Liebherr R 934 C Litronic 1006 1007 Machine for Industrial Operating Manual SN 78025 - PDF DOWNLOAD

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Operating manual Machine for Industrial Applications R 934 C Litronic from serial number 78025

Document identification ORIGINAL OPERATING MANUAL Id. number:

11692682

Edition:

02 / 2015

Valid for:

R 934 C Litronic from serial number 78025

Author:

LHB - Technical documentation department

Product identification Manufacturer:

LIEBHERR Hydraulikbagger GmbH

Type:

R 934 C Litronic

Type no.:

1006 / 1007

Conformity:

CE

Address Liebherr Machinery (DaLian) Co. Ltd. No. 30, Wanli Street Dalian Development Area China

Operating manual

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

This will also be helpful when ordering spare parts.

Vehicle Id. No.: WLHZ . . . . . . . . . . . .

Year of manufacture: . . . .

Delivery date: . . / . . / . .

MJFCIFSS

R 934 C Litronic / 11692682

Introduction

This operating manual has been specifically devised for machine operators and maintenance personnel. It contains important warnings, information and tips regarding the maintenance and proper operation of the machine. It assists you in becoming familiar with the functions and features of the machine and helps prevent incorrect operation.

By strictly adhering to the instructions in the operating manual, you can significantly enhance the reliability and service life of the machine.

The operating manual is an integral part of the scope of delivery of the machine. Ensure that a copy is at all times available in the storage compartment in the operator's cab.

Carefully read the operating manual before starting the machine and then regularly read it again. All persons carrying out work on or with the machine must be fully familiar with the content of the operating manual and must adhere to the instructions.

Such work include: – Machine operation including tooling, troubleshooting during work, general care and cleaning, disposal of fuels and lubricants.

– Maintenance including inspection, servicing and repair.

– Transport or loading of the machine.

The machine owner must ensure that this operating manual is complemented with the relevant statutory regulations for accident prevention and the protection of the environment. Apart from the instructions in this operating manual and the statutory accident prevention, health and safety regulations applicable in the country of operation, all personnel working on or with the machine must adhere to best practice for safe and proper operation.

Certain sections in this manual might not apply to your specific model.

Some of the figures in this operating manual might show details or equipment that differ from those in your machine.

Some of the figures show the equipment with guards or covers removed (for better depiction).

As our products are constantly being improved, certain changes might be made to the equipment which are not referred to specifically in this operating manual.

Should you require additional information or if you have any queries, please contact the LIEBHERR customer service department.

Warranty and liability Due to the range of products (e.g. fuels, lubricants, tool attachments, spare parts) available from other manufacturers, LIEBHERR is not in a position to assess the compatibility of these products with its own machines. This also applies in relation to possible effects that third-party products have on LIEBHERR products and vice versa.

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Operating manual

It is therefore the responsibility of the machine owner to assess whether third-party products can be safely used in conjunction with the LIEBHERR machine. LIEBHERR shall not be liable for damage to or downtimes of LIEBHERR machine caused by the use a third-party products. Such damage is not covered by the LIEBHERR warranty.

LIEBHERR shall not be liable for damage caused by improper operation, insufficient maintenance or non-compliance with safety instructions.

Amendments, general terms and conditions, copyright We reserve the right to modify our products and amend the instructions in this operating manual without prior notice.

The reproduction or publication of the content of this operating manual (including figures) is prohibited. LIEBHERR reserves all rights in this operating manual, including copyright.

The warranty and liability clauses of the general business terms and conditions of LIEBHERR apply.

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Operating manual

Table of contents 1

Product description ....................................................................................................................................... 1-1 1.1

1.2 1.3 1.4 2

Safety notes, signs ........................................................................................................................................ 2-1 2.1 2.2 2.3

2.4

3

Design and overview ............................................................................................................................. 1-1 1.1.1 General overview ..................................................................................................................... 1-1 1.1.2 Uppercarriage........................................................................................................................... 1-2 1.1.3 Undercarriage........................................................................................................................... 1-3 Vibration emissions................................................................................................................................ 1-3 Sound emission ..................................................................................................................................... 1-4 Technical data ....................................................................................................................................... 1-4

Symbols used in this operating manual ................................................................................................. 2-1 Proper use ............................................................................................................................................. 2-2 Safety instructions ................................................................................................................................. 2-2 2.3.1 General safety instructions ....................................................................................................... 2-2 2.3.2 Crushing and burn prevention .................................................................................................. 2-3 2.3.3 Fire and explosion prevention .................................................................................................. 2-4 Signs on the machine ............................................................................................................................ 2-4 2.4.1 Safety and information signs .................................................................................................... 2-4 2.4.2 ID tag........................................................................................................................................ 2-6

Control, operation.......................................................................................................................................... 3-1 3.1

3.2

3.3

3.4

Operating and control elements............................................................................................................. 3-1 3.1.1 Overview of operator's platform................................................................................................ 3-1 3.1.2 Control unit ............................................................................................................................... 3-4 3.1.3 Monitoring screen..................................................................................................................... 3-9 3.1.4 Main screen ............................................................................................................................ 3-12 3.1.5 Information symbols on the main screen................................................................................ 3-13 3.1.6 Operator's menu..................................................................................................................... 3-15 Control ................................................................................................................................................. 3-30 3.2.1 Entering and exiting the operator's cab .................................................................................. 3-30 3.2.2 Adjusting vertical position of the operator's cab (optional equipment) ................................... 3-32 3.2.3 Emergency lowering of the operator's cab ............................................................................. 3-33 3.2.4 Safety lever ............................................................................................................................ 3-34 3.2.5 Operator seat ......................................................................................................................... 3-35 3.2.6 Windscreen ............................................................................................................................ 3-38 3.2.7 Sun blind ................................................................................................................................ 3-39 3.2.8 Emergency exit through rear window ..................................................................................... 3-39 3.2.9 Inside lighting ......................................................................................................................... 3-40 3.2.10 Fire extinguisher (optional equipment)*.................................................................................. 3-40 3.2.11 Windshield wiper .................................................................................................................... 3-40 3.2.12 Lighting................................................................................................................................... 3-42 3.2.13 Radio mute mode (optional equipment) ................................................................................. 3-43 3.2.14 Heating and air-conditioning system ...................................................................................... 3-43 Operation ............................................................................................................................................. 3-49 3.3.1 Safety instructions .................................................................................................................. 3-49 3.3.2 Starting machine .................................................................................................................... 3-51 3.3.3 Switching off the diesel engine............................................................................................... 3-57 3.3.4 Starting aids ........................................................................................................................... 3-57 3.3.5 Jump start procedure ............................................................................................................. 3-60 3.3.6 Travel operation ..................................................................................................................... 3-61 3.3.7 Travel warning device (option) ............................................................................................... 3-64 3.3.8 Drive deactivation (optional extra).......................................................................................... 3-64 Working with the machine.................................................................................................................... 3-65 3.4.1 Safety Instructions .................................................................................................................. 3-65

