic quick-change adapter (optional extra) Safety information

MJFCIFSS

3 - 157

Overview

Fig. 3-105 Hydraulic quick-change adapter 1

3 - 158

5

MJFCIFSS

6

Operating elements

Fig. 3-106 Operating elements for the hydraulic quick-change adapter

Touch S19 S19

Touch S47 S47

Pushbuttons L and R L

R

L R

MJFCIFSS

3 - 159

Fig. 3-107 Pushbutton on the joystick E

F

Warning symbol "Quick change adapter"

Safety symbol "Quick change adapter"

Two-hand operation S47

L

R

L

S47 S47

L

R

Caution !

S47

Attaching the work tool To move the equipment into position:

Fig. 3-108 Positioning the equipment

To unlock the quick-change adapter: S19

3 - 160

MJFCIFSS

R

S47

S497

S47

R

Taking up the work tool:

Fig. 3-109 Taking up the work tool

MJFCIFSS

3 - 161

To lock the quick-change adapter: L

S47

S19

Caution!

Danger!

3 - 162

MJFCIFSS

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

To unlock the quick-change adapter: Danger!

S19

S47

S497

S47

R

MJFCIFSS

3 - 163

S47

S19

To put down the work tool:

Fig. 3-110 Putting down the work tool

Using the quick-change adapter for lifting work

Fig. 3-111 Hydraulic quick-change adapter

3 - 164

MJFCIFSS

Danger!

6

S47

To cancel the buzzer (safety tone)

Double hydraulic quick-change adapter

1st quick-change adapter

MJFCIFSS

2nd quick-change adapter

3 - 165

3.7.8

LIKUFIX – hydraulic coupling system (optional extra)

Overview

Fig. 3-112 LIKUFIX 1

4

2

5

3

Attaching and dismounting work tools

Fig. 3-113 Connecting LIKUFIX

1

3 - 166

MJFCIFSS

2 3

1

4

2

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

Fig. 3-114 LIKUFIX work tool on quick-change adapter without LIKUFIX Caution!

6

4 5

MJFCIFSS

3 - 167

3.8 General working methods 3.8.1

Minimum impact working methods for your machine

3.8.2

Preparatory activities Danger!

Fig. 3-115 Working position – machine

3 - 168

MJFCIFSS

Danger! not

Fig. 3-116 Safe working Danger! r

Caution!

3.8.3

Using a backhoe bucket Danger!

MJFCIFSS

3 - 169

Fig. 3-117 Aligning the stick and backhoe bucket

Fig. 3-118 Taking up grab material

Fig. 3-119 Raising grab material

3 - 170

MJFCIFSS

3.8.4

Loading a transport vehicle Danger!

Fig. 3-120 Emptying grab material

3.8.5

Skimming

MJFCIFSS

3 - 171

Fig. 3-121 Skimming

Danger!

Caution!

3.8.6

Using a clamshell bucket (earthmoving attachment) Danger!

3 - 172

MJFCIFSS

Fig. 3-122 Straightening the stick

Fig. 3-123 Closing the grab shells

Danger!

MJFCIFSS

3 - 173

Fig. 3-124 Raising grab material

Fig. 3-125 Emptying grab material

3 - 174

MJFCIFSS

3.8.7

Using a multiple tine grapple (industrial attachment)

Fig. 3-126 Taking up the load

Fig. 3-127 Transporting a load

Caution!

MJFCIFSS

3 - 175

3.8.8

Using an hydraulic hammer

Danger!

Fig. 3-128 Hydraulic hammer

3 - 176

MJFCIFSS

Fig. 3-129 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. 3-130 Permitted working range for large attachments 1

2

MJFCIFSS

3 - 177

3

4

5

Caution !

3.9 Transport Transporting the machine safely

3 - 178

MJFCIFSS

3.9.1

Transporting the machine on a low loader Caution

Loading the machine onto the low loader Preparatory activities

Fig. 3-131 Loading ramp W

MJFCIFSS

3 - 179

To drive the machine up onto the low loader:

Fig. 3-132 Driving up onto the low loader 1

2 2

Danger!

Note

Fig. 3-133 Transport position - machine

3 - 180

MJFCIFSS

To secure the machine: Danger!

Fig. 3-134 To secure the machine equiped with four stowage ears

Ears nbr.

Angle

Angle

Note!

Note!

MJFCIFSS

3 - 181

40

Transport route Danger!

3.9.2

Loading the machine with a crane

Danger!

Loading a machine with a gooseneck boom:

Fig. 3-135 Suspending the machine with gooseneck boom

3 - 182

MJFCIFSS

Danger!

F1 (daN)

F2 (daN)

Danger!

MJFCIFSS

3 - 183

3 - 184

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 Faults and remedies 4.1.1 Fault / error

Diesel engine and fuel system Cause

MJFCIFSS

Solution

Fault / error

Cause

Note!

MJFCIFSS

Solution

4.1.2 Fault / error

Hydraulic system Cause

Solution

Note!

4.1.3 Fault / error

Transmission Cause

MJFCIFSS

Solution

Fault / error

Cause

4.1.4 Fault / error

Solution

Electrical system Cause

MJFCIFSS

Solution

4.1.5 Fault / error

Work equipment Cause

4.1.6 Défaillance / Erreur

Solution

Heating/air-conditioning system, fan Cause

Manual setting

MJFCIFSS

Remède

Fig. 4-2

Display in manual functioning

1

4.1.7

2

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

MJFCIFSS

LCD display message

LED

Cause

Remedy

"Filter breakage or pressure line clogged"

E

"Call service"

E

4.2 Fuses and relays 4.2.1

Electric box E50

Fig. 4-3

Electic box E50 location

MJFCIFSS

Fig. 4-4

Electric box E50

F1 F2 F3 F4 F5 F6 F7 F8

MJFCIFSS

F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 F30 F31 F32 F33 F34 F35 F36 F37 F44 F45 F46 F47 F48 F49 F110 K1A K1B K2A K2B K3 K4 K9A1 K9B1 K10-A

MJFCIFSS

K10-B K11 K12

4.2.2

Central plate A161

Danger

MJFCIFSS

Fig. 4-5

Resettable fuses and relays, central plate A161

MJFCIFSS

Resettable fuses on terminal 15 (Kl15) F6 F7 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F28 F29 Resettable fuses on terminal 30 (Kl30) F1_1 F1_2 F1_3 F2_1 F2_2 F2_3 F3_1 F3_2 F3_3 F4 F5 F7 F8 F9 F10 F11 F12 F28 F29 F30 F31 F32 F33 F34* F35 Resettable fuses on terminal 58 (Kl58) F23

MJFCIFSS

F24 F25 F26 F27 Relay on central electric plate A161 K01 K02 K03 K04 K05 K06* K07 K08 K09 K10 K11 K1_1 K1_2 K1_3 K2_1 K2_2 K2_3 K3_1 K3_2

MJFCIFSS

4.2.3

Main fuses

Fig. 4-6

Fuses in the fuel tank box

F156 F157

MJFCIFSS

MJFCIFSS

5 Maintenance 5.1 Servicing the machine safely General safety instructions

Cleaning

Sight field

5-2

MJFCIFSS

Crack testing

Welding, drilling, firing and grinding work

MJFCIFSS

5-3

Process materials

Repair work

5-4

MJFCIFSS

Electrical system

Hydraulic accumulator

MJFCIFSS

5-5

Hydraulic hoses and sheathed cables.

5-6

MJFCIFSS

MJFCIFSS

5-7

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

5-8

MJFCIFSS

Caution!

Access door

Tab. 5-1

5.2.2

Lock

Access to:

Access doors

Door lock

Fig. 5-2

Door lock

MJFCIFSS

5-9

5.2.3

Engine hood lock 17

Caution!