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Operating manual

3.5

3.6

3.7 3.8

4

3.4.2 Sensor controlled low idle automatic ...................................................................................... 3-68 3.4.3 Operating working attachment................................................................................................ 3-69 3.4.4 Swivelling the uppercarriage .................................................................................................. 3-71 3.4.5 Halting the uppercarriage ....................................................................................................... 3-71 3.4.6 Lowering the working attachment when diesel engine is shut off........................................... 3-72 3.4.7 Electronic stick cylinder shut-down function (optional equipment) ......................................... 3-73 3.4.8 Mechanical stick cylinder shut-down function......................................................................... 3-75 3.4.9 Adjustment of attachment tool ................................................................................................ 3-78 3.4.10 Operating the attachment tool (by pedals, push buttons) ....................................................... 3-78 3.4.11 Changeover of control (optional equipment) .......................................................................... 3-80 3.4.12 Operating attachment tool (mini joystick control, optional equipment) ................................... 3-80 3.4.13 Changeover of joystick control (optional equipment).............................................................. 3-83 3.4.14 Magnetic system (option) ....................................................................................................... 3-83 Installation and removal of attachment parts ....................................................................................... 3-84 3.5.1 Safety Instructions .................................................................................................................. 3-84 3.5.2 Installation and removal of digging tool .................................................................................. 3-86 3.5.3 Attachment of grapple to bucket stick..................................................................................... 3-88 3.5.4 Attachment of grapple to industrial stick ................................................................................. 3-91 3.5.5 Multi-coupling system (optional equipment) ........................................................................... 3-93 3.5.6 Industrial stick with mechanical quick-change adapter (optional equipment) ......................... 3-96 3.5.7 Industrial stick with hydraulic quick-change adapter (optional equipment)........................... 3-100 3.5.8 LIKUFIX MH 40 quick-coupling system (optional equipment) .............................................. 3-106 3.5.9 Hydraulic quick-change adapter (optional equipment) ......................................................... 3-111 3.5.10 Hydraulic quick-change adapter with LIKUFIX (optional equipment) ................................... 3-117 3.5.11 Mechanical quick-change adapter (optional equipment) ...................................................... 3-118 General working methods .................................................................................................................. 3-122 3.6.1 Tips for the proper operation of the machine preventing damage and wear ........................ 3-122 3.6.2 Preparation ........................................................................................................................... 3-124 3.6.3 Working with grapples .......................................................................................................... 3-125 3.6.4 Excavating and moving material with grapples..................................................................... 3-125 3.6.5 Loading operation ................................................................................................................. 3-126 3.6.6 Load lifting operation ............................................................................................................ 3-127 3.6.7 Use of quick-change adapter for load lifting operation ......................................................... 3-128 3.6.8 Overload warning system (optional equipment) ................................................................... 3-129 Parking and exiting machine.............................................................................................................. 3-130 Transport............................................................................................................................................ 3-131 3.8.1 Safety instructions ................................................................................................................ 3-131 3.8.2 Transport of the machine on a low-loader ............................................................................ 3-131

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

4.3

4.4

Error code list......................................................................................................................................... 4-1 Troubleshooting ..................................................................................................................................... 4-8 4.2.1 Diesel engine and fuel system.................................................................................................. 4-8 4.2.2 Hydraulic system ...................................................................................................................... 4-9 4.2.3 Travel gearbox........................................................................................................................ 4-10 4.2.4 Electrical system..................................................................................................................... 4-10 4.2.5 Heating and air-conditioning system ...................................................................................... 4-11 4.2.6 Working attachment................................................................................................................ 4-11 Fuses and relays.................................................................................................................................. 4-11 4.3.1 Fuse box E50 ......................................................................................................................... 4-12 4.3.2 ESP02 printed circuit board .................................................................................................... 4-13 Emergency operation........................................................................................................................... 4-14 4.4.1 Purpose .................................................................................................................................. 4-14 4.4.2 Identifying solenoid valve ....................................................................................................... 4-15 4.4.3 Emergency mode control........................................................................................................ 4-15 4.4.4 Emergency operation of hydraulic pump ................................................................................ 4-18 4.4.5 Emergency operation of electric stick cylinder shut-down function ........................................ 4-18 4.4.6 Towing the machine ............................................................................................................... 4-19

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Operating manual

5

Maintenance ................................................................................................................................................... 5-1 5.1

Safety instructions ................................................................................................................................. 5-1 5.1.1 General safety instructions ....................................................................................................... 5-1 5.1.2 Checking for cracks.................................................................................................................. 5-1 5.1.3 Welding .................................................................................................................................... 5-2 5.1.4 Fuels, lubricants and process chemicals.................................................................................. 5-2 5.1.5 Repair ....................................................................................................................................... 5-2 5.1.6 Electrical system ...................................................................................................................... 5-3 5.1.7 Pressure accumulator .............................................................................................................. 5-3 5.1.8 Hydraulic hoses and lines ........................................................................................................ 5-4 5.1.9 Cab protection (FOPS)............................................................................................................. 5-5 5.2 Maintenance access doors .................................................................................................................... 5-5 5.2.1 Overview of access doors ........................................................................................................ 5-5 5.2.2 Door locking mechanism .......................................................................................................... 5-6 5.2.3 Engine hood locking mechanism.............................................................................................. 5-7 5.3 Cleaning machine .................................................................................................................................. 5-7 5.4 Care for rubber components.................................................................................................................. 5-8 5.5 Fuels, lubricants and process chemicals ............................................................................................... 5-8 5.5.1 General information .................................................................................................................. 5-8 5.5.2 Filling volumes, lubrication chart .............................................................................................. 5-9 5.6 Specifications for fuels, lubricants and process chemicals.................................................................. 5-11 5.6.1 Diesel fuels............................................................................................................................. 5-11 5.6.2 Lubricating oil for the diesel engine ........................................................................................ 5-12 5.6.3 Coolants for diesel engine...................................................................................................... 5-14 5.6.4 Hydraulic oil ............................................................................................................................ 5-17 5.6.5 Lubricants for axles and gearboxes ....................................................................................... 5-23 5.6.6 Lubricating oil for transmission............................................................................................... 5-24 5.6.7 Grease.................................................................................................................................... 5-25 5.6.8 Lubricants and care products for electrical and mechanical components .............................. 5-25 5.7 Diesel engine ....................................................................................................................................... 5-26 5.7.1 Checking the oil level in the diesel engine ............................................................................. 5-26 5.7.2 Changing the diesel engine oil ............................................................................................... 5-26 5.7.3 Ribbed V-belt for A/C compressor and alternator installation................................................. 5-28 5.7.4 Crankcase bleeding point ....................................................................................................... 5-28 5.7.5 Grease the starter tooth ring .................................................................................................. 5-29 5.8 Cooling system .................................................................................................................................... 5-30 5.8.1 Checking and cleaning the cooling system ............................................................................ 5-30 5.8.2 Checking the coolant level ..................................................................................................... 5-30 5.8.3 Changing the coolant ............................................................................................................. 5-31 5.8.4 Checking coolant, adjusting mixing ratio ................................................................................ 5-33 5.9 Fuel system ......................................................................................................................................... 5-37 5.9.1 Refuelling ............................................................................................................................... 5-37 5.9.2 Dewatering fuel tank............................................................................................................... 5-38 5.9.3 Emptying and cleaning fuel tank ............................................................................................ 5-39 5.9.4 Maintenance of fuel filter ........................................................................................................ 5-40 5.9.5 Bleeding fuel system .............................................................................................................. 5-42 5.10 Dry air filter .......................................................................................................................................... 5-44 5.10.1 Changing the main element ................................................................................................... 5-45 5.10.2 Changing the safety element.................................................................................................. 5-46 5.10.3 Checking the filtered air line ................................................................................................... 5-46 5.11 Hydraulic system ................................................................................................................................. 5-47 5.11.1 Preparation............................................................................................................................. 5-47 5.11.2 Check the oil level in the hydraulic tank ................................................................................. 5-48 5.11.3 Depressurising the hydraulic system...................................................................................... 5-48 5.11.4 Changing the breather filter .................................................................................................... 5-49 5.11.5 Emptying and refilling the hydraulic tank ................................................................................ 5-50 5.11.6 Return filter ............................................................................................................................. 5-51 5.11.7 Control oil filter ....................................................................................................................... 5-52

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Operating manual

5.12

5.13

5.14

5.15

5.16

5.17

5.18

5.19

5.20

5.11.8 Control circuit.......................................................................................................................... 5-53 5.11.9 Bleeding the hydraulic pumps ................................................................................................ 5-53 5.11.10 Removing the suction hose .................................................................................................... 5-55 5.11.11 Feed line filter of the slewing gear circuit ............................................................................... 5-55 5.11.12 Leak oil filter ........................................................................................................................... 5-56 5.11.13 Bypass oil filter (optional extra) .............................................................................................. 5-56 5.11.14 Maintenance of hydraulic cylinders ........................................................................................ 5-58 5.11.15 Replacing hydraulic hoses...................................................................................................... 5-58 Changing the oil on components ......................................................................................................... 5-59 5.12.1 General notes ......................................................................................................................... 5-59 5.12.2 Swin gear - oil change ............................................................................................................ 5-60 5.12.3 Pump distributor gear - oil change.......................................................................................... 5-61 5.12.4 Travel gear - oil change .......................................................................................................... 5-62 Drive..................................................................................................................................................... 5-62 5.13.1 Cleaning drive......................................................................................................................... 5-62 5.13.2 Checking fixtures of drive components................................................................................... 5-63 5.13.3 Checking chain tension .......................................................................................................... 5-64 5.13.4 Tensioning chain .................................................................................................................... 5-64 5.13.5 Releasing chain ...................................................................................................................... 5-65 5.13.6 Changing lubrication nipple .................................................................................................... 5-66 Electrical system .................................................................................................................................. 5-66 5.14.1 Notes regarding the electrical system .................................................................................... 5-66 5.14.2 Battery main switch ................................................................................................................ 5-67 5.14.3 Battery care ............................................................................................................................ 5-67 5.14.4 Slip ring body (optional equipment) ........................................................................................ 5-69 Heating and air-conditioning system.................................................................................................... 5-70 5.15.1 Recirculated and ambient air filter .......................................................................................... 5-70 5.15.2 Heating system ....................................................................................................................... 5-71 5.15.3 air-conditioning system ........................................................................................................... 5-71 Automatic lubrication of the machine ................................................................................................... 5-72 5.16.1 Semi-automatic central greasing system................................................................................ 5-72 5.16.2 Fully automatic central greasing system (optional extra)........................................................ 5-74 Manual lubrication of the machine ....................................................................................................... 5-76 5.17.1 Attachments (optional equipment) .......................................................................................... 5-76 5.17.2 Industrial stick with mechanical quick-change adapter........................................................... 5-77 5.17.3 Industrial stick with hydraulic quick-change adapter............................................................... 5-77 5.17.4 LIKUFIX MH 40 quick-coupling system .................................................................................. 5-78 5.17.5 Hydraulic quick change adapter ............................................................................................. 5-79 5.17.6 Mechanical quick-change adapter .......................................................................................... 5-79 Couplings of the quick-change adapter systems (optional equipment) ............................................... 5-80 5.18.1 Hydraulic coupling .................................................................................................................. 5-80 5.18.2 LIKUFIX electric coupling ....................................................................................................... 5-81 General maintenance tasks ................................................................................................................. 5-82 5.19.1 Replacing wear parts .............................................................................................................. 5-82 5.19.2 Replacing teeth on digging tool .............................................................................................. 5-83 5.19.3 Welded parts on the machine ................................................................................................. 5-84 Inspection and maintenance schedule................................................................................................. 5-85

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1 Product description 1.1 Design and overview 1.1.1

General overview

Fig. 1-1

General overview

1

Uppercarriage

2

Operator's platform

3 5

Industrial boom Grapple

4 6

Industrial stick Undercarriage

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Product description

Operating manual

Design and overview

1.1.2

Uppercarriage

Fig. 1-2

Uppercarriage

1

Dry air filter

2

Diesel engine

3

Control valve block

4

Radiator

5

Cab

6

Control Panel, left

7 9

Control cab Rotary connection

8 Control Panel, right 10 Swing gear

11 Hydraulic oil tank

12 Fuel tank

13 Hydraulic pump

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Operating manual

Product description Vibration emissions

1.1.3

Undercarriage

Fig. 1-3

Undercarriage

1

Travel drive

2

Idler

3 5

Chain Chain tensioner

4

Rotary Connection

1.2 Vibration emissions The operator seat built into the machine by the manufacturer conforms to ISO 7096:2000, EM 6. When replacing the seat, ensure that the new seat also conforms to this standard.

Hand-arm vibration If the machine is operated according to the manufacturer instructions, the weighted (frequency-rated) effective hand-arm vibration is below 2.5 m/s² according to ISO 5349-1:2001.

Whole-body vibration If the machine is operated according to the manufacturer instructions, the weighted (frequency-rated) effective vibration shown for specific machine applications in the table below apply. These values conform to the specifications in the technical report ISO/TR 25398:2006 "Earth-moving machinery – Guidelines for assessment of exposure to whole-body vibration of ride-on machines – Use of harmonized data measured by international institutes, organizations and manufacturers". The method

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Product description

Operating manual

Sound emission

of assessment conforms to ISO 2631-1:1997. The effective values in the table for representable machines are shown with the applicable standard deviations. These deviations are classified according to the operating conditions in the classes "lightduty", "normal" and "heavy-duty". It is the responsibility of the machine owner to assess the operating conditions according to the classes, taking into account the terrain, site conditions, site organisation, material, machine equipment, working procedure and training of the operator.

As the quoted values are effective values for specific, common applications, the whole-body vibration to which the operator is exposed can only be estimated. For a more detailed assessment of the daily exposure of the operator across an 8-hour shift, please refer to the LIEBHERR brochure on whole-body vibration and the software designed for the assessment. This document and software are available from the LIEBHERR dealer and are included as standard on the documentation CD (Liebherr-Parts) shipped with new machines.

For instructions how to reduce whole-body vibration during operation of mobile construction machinery, please refer to chapter "Control, operation / working with machine / safety instructions / vibration protection".

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

Crawler excavator

Mobile excavator

Typical working cycles

x-axis

y-axis

z-axis

1

2

3

1

2

3

1

2

3

Excavator

0.14

0.31

0.49

0.08

0.19

0.31

0.13

0.30

0.47

with hydraulic hammer

0.16

0.38

0.59

0.09

0.22

0.35

0.27

0.55

0.83

Use for mining

0.31

0.46

0.61

0.19

0.30

0.41

0.29

0.61

0.93

Transfer travel

0.21

0.34

0.48

0.09

0.23

0.37

0.56

0.79

1.02

Excavator

0.19

0.37

0.56

0.09

0.25

0.41

0.16

0.29

0.42

Transfer travel

0.21

0.29

0.38

0.24

0.38

0.52

0.42

0.61

0.80

The measurement uncertainty is defined in standard EN 12096:1997.