5.3 Lubricants and operating fluids 5.3.1

General information on changing lubricants and operating fluids Note

Note!

Note!

5 - 10

MJFCIFSS

Danger!

0

MJFCIFSS

5 - 11

5.3.2

Lubrication chart

Fig. 5-3

5 - 12

Lubrication chart - R 926 Advanced

MJFCIFSS

Symbol

Tab. 5-2

Display

Lubrication chart key

MJFCIFSS

5 - 13

5.3.3

Designation

Lubricant chart

Medium

Tab. 5-3

5 - 14

Symbol

Classification

Lubricant chart

MJFCIFSS

Viscosity

Quantities* Liter / (USgal)

5.3.4 Designation

Operating material chart Medium

Tab. 5-4

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

MJFCIFSS

5 - 15

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

5 - 16

Lubricating oil for the Diesel engine

MJFCIFSS

Classification

Tab. 5-5

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

MJFCIFSS

5 - 17

adverse factors

Operating conditions

Tab. 5-6

5.4.3

Oil change intervals for the Diesel engine

Coolant for the diesel engine

General recommandations

5 - 18

Oil change interval dependent on oil quality:

MJFCIFSS

Note!

Water quality

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

Contents

Tab. 5-7

Quantity

Fresh water quality

Fresh water quality when using coolant with DCA 4 Contents

Tab. 5-8

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 %

Tab. 5-9

°F

A%

Mixture ratio (for all seasons)

MJFCIFSS

5 - 19

Fig. 5-5

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

A

Permitted corrosion inhibitors / antifreeze agent Note!

Product description

5 - 20

MJFCIFSS

Manufacturer

Country

Product description

Manufacturer

Country

Permitted premixed coolants Note!

Product description

Manufacturer

Country

Checking and replacing the coolant Note!

MJFCIFSS

5 - 21

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

5 - 22

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

MJFCIFSS

ze 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 %

MJFCIFSS

92.5 %

5 - 23

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

5 - 24

MJFCIFSS

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):

MJFCIFSS

5 - 25

Tab. 5-10 Engine oils for use as hydraulic oil

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!

5 - 26

MJFCIFSS

Liebherr Hydraulic Plus

Liebherr Hydraulic Plus Arctic

Fully saturated synthetic ester-based oils, HEES

Monitoring, filter change and oil change Note! biodegradable hydraulic oils

mineral oils .

Symbol

Signification

Tab. 5-11 Key to figures

MJFCIFSS

5 - 27

Hydraulic oil in normal use

Fig. 5-11

Oil sampling and filters change in normal use

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

5 - 28

MJFCIFSS

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. 5-12 Grease and other process chemicals

MJFCIFSS

5 - 29

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

5 - 30

MJFCIFSS

max

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

MJFCIFSS

5 - 31

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:

5 - 32

MJFCIFSS

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

MJFCIFSS

5 - 33

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

5 - 34

MJFCIFSS

5.5.7

Oil separator

Fig. 5-19

Replacing the oil separator

MJFCIFSS

5 - 35

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 !

5 - 36

MJFCIFSS

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

MJFCIFSS

3

2

5 - 37

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

5 - 38

3

MJFCIFSS

4

F

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

MJFCIFSS

5 - 39

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

5 - 40

MJFCIFSS

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

MJFCIFSS

5 - 41

Note!

Fig. 5-27

5 - 42

Shutoff valves for the heating circuit

MJFCIFSS

Draining the coolant

Fig. 5-28

Draining the coolant

9a

9c

9b

Fig. 5-29

Draining the engine

2

MJFCIFSS

5 - 43

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!

5 - 44

MJFCIFSS

5.7.5

Reversible fan drive (option).

Fig. 5-30

Reversible fan drive Reversible fan drive

S160

Danger !