1.3 Sound emission The sound values of the machine are specified in the technical data.

The sound power level (Lwa) is determined according to Directive 2000/14/EC. The measurement uncertainty of the sound power level value corresponds to the difference between the guaranteed and the measured value.

The sound pressure level (Lpa) is determined according to ISO 6396. The measurement uncertainty is defined in the above standard.

1.4 Technical data See technical description on the following pages.

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2 Safety notes, signs There are certain risks associated with the operation of the machine. These risks might concern you as the owner, operator or maintenance technician of the machine.

Read the safety notes and instructions in this operating manual carefully and on a regular basis. Strictly adhere to the safety notes and instructions in order to prevent dangerous situations and accidents. This applies especially to persons who only rarely work on or with the machine, e.g. in the context of maintenance work.

In addition to the safety instructions in this manual, always adhere to all safety regulations applicable at the place of operation. Such regulations might include statutory regulations or instructions issued by trade associations.

For operation in EU member states, the minimum safety requirements to be met by the machine owner are laid down in Directive 2009/104/EC.

2.1 Symbols used in this operating manual Potential dangers in connection with work on or with the machine are labelled with safety notes and signs as follows: Danger, Caution and Note.

These terms have the following meaning: Danger!

Warning referring to a danger where there is a high probability of death or serious injury to operators, unless the prescribed safety measures are taken.

Caution!

Warning relating to dangers that might lead to injury and/or damage to the machine, unless the prescribed safety measures are taken.

Note!

This symbol accompanies instructions and tips regarding the operation and maintenance of the equipment. If adhered to, the service life of the machine can be extended and/or procedures are made easier.

The following symbols are used to guide you through the prescribed procedures: Identifies a precondition or prerequisite that must be met before the subsequent procedures can be carried out.

Identifies a procedure or activity.

Identifies the result of a procedure or activity.

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Safety notes, signs

Operating manual

Proper use

2.2 Proper use – The hydraulic excavator is a machine equipped with an attachment (e.g. backhoe bucket, grapple, front shovel) designed to loosen, lift, transport and disperse soil, stones and other material, whereby the load is normally transported with the machine being stationary during the process. If the machine is to travel with a load, special safety measures must be taken (see section "Instructions for safe work").

– Machines used to lift loads are subject to special safety requirements and must be equipped with specific safety devices (see section "Load lifting operation").

– Machines used underground (deep mining and tunnel construction) must be equipped with exhaust gas reducing equipment (e.g. diesel particle filter). Always comply with the statutory regulations applicable at the location of operation.

– Special tasks such as demolition work and goods handling require special attachments and possibly also special safety devices. This equipment (e.g. tree grapple, demolition hammer, concrete shear, etc.) may only be attached to the machine and used with the explicit consent of and according to the instructions of the manufacturer of the basic machine.

– Any other use, in particular transportation of persons or working in explosive atmospheres or contaminated environments is deemed improper. The manufacturer shall not be liable for any damage arising from such use. The operator shall be solely responsible for any damage caused by improper use of the equipment.

– Compliance with the instructions in the operating manual and the inspection and maintenance schedules is an integral part of proper use.

2.3 Safety instructions 2.3.1

General safety instructions – Please familiarize yourself with the operating instructions before starting the machine.

– Please verify that you have read and understood supplemental instructions (this may concern special options for the machine).

– Only explicitly authorized personnel may operate, maintain or repair the machine.

The legal minimum age must be observed.

– Use only trained or instructed personnel. Clearly define who is responsible for the operation or set up, maintenance and repair. Reject unsafe instructions by third parties and/or allow your personnel to reject these. This also applies in regards to traffic regulations.

– Any person still in training should only operate or work on the machine under the constant supervision and guidance of an experienced person.

– Check and observe all persons working or operating the machine at least periodically to ensure that they observe safety instructions and guidelines given in the operating manual.

– Wear proper work clothing when operating or working on the machine. Avoid wearing rings, watches, ties, scarves, open jackets or loose clothing. There is a danger of injury, as these items could get caught or be pulled in.

Wear task-appropriate personal protective equipment at all times.

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Operating manual

Safety notes, signs Safety instructions

– Consult the supervisor for any special safety procedures applicable to your job site.

– Always raise the safety lever before leaving the operator’s seat.

– Keep steps, ladders and handholds (handles) in proper condition. Make especially sure that they are free of dirt, oil, ice and snow.

NOTE: To ensure that the doors open in all weather conditions, lubricate the weather strips at least every two months, or more often, if necessary, with talcum powder or silicon. Lubricate the door hinges and locks regularly.

– When entering or leaving the cab, do not use the steering column, the control panel or the joysticks as handholds.

– Never jump off the machine, always use the steps, ladders, rails and handles provided to climb off or on the machine.

– Always face towards the machine when climbing on and off it, and always use the three points of contact with the machine (all times either two hands and one foot, or two feet and one hand are in contact with the access system).

– Familiarize yourself with the emergency exit.

– Proceed as described in the operating manual, if no other instructions are available for maintenance and repairs: • Place the machine on a solid and level ground and lower the working attachment to the ground.

• Depressurize the hydraulic system.

• Move all control levers to the neutral position.

• Move the safety levers up prior to leaving the machine.

• Remove the ignition key.

– Before servicing the hydraulic system you must reduce the pressure in the hydraulic system and tank, as described in this operating manual.

– Secure all loose parts on the machine.

– Never start a machine before completing a thorough walkaround inspection.

Insure that all required safety signs are in place and legible.

– Do not modify, alter or otherwise change any safety-related systems of components without the specific approval of LIEBHERR. – Do not stand near the running diesel engine. Persons with a pacemaker must keep clear of the vicinity of the running diesel engine (minimum distance 50 cm).

– While the diesel engine is running, do not touch the powered components at the electrical connection of the solenoid valve-controlled injection pumps.

2.3.2

Crushing and burn prevention – Never work underneath the attachment as long as it is not safely resting on the ground or properly supported.

– Insure that all load supporting systems are in good repair and rated for the required load.

– Always wear work gloves when handling wire ropes.

– When working on the attachment, never align bores with your fingers, always use a suitable alignment tool.

– Keep hands, tools and any other objects away from contact with the cooling fan.

The cooling fan can cause severe injury, objects can be catapulted away or destroyed, and the fan can be damaged by the objects.

– At or near operating temperature, the engine cooling system is hot and under pressure. Avoid contact with any components containing coolant. Danger of severe burns.

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2-3

Safety notes, signs

Operating manual

Signs on the machine

– Check the coolant level only after the radiator cap on the expansion tank is cool enough to touch. Turn the cap carefully to relieve the pressure.

– At or near operating temperature, the engine and the hydraulic oil are hot. Do not allow your skin to come into contact with hot oil or components containing hot oil.

– Always wear safety glasses and protective gloves when handling batteries. Avoid sparks and naked flames.

– Do not let any assisting personnel hold the attachment, bucket or grapple to assist in any operation.

– When working on the engine area, make sure that the side doors are properly secured to remain open during the service operation.

2.3.3

Fire and explosion prevention – Switch off the diesel engine prior to filling the tank.

– Have skilled personnel immediately repair all defects, such as loose connections, blown fuses and burned out light bulbs, burned or frayed cables.

– Do not smoke and avoid naked flames when filling the tank or loading the batteries.

– Always start the diesel engine according to the operating instructions.

– Never store flammable fluids on the machine except in appropriate storage tanks.

– Regularly inspect all lines, hoses and fittings for leaks and damage.

– Repair any leaks immediately and replace damaged components.

– Be certain that all clamps, guards and heat shields are properly installed to prevent vibration, rubbing and heat build up.

– Do not use cold start aids (ether) near heat sources or naked flames or in insufficiently ventilated areas.

– Do not use ether containing starting aids to start diesel engines with pre-heat system or flame glow systems.

– Familiarize yourself with the location and use of fire extinguishers on the machine as well as the local fire reporting procedures and fire fighting possibilities.

2.4 Signs on the machine 2.4.1

Safety and information signs The signs refer to specific hazards and accident prevention measures. They contain information for the operation, maintenance and transportation of the machine as well as details of machine properties.

Danger!

Non-compliance with safety and other information provided on the signs can result in serious or even fatal injury and damage to the machine.

Ensure that all required safety signs are in place and legible.

Always replace missing and illegible signs without delay.

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R 934 C Litronic / 11692682

Operating manual

Safety notes, signs Signs on the machine

Fig. 2-1

Position of the signs on the machine

4

Identification tag

60

Sound pressure level Lwa

15

Lubrication schedule

65

Load lift chart

20 22

Prohibition sign Control symbols

71 73

Risk of explosion Risk of electric shock when touching high voltage lines

30 35

Lubricating chart (engine) Loading and tie-down points

74 75

High pressure Risk of injury from impact or crushing

36*

Waxoyl

76

Hot machine components

40 45

Identifies tie-down points Identifies attachment points for lifting

77 80

Hot liquids Safety belt

47

Jump start

90*

50

Danger zone

91*

Danger - no attachment point for lifting Counterweight removal

52

Engine shut-down

101

Risk of injury from crushing

54 55

Accident prevention Safety lever

103 Propelled objects 250* Emergency exit through rear window

56

Attachment

* = model variant

copyright by R 934 C Litronic / 11692682

2-5

Safety notes, signs

Operating manual

Signs on the machine

2.4.2

ID tag The machine and its components (e.g. diesel engine, gearbox, pumps) are equipped with ID tags. The ID tags indicate the ID numbers of the components.

The ID tag of the machine is located at the front of the uppercarriage. It contains the following information: – Vehicle ID no.

– Type – Year of manufacture – Motor output – Max. speed – Permissible total weight – Permissible front axle load – Permissible rear axle load

Fig. 2-2

ID tag of the machine

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R 934 C Litronic / 11692682

3 Control, operation 3.1 Operating and control elements 3.1.1

Overview of operator's platform

copyright by R 934 C Litronic / 11692682

3-1

Control, operation

Operating manual

Operating and control elements

Fig. 3-1

Operator's platform seen from the operator

1

Safety lever of servo control

3

Right joystick

4

Left joystick

5

Pedal for left drive gear

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R 934 C Litronic / 11692682

Operating manual

Control, operation Operating and control elements

6

Pedal for right drive gear

9

Pedal for special attachment *

10

Positioning brake of slewing gear 15 *

Control devices for auxiliary attachment *

A3

Radio *

E8

Cigarette lighter

H10

Warning buzzer

H1

Monitoring display

P5

Hours counter

S1

Start key

S2

Switching unit

S5L

Push button with rotating unit, left S5M Horn (grapple, tilt bucket, etc.)

S5R Push button with rotating unit, S6L Push button for lifting magnet right (grapple, tilt bucket, etc.)

S6M Reserve S55 S71

S6R Push button for travel alarm interruption

Switch for special function (see S57 below) Emergency start switch for diesel S72 engine

S73

Emergency switching of servo circuit

U38

A/C system control unit

*

optional equipment

Switch for slewing gear brake operating mode preselection Speed regulator for emergency operation

S84-1 Button / central lubrication system

* optional equipment

copyright by R 934 C Litronic / 11692682

3-3

Control, operation

Operating manual

Operating and control elements

3.1.2

Control unit

Fig. 3-2

Control unit

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Operating manual

Control, operation Operating and control elements

S10 – Work headlight Press the button. Upon pressing the button, the following functions are performed in the sequence listed here: the uppercarriage headlights are switched on (LED 1 lit), the attachment headlights are switched on (LED 2 lit), the uppercarriage headlights are switched off simultaneously (LED 1 off), the uppercarriage and the attachment headlights are switched on simultaneously (LED 1 and LED 2 lit), the uppercarriage and the attachment headlights are switched off simultaneously (LED 1 and LED 2 off).

S11 – Windscreen washer system Press and hold the button: windscreen washing solution is sprayed onto the front screen, the windscreen wiper is on in continuous mode.

Release the button: windscreen washing solution spraying stops, the windscreen wiper stops with a delay of approx. 3 seconds.

S14 – Windscreen wiper Press the button: the windscreen wiper runs in interval mode, LED I in the button is lit.

Press the button again: the windscreen wiper runs continuously, LED C in the button is lit and LED I is off.

Press the button again: the windscreen wiper is switched off, LED C in the button is off.

The intervals for operation in interval mode can be set with the button S14: Select interval mode operation by pressing the button and hold the button: after a few seconds, LED I begins to flash. when the desired interval time (between 2 and 9 seconds) is reached, release the button.

S17 – Slewing gear brake Press the button: LED in the button is lit, the slewing gear brake is applied.

Press the button again: LED in the button is off, the slewing gear brake is set to semi-automatic operating mode. In this mode, the brake is controlled based on the position of the switch S57 at the control lever.

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3-5

Control, operation

Operating manual

Operating and control elements

S18 – Overload warning system (optional equipment) Press the button: LED in the button is lit, the overload warning system is activated.

Press the button again: LED in the button is off, the overload warning system is deactivated.

If the machine is not equipped with an overload warning system, or if it has not been properly configured or started: upon activating the overload warning system, the symbol for "No overload warning system" is displayed at the monitoring display (LED in the button is lit).

S19 – Rotating mechanism (optional equipment) The rotating mechanism is an auxiliary hydraulic unit required for the operation of certain special attachments (rotating grapple, tilt bucket, rotating telescopic stick, quick-change adapter, etc.).

Press the button: LED in the button is lit, the control circuit of the rotating mechanism (e.g. for rotating grapple) is activated. The auxiliary attachment can now be controlled with the push buttons S5L and S5R at the left control lever.

Press the button again: LED in the button is off, the control circuit of the rotating mechanism is activated. The auxiliary attachment cannot be operated.

S20 – Low idle automatic Press the button: LED in the button is lit, low idle automatic is activated.

Press the button again: LED in the button is off, low idle automatic is deactivated.

Configuring delay time of low idle automatic The time between releasing the joystick and the automatic switching to low idle speed by the diesel engine can be adjusted by means of push button S20 as follows: Activate low idle automatic, press and hold the button: after a few seconds, LED I begins to flash.

When the desired time (between 2 and 9 seconds) is reached, release the button.

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Operating manual

Control, operation Operating and control elements

S21 – Fast travel speed Press the button: LED 1 in the button is lit, switching over from normal to fast travel speed is activated.