MJFCIFSS

5 - 45

5.8 Fuel system Danger!

5.8.1

Refuelling Fuel filler cap

Fig. 5-31

Fuel filler cap 15 20

5 - 46

MJFCIFSS

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

MJFCIFSS

5 - 47

15

5.8.3

Draining the fuel tank

Fig. 5-33

Draining the fuel tank

15

20

To drain the fuel tank and the fuel system daily:

36

36

5 - 48

MJFCIFSS

36

Note!

1

5.8.4

Emptying and cleaning the fuel tank 36

36

15

36

20 20

MJFCIFSS

5 - 49

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

5.8.6

Changing fuel filter cartridges Danger !

5 - 50

MJFCIFSS

3

Changing the fuel pre-filter

Fig. 5-35

Changing the fuel pre-filter

1 3

2 4

5 7

6 8

9

10 3

6

5

3 4

3

4 9 3 9 4 5 1

10

MJFCIFSS

3

5 - 51

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

12 11

5 - 52

MJFCIFSS

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 13

15 16

To bleed the fuel pre-filter 6 2 6 2 To bleed the fuel fine filter 13 2 13

MJFCIFSS

5 - 53

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 - 54

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

Notice !

MJFCIFSS

5 - 55

5.9 Dry air filter

Fig. 5-39

Dry air filter

3

Fig. 5-40

5 - 56

4

Vacuum gauge, dust discharge valve, engine intake pipe

MJFCIFSS

9 10

20 21

11

22 9 10

11

5.9.1

Changing the main element Caution!

Fig. 5-41

Changing the filter cartridges

1

3

2

4 1 3

MJFCIFSS

5 - 57

2

5.9.2

1

Changing the safety element Note!

3 4

Caution!

4 3 2

5.9.3

1

Monitoring the filtered air line 20 21

5.9.4

5 - 58

Spark catcher (option)

MJFCIFSS

22

Fig. 5-42

Pare-étincelles avec bouchon de vidange C

A B

Note !

5.10 Hydraulic system

Note!

5.10.1

Depressurizing the hydraulic system

MJFCIFSS

5 - 59

Danger!

To depressurize the high pressure system

To depressurize the servo oil system

Fig. 5-43

Depressurizing the hydraulic system

To depressurize the hydraulic tank 1

maximum

1

2

Note!

2

5 - 60

MJFCIFSS

Danger!

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

MJFCIFSS

5 - 61

MAXI 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:

5 - 62

MJFCIFSS

1 2 5

6

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

7

2 Caution!

To drain off condensate water

5

6

Note!

MJFCIFSS

5 - 63

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

5

Caution!

8

5 - 64

MJFCIFSS

4

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

MJFCIFSS

5 - 65

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 12 14

5 - 66

1

15

MJFCIFSS

2 1/4

5.10.6

Control circuit

Danger!

10

5.10.7

Bleeding the hydraulic pumps

Fig. 5-50

Hydraulic pumps

T T T

MJFCIFSS

5 - 67

Fig. 5-51

Pompe d’entrainement du ventilateur

60

62

61 61a

62a

60

5.10.8

5 - 68

61a

Removing the intake hose to the pumps

MJFCIFSS

61 61a

61

Fig. 5-52

Shut off valve on the hydraulic tank

27

29

28

a b

b 27

27 a

5.10.9

Bleeding the hydraulic cylinders

MJFCIFSS

5 - 69

Fig. 5-53

Hydraulic cylinder

2

3 2

Procedure 1 2 3

3 2

Procedure 2

Danger!

5 - 70

MJFCIFSS

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!