During travel, the machine now switches from normal travel to fast travel speed as soon as the ground conditions permit this; it also switches from fast travel to normal travel speed, as soon as ground conditions become unfavourable.

Press the button again: LED 1 in the button is off, switching over from normal to fast travel speed is deactivated. The travel motors are set to normal travel speed by default.

S22 – Auxiliary headlights (optional equipment) Press the button: LED in the button is lit, the auxiliary headlights are switched on.

Press the button again: LED in the button is off, the auxiliary headlights are switched off.

S36 – Special function 1 (optional equipment) Assignment and activation depend on kit.

S41 – Beacon (optional equipment) Press the button: LED in the button is lit, the beacon is switched on.

Press the button again: LED in the button is off, the beacon is switched off.

S56 – Additional pressure level (optional equipment) Press the button: LED in the button is lit, the safety shut-off point of the primary pressure-relief valves is increased, the maximum force of the attachment is increased.

Press the button again: LED in the button is off, the safety shut-off point of the primary pressure-relief valves is reset to the initial value.

S85 – Grab control The grab control improves the control of the equipment during grapple operation. It limits the hydraulic pressure and thus the clamping forces (closing forces) of the grapple. This means that there is more pressure available for other functions.

Grab control is not suitable for loads that can only be held by the grapple when the maximum clamping force is applied.

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3-7

Control, operation

Operating manual

Operating and control elements

S86 – Power selection (mode) Four different modes can be selected by pressing the switch. The active mode is indicated by the LED below the respective letter.

– L: LIFT mode (sensitive lifting of loads) – F: FINE mode (precision operation) – E: ECO mode (economical operation) – P: POWER mode P4 – Engine speed indicator Indicates the preselected engine speed (10 speed levels).

S228 – Increase speed Increases the nominal speed of the diesel engine.

S229 – Reduce speed Reduces the nominal speed of the diesel engine.

S354 – Super Finish (flow reduction) With the Super Finish function, the movement of the attachment can be slowed down, so that tasks can be carried out with greater precision. The function is based on flow reduction.

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Operating manual

Control, operation Operating and control elements

3.1.3

Monitoring screen

Fig. 3-3

Monitoring screen

A B

Analog-value display Indicator display

H24 P2

Indicator light, steering Coolant temperature indicator

C

Main screen

D

Menu control, screen

P2.1 Indicator when coolant temperature in red area P3 Fuel level display

H2

Indicator light, engine oil pressure P3.1 Indicator that fuel level is in red area

H12 H19

Battery indicator light Indicator light for vehicle indicators

S349 Back button S350 Down button

H20 H23

Indicator light, parking brake Indicator light, service brake reservoir pressure

S351 Up button S352 Menu button

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Control, operation

Operating manual

Operating and control elements

3.1.3.1

Area A: Monitoring the diesel engine P2 –Diesel engine coolant temperature display The indicator must be in the green area when the machine is being operated.

In the event of overheating (above 98 ºC), the red LEDs P2.1 at the end of indicator P2 will flash.

The buzzer in the cab will also sound.

Stop working as soon as possible.

Allow the engine to continue idling high.

The alarm warning lasts longer than 60 seconds.

Immediately bring the engine to a low idle.

Allow the engine to idle for another 3 to 5 minutes.

Switch off the engine.

Find and rectify the cause of the problem.

P3 – Fuel level display The LEDs illuminated in the display indicate the amount of fuel remaining in the tank.

When the red LEDs P3.1 are lit, a reserve quantity of 100 litres is still in the tank.

H2 – Indicator light, low engine oil pressure The indicator light illuminates if the engine oil pressure drops below a given value when the machine is running.

The buzzer in the cab will also sound.

When this indicator light illuminates, the error will be saved as error code E501.

Immediately bring the engine to a low idle.

Switch off the engine.

H12 – Indicator light, battery The indicator light illuminates if the ignition key is turned to the contact position.

The indicator light goes out as soon as the engine is started.

During operation this indicator light is lit if the V-belt alternator or electrical charging system is defective.

Immediately bring the engine to a low idle.

Allow the engine to idle for approximately another 5 seconds.

Switch off the engine.

Rectify the error.

H19 – Indicator light, vehicle indicator lamps The indicator light lights up if the turn signal switch and the hazard warning system are actuated.

H20 – Indicator light, parking brake The indicator light illuminates if the parking brake is engaged (S16) or if the parking brake release pressure is too low.

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Operating manual

Control, operation Operating and control elements

H23 – Indicator light, reservoir pressure (service brake) The indicator light illuminates if the reservoir pressure is too low. The brakes may not function correctly.

When this indicator light illuminates, the error will be saved as error code E510.

Bring the machine to a stop.

Immediately bring the engine to a low idle.

Push the safety lever up.

Check the brake system.

H24 – Indicator light, steering No function

3.1.3.2

Area B: Screen menu control

Fig. 3-4

Screen menu control

The screen can be operated using the following 4 buttons: – S349: Back – S350: Down – S351: Up – S352: Menu* * = Change from main to submenus

These buttons are used to jump from the operator menu to the submenus or to move from page to page.

3.1.3.3

Area C: Screen To change the screen contrast: Simultaneously press button Menu and arrow button Up (higher contrast) or Down (lower contrast).

The set value will be saved.

To alter the brightness of the main screen: Simultaneously press button Back and arrow button Up (brighter) or Down (darker).

The set value will be saved.

Note!

A light sensor built into the top left of the monitoring screen controls the illumination of the main screen depending on the ambient brightness. Fine adjustment of these basic settings is performed using the buttons. Illumination will be automatically reduced in conditions of low ambient light.

To change the brightness and contrast settings to the factory-default setting: Turn off the ignition.

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Control, operation

Operating manual

Operating and control elements

Press and hold the Up and Down buttons simultaneously.

Turn on the ignition again.

Release the buttons once the automatic check has completed.

3.1.4

Main screen

Fig. 3-5 SY INF

Display: main screen

Time / warning symbols EC Information symbols TI

Error codes Total operating hours, daily counter, current tool (Tool Control)

The "Main screen" menu serves as the main source of information of the machine operator. It is automatically displayed when the ignition is switched on. The menu shows operating data and other information in the form of text or symbols and allows the operator to access the operator' menu.

Field SY This section shows the time and warning symbols. These symbols indicate unfavourable operating statuses and improperly locked quick-change adapter systems.

If the system needs to display more than 2 warning symbols, the clock is not displayed. If more than 4 warning symbols are to be displayed, they are moved across the screen from left to right by one symbol every 10 seconds.

Field EC This section shows error codes* (E xxx) of pending electrical errors (e.g. line faults, sensor errors).

If the operator has called up a different menu while such an error occurred, the system automatically returns to the main screen. Depending on the type of the error and its level of urgency, the buzzer emits a continuous signal or a sequence of short signals.

Certain error codes are accompanied by warning symbols. For a description of the error codes and warning symbols, see chapter "Malfunctions - error code list".

The main screen can show maximum 7 error codes at the same time. If there are more than 7 faults or errors, an arrow is displayed beside the error code field, indicating that there are more codes outside the current display range.

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Operating manual

Control, operation Operating and control elements

Press the Up or Down button.

The display scrolls through the list in the selected direction.

Danger!

If the indicated error or fault is not eliminated immediately, there is a danger persons might be injured or equipment becomes damaged.

Make sure that all faults are dealt with without delay.

Acknowledging errors: When an error code is displayed, the error acknowledgment symbol is shown in the INF field.

Press the Back button.

The error message is acknowledged and stored.

The buzzer is off.

Field INF This section shows information symbols. They indicate operating statuses and events that occurred during operation and are relevant for the further operation of the machine.

If more than 3 information symbols are to be displayed, they are moved across the screen from left to right by one symbol every 10 seconds.

Field TI This section shows the operating hours of the machine, the daily operating hours counter and the selected working tool.

The ® symbol indicates that an optional piece of equipment or a working tool with flow reduction is in operation.

3.1.5 Symbol

Information symbols on the main screen

Description Preheating This symbol is displayed during preheating, indicating to the operator that the diesel engine must only be started after preheating is completed.

End of preheating This symbol is displayed when preheating is completed. It remains visible for approx. 2 seconds on the display and indicates to the operator that the diesel engine can now be started.

Service interval symbol This symbol is displayed for a short period prior to starting the ignition, if a service is due.

Acknowledge error This symbol is displayed if a machine fault or error occurred. It is accompanied by a buzzer signal. To acknowledge the error and switch off the buzzer signal, press the Back button.

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Control, operation

Operating manual

Operating and control elements

Symbol

Description Overload warning system* This symbol is displayed, if the overload warning system* is switched on and the maximum permissible load of the machine is reached.

It indicates to the operator that the load must be reduced.

No overload warning system This symbol is displayed, if the operator attempts to switch on the overload warning system* in a machine that is not equipped with this function.

It indicates to the operator that the machine does not feature an overload warning system.

Stick cylinder shut-off Shut-off point reached when stick is being retracted.

Overriding stick cylinder shut-off function The shut-off point for retracting is overridden. The industrial stick can be retracted without restrictions.

Stick cylinder shut-off Shut-off point reached when stick is being extended.

Overriding stick cylinder shut-off function The shut-off point for extending is overridden. The industrial stick can be extended without restrictions.

Emergency operation of diesel engine This symbol is displayed if the diesel engine is run in emergency mode.

It indicates that, in emergency mode, the speed can be adjusted with an additional switch.

The machine must only be operated in emergency mode for a limited period of time.

Emergency operation of control devices: Danger This symbol is displayed if the emergency control mode is activated.

It indicates that the control devices are set to emergency mode. The machine can thus not be operated as normal, and there is an increased risk of accidents.

The machine must only be operated in emergency control mode for a limited period of time and by operating personnel who know how to operate the affected functions.

Emergency operation of control devices of brake This symbol is displayed if the emergency control mode is activated.

It indicates that the parking and slewing gear brakes are in emergency mode and cannot be operated through the normally used switches.

Emergency operation of servo control This symbol is displayed if the emergency control mode is activated.

It indicates that the servo control cannot be operated through the normally used switch. * optional equipment

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Operating manual

Control, operation Operating and control elements

3.1.6

Operator's menu Changing to operator's menu:

Fig. 3-6

Main screen

To change to the operator's menu, you must first call up the main screen.

Press the Menu button on the main screen.

The operator's menu is displayed.

The list of the accessible submenus is indicated by symbols.

Fig. 3-7

Operator's menu

Scrolling through the operator's menu: Press the arrow buttons UP and/or DOWN. The preceding and/or subsequent submenu is displayed on a black background.

Depending on the equipment of the machine, there might be more menus in addition to the above listed. These can be accessed by scrolling to the bottom of the screen.

Select a menu: The menu showing a black background is selected.

Press the Menu button.

The submenu of the selected function is displayed.

Press the BACK button.

The submenu is closed.

Symbol

Description Resetting of daily operating hours counter

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3 - 15

Control, operation

Operating manual

Operating and control elements

Symbol

Description Fine adjustment for rotating grapple (optional equipment)

Confirmation of service interval

Tool Control – selection of settings for working tool (optional equipment) Operating hours, machine data

Status of hydraulic pumps and electrical inputs/outputs

Detected and saved errors

Time

Electronic stick cylinder shut-down (optional equipment)

Automatic central lubrication system mode (optional equipment) Purge mode Starting diesel engine in PURGE mode

Reset menu for daily operating hours counter

Fig. 3-8

Resetting the daily operating hours counter

Use this menu to reset the daily operating hours counter.

Press the UP button.

Option OK is not stricken through and is highlighted in black.

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R 934 C Litronic / 11692682

Operating manual

Control, operation Operating and control elements

Press the Menu button.

The operating hours counter is reset.

The UP and DOWN buttons and the Menu symbol are no longer visible.

Press the BACK button.

The submenu is closed.

Fine adjustment menu for rotating grapple This menu is available in machines equipped with mini joystick control (optional equipment). On the menu page, the maximum achievable speed of the "rotate grapple" function can be adjusted.

The function is used to rotate grapples or adjust other attachment tools.

Note!

After fine adjustment: Before resuming work, check the response of the machine to the control movements. Familiarise yourself with the operation of the control devices at the modified settings.

Fig. 3-9

Fine adjustment menu for rotating grapple

The bar indicator indicates the maximum achievable speed of the "rotate grapple" function. The speed can be set to slow (min) or fast (max).

The higher the chosen value, the faster the working tool is moved when the mini joystick is operated. If a high value (bar near "max") is selected, the attachment tool is moved at high speed, even if the mini joystick is only moved a short distance. We recommend choosing low to medium values.

The settings remain permanently activated and can only be disabled or modified in the menu.

Press the UP or DOWN arrow button to select the desired speed.

Press the BACK button.

The submenu is closed.

The settings are saved.

Alternatively Press the Menu button again.

The menu page is displayed.

The settings are saved.

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3 - 17

Control, operation

Operating manual

Operating and control elements

Menu: Service interval confirmation

Fig. 3-10

Service interval menu

This menu provides information concerning scheduled service checks. It also allows for the confirmation of completed services. The current operating hours (e.g.

"478 Hrs") are displayed together with the scheduled service interval (e.g.

"500 Hrs").

The service can be completed earliest 50 operating hours before it is due.

As soon as the pre-set operating hours are reached, the operator is requested to indicate whether the service tasks have been completed.

Service has been carried out: Press the UP button.

The OK symbol is not stricken through and is highlighted in black.

Press the Menu button.

The service is confirmed to have been completed at the current operating hours.

Service has not been carried out: Press the BACK button.

The submenu is closed.

Tool Control menu Selection of working tool settings This menu is used to assign pre-set pressure and flow reductions to the working tools (activation of foot pedals, e.g. for hydraulic hammer or grapple).

A

Caution!

Incorrect pressure or flow reduction settings may result in damage to the working tool (e.g. hydraulic hammer) or impair its functions (e.g. mill).

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Operating manual

Control, operation Operating and control elements

Fig. 3-11

Tool Control menu

EV1 = oil volume 1

EV2 = oil volume 2 (from A 934 B LI)

EV6 = pressure The currently activated option is highlighted by a black background. To select a different option, move the arrow and press the Menu button.

In the example (see Fig. 3-11) option 3 is initially activated.

Press the UP or DOWN button.

A different pre-defined option (1 - 10) can be selected (e.g. if the working attachment has been changed).

Press the Menu button.

Your selection is confirmed.