MJFCIFSS

5 - 71

Fig. 5-55

Bypass oil filter for hydraulic system

1

2

3

4

1

Checking filter contamination:

Replacing filter element:

2 4

4 3,

5 - 72

MJFCIFSS

2

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

MJFCIFSS

5 - 73

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

5 - 74

Machine with piston rods drawn in

MJFCIFSS

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

Conical flange 5c

Tab. 5-13 Tightening torques for SAE fittings - Quality 10.9 Size of screw 4

Torque value in Nm - Quality 8.8 Half flanges 5a

Tab. 5-14 Tightening torques for SAE fittings - Quality 8.8

MJFCIFSS

5 - 75

Size of screw 4

Torque value in Nm - Quality 8.8 Half flanges 5a

Tab. 5-14 Tightening torques for SAE fittings - Quality 8.8

5.11 Oil changes on components 5.11.1

5 - 76

General information

MJFCIFSS

5.11.2

Swing gear - Oil level check and oil change

Fig. 5-60

Checking oil level and changing oil in swing gear

1 2

3 4

To check the oil level: 1 Min. Max. To drain the oil: 2 3 4

3

4 3 To add the oil: Max. 2

MJFCIFSS

5 - 77

5.11.3

Splitterbox - Oil change

Fig. 5-61

Changing oil in splitterbox

5

6

7

8

Oil draining : 5 6

7

6 7 Oil fulling : 8 5 5 8 5

Check oil level :

5 - 78

MJFCIFSS

5 5

5

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!

MJFCIFSS

5 - 79

5.12 The track components

5.12.1

Checking the mounting screws of the track components

Fig. 5-63

Track components mounting screws

7 570 Nm (420 ft.lbs) 800 Nm (590 ft.lbs) 675 Nm (498 ft.lbs) 8 560 Nm (413 ft.lbs) 9 560 Nm (413 ft.lbs) 10 185 Nm (136 ft.lbs) 280 Nm (206 ft.lbs) 560 Nm (413 ft.lbs)

5.12.2

5 - 80

Checking the track chains tension

MJFCIFSS

Fig. 5-64

Track unsufficiently (A) and properly (B) tightened

Fig. 5-65

Monitoring the track tension

1 A

15 to 20 mm Note!

MJFCIFSS

5 - 81

5.12.3

Retensioning the track

Fig. 5-66

Retensioning the track 6 2

1 2

3

4

1

5.12.4

Releasing the track chain tension Danger!

5

5 - 82

MJFCIFSS

2

6

3 3

5.12.5

Cleaning the track components Before working

Caution!

At the end of a workday

Fig. 5-67

Raising the machine on one side

Danger!

MJFCIFSS

5 - 83

5.13 Electrical system 5.13.1

Notes on the electrical system Danger!

Danger!

5.13.2

Main battery switch Caution!

5 - 84

MJFCIFSS

Fig. 5-68

Main battery switch 0

Note!

0

5.13.3

Battery care A

Danger!

B

MJFCIFSS

5 - 85

Fig. 5-69

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

5.13.4

Slip ring assembly (optional extra)

Fig. 5-70

Slip ring assembly

1 2

1

5 - 86

MJFCIFSS

1

2

5.14 Heating and air conditioning system Have the heating and air conditioning system work regularly.

Caution!

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

14

MJFCIFSS

15

5 - 87

Fig. 5-71

Centralized lubrication system

6 8

7 13

14 U4

15 LP LP

Lube points connected to the central lubrication system:

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

5 - 88

MJFCIFSS

Notice!

5.15.2

Operation of the full automatic system Function of the lubrication system

B51

6

MJFCIFSS

5 - 89

Fig. 5-72

Full automatic lubrication system

6 14

13 15

B51 U4

S84

B51 16

Starting an additional lubrication procedure S84 19

Monitoring of the automatic lubrication system 2 S84

5 - 90

MJFCIFSS

17

B51 18

17 S84

26 B51 13 14

Adjustments at the automatic system and grease consumption CD

NS

5.15.3

Emergency lubrication with defective lubrication system 15 25 25

Fig. 5-73

Emergency lubrication

MJFCIFSS

5 - 91

15

5.15.4

25

To refill a grease container 13

21 Note!

13

23 15 31 21 13

31 13

Fig. 5-74

5 - 92

22

Refilling the grease container

13

15

21

22

MJFCIFSS

23

5.15.5

31

Changes in the lubrication circuit

Fig. 5-75

Main and secondary distributor

MJFCIFSS

5 - 93

5.15.6

Greasing the grab (optional extra)

Fig. 5-76

5 - 94

Greasing the grab

MJFCIFSS

5.16 Quick-change systems 5.16.1

Greasing the mechanical quick-change adapter (optional extra)

Fig. 5-77

Greasing the mechanical quick-change adapter

Note!

5.16.2

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

Fig. 5-78

Greasing the quick-change adapter

MJFCIFSS

5 - 95

1 Note!

Cleaning the sieve filter

Fig. 5-79

Cleaning the sieve filter 12

20

21 10 13 12

12 13

20

5 - 96

MJFCIFSS

11

21

5.16.3

LIKUFIX (optional extra) Cleaning LIKUFIX

Replacing the sealing ring

Fig. 5-80

Replacing the sealing ring A

B C D E F

MJFCIFSS

5 - 97

5.16.4

Checking and maintenance of quick change coupler Daily visual check out

Fig. 5-81

Functional check out of quick change adapter

A B C

5.17 Check mounting bolts for tightness

Caution!

Notice :

5 - 98

MJFCIFSS

5.17.1

Mounting bolts of the counterweight

Fig. 5-82

Counterweight mounting bolts 1

5.17.2

Mounting screws of the swing ring

Fig. 5-83

Swing ring mounting bolts 3 4

MJFCIFSS

5 - 99

5.17.3

Mounting screws of the hydraulic oil and fuel tank

Fig. 5-84

Hydraulic oil tank and fuel tank mounting bolts 5

5.17.4

Mounting screws of the swing gear and motor

Fig. 5-85

Swing gear and swing motor mounting bolts 2

5 - 100

MJFCIFSS

5.18 Drive unit brakes and swing gear brakes

5.19 General maintenance points 5.19.1

Replacing working parts

5.19.2

Checking or replacing the teeth on the bucket Note!

MJFCIFSS

5 - 101

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

Fig. 5-86

Replacing the teeth 1

2 A

3

B

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

1

2

3 5

4 10 5 3 10

3 A

3 2

5 - 102

MJFCIFSS

1

4

To install a new tooth

Note!

3

4

4

1 2

1

3 10 3 3a

4a 5 3

5.19.3

Welding work on the machine

Caution!

MJFCIFSS

5 - 103

5.20 Control and maintenance chart Caution!

Note

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 926 Advanced By maintenance personnel (machine owner)

By authorized specialist personnel

DIESEL ENGINE AND SPLITTERBOX

5 - 104

MJFCIFSS

Note

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 926 Advanced By maintenance personnel (machine owner)

By authorized specialist personnel

Note

HYDRAULIC SYSTEM

MJFCIFSS

5 - 105

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 926 Advanced By maintenance personnel (machine owner)

By authorized specialist personnel

ELECTRICAL SYSTEM

SWING GEAR TRANSMISSION

5 - 106

MJFCIFSS

Note

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 926 Advanced By maintenance personnel (machine owner)

By authorized specialist personnel

Note

BALL SWING RING

TRAVEL GEAR

TRACKS

CAB + HEATING

AIR-CONDITIONING SYSTEM

MJFCIFSS

5 - 107

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 926 Advanced By maintenance personnel (machine owner)

By authorized specialist personnel

UNDERCARRIAGE + UPPERCARRIAGE + ATTACHMENT

HYDRAULIC QUICK-CHANGE ADAPTER

5 - 108

MJFCIFSS

Note

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 926 Advanced By maintenance personnel (machine owner)

By authorized specialist personnel

Note

MECHANICAL QUICK-CHANGE ADAPTER

Tab. 5-15 Control and maintenance chart 1 2 3 4

MJFCIFSS

5 - 109