The selected option is activated, and the symbol is highlighted by a black background (in the example: option 1).

To exit the submenu: Press the BACK button.

The submenu is closed.

In the main menu, the selected working tool is shown (e.g. "Option 1"), and the selected pressure and flow combination is available.

The working tool is now operated at reduced oil pressure / reduced flow rate.

Fig. 3-12 1

Main screen, display of selected working tool

Selected option (attachment)

2

The symbol "R" is displayed only, if the attachment is operated with pressure / flow reduction.

copyright by R 934 C Litronic / 11692682

3 - 19

Control, operation

Operating manual

Operating and control elements

Note!

On request, LIEBHERR and the customer service department will label the options with the name of the associated tool, e.g. "hammer" or "grapple".

Menu: Operating hours and machine data This menu consists of 4 pages and provides information regarding the operating hours of the individual units, processes, operating modes and machine data.

Repeatedly press the Menu button until the desired page is displayed.

Fig. 3-13

Engine operating hours menu

Page 1 indicates the operating hours of: – Diesel engine in mode "P" – Diesel engine in mode "E" – Diesel engine in mode "F" – Diesel engine in mode "L" – Diesel engine at maximum nominal speed H – Diesel engine at low idle speed L – Diesel engine in manual speed adjustment mode

Fig. 3-14

Machine movement hours menu

Page 2 indicates the operating hours of: – Attachment movements controlled by means of joysticks – Travel movement controlled by means of the travel pedal in creeper and fast gear Page 3 indicates the operating hours of: – Swivelling movement of the slewing gear (no activation from model A 934) – Activated additional equipment controlled with foot pedals

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Operating manual

Control, operation Operating and control elements

Fig. 3-15

Technical data

Page 4 provides information regarding machine data: – typ, serie: Excavator model with type and serial number – ver: Software version (machine and diesel engine) – volt: Current operating voltage (V) The "nom" and "hours" fields are not used in this machine.

To exit the menu: Press the BACK button.

The display returns to the operator's menu.

Menu: Status of hydraulic pumps and electrical inputs/outputs

Fig. 3-16

Pressure and flow reduction currents menu

Repeatedly press the Menu button until the desired page is displayed.

Page 1 shows the signals of the activated flow and pressure reductions.

In the example shown here, the signals of one working tool are shown, which is saved with the name "Option 1" (for the adjustment of the working tool settings, see Tool Control menu).

For the consumer used here, an oil flow rate (EV1) is reduced to 80 %, while the pressure (EV6) is reduced to 75 %.

If several reductions are activated simultaneously, the smallest value is relevant.

When a consumer with a set reduction is activated, the ® symbol is displayed on the main screen (if enabled).

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Control, operation

Operating manual

Operating and control elements

Fig. 3-17

Power control solenoid and fan speed currents menu

Page 2 shows the current of the power control solenoid.

Page 3 shows the current of the proportional valve EV5 for the control of the speed of the hydrostatic fan drive.

Fig. 3-18

Slewing gear current

Page 4 shows the current of the slewing gear control.

Fig. 3-19

Electrical inputs

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Operating manual

Control, operation Operating and control elements

Fig. 3-20

Electrical inputs

Pages 5 to 8 provide an overview of the status of the various electrical inputs. "

" indicates that the input is not activated.

"

" indicates that the input is activated.

"NC" below the terminal designation indicates that the respective input is deactivated via the software.

M4 / Time (or B19 / Time) refers to the set delay times for the interval function of the windscreen wipers or the idle automatic.

To exit the menu: Press the BACK button.

The display returns to the operator's menu.

Menu: errors (operating errors and electrical system errors)

Fig. 3-21

Errors menu

This menu offers 3 choices for selection: – Select list Exxx to obtain a list of the machine errors detected by sensor devices.

– Select list E-elec. to obtain a list of the electrical wire faults of the LCD display stored during operation.

– Select list S-Exxx to obtain a list of the machine errors displayed when the service plug is connected.

To select the error type: Press the UP and/or DOWN buttons.

The preceding or next error type is highlighted in black.

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3 - 23

Control, operation

Operating manual

Operating and control elements

Press the Menu button.

The submenu highlighted in black is displayed.

When more than 6 error codes are shown, press the UP and DOWN buttons to scroll through the list.

Machine errors list Exxx:

Fig. 3-22

Error list (left) and occurrence of errors (right) menu

Select list Exxx.

Press the Menu button.

The first page of the submenu is displayed.

The first screen shows all errors with the respective error code.

Press the UP or DOWN button to select the desired error code.

Press the Menu button again.

The second page of the submenu is displayed.

The second page shows the operating hours and the duration of the first and last ten occurrences of the selected error.

Press the BACK button.

The first page of the submenu is displayed.

Press the BACK button again to select a different error type. Alternatively, press the UP or DOWN button to select a new error code. s*: Error was announced by a buzzer signal and confirmed by the operator with pressing the BACK button. The duration is indicated in seconds. m*: Error was announced by a buzzer signal and confirmed by the operator with pressing the BACK button. The duration is indicated in minutes.

Note!

Menu list Exxx shows only operating errors assigned the E5xx error code.

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R 934 C Litronic / 11692682

Operating manual

Control, operation Operating and control elements

Wire fault list E-elec.:

Fig. 3-23

Occurrence of electrical faults (left) and fault statistics (right)

Select list E-elec.

Press the Menu button.

The submenu is displayed.

It contains a list of all electrical faults with codes.

The "Test" column shows the number of faults that have occurred since the last reset of the list.

The figure in the "reset test at x Hrs" field (e. g. 12 Hrs) indicates the time at which the "Test" column was last deleted.

Press the BACK button.

Select a different fault type, if required.

Other error list S-Exxx:

Fig. 3-24

Service operation error list menu

This menu shows additional information when the service plug is connected to the machine.

To exit the menu: Repeatedly press the Menu button until the operator's menu is displayed.

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3 - 25

Control, operation

Operating manual

Operating and control elements

Menu: Time

Fig. 3-25

Adjusting the time settings

This menu is used to adjust the time settings. When the menu is called up, the right digit of the time is highlighted.

To adjust the time, press the UP or DOWN button.

Press the Menu button.

The next figure to the left is highlighted.

Repeat the above procedure to adjust all digits of the time display.

Press the BACK button.

The new time is confirmed, and the operator's menu is displayed.

Menu: Stick cylinder shut-down (optional equipment) This menu is available in machines equipped with an electronic stick cylinder shutdown system.

When the boom is moved, it can reach great heights and outreaches. The stick with attached load might collide with the operator's cab or impact on other objects.

There is even a risk of collision with the operator's cab or the object, which would likely result in injury to the operator, and damage to the working attachment or the attached load.

In order to assist the machine operator, the range of movement of the stick is limited by the electronic stick cylinder shut-down system.

The movement range of the stick cylinder is determined by two shut-down points that can be adjusted through the operator's menu. The shut-down points of the stick and the boom settings determine the reach of the working attachment.

Danger!

While the settings are made in the "stick cylinder shut-down" menu, the stick can be moved freely and without limits in all directions. Risk of accident!

Proceed with great care when moving the stick during the adjustment.

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R 934 C Litronic / 11692682

Operating manual

Control, operation Operating and control elements

Fig. 3-26

Shut-down points: Retracting stick (min), extending stick (max)

Safety distance (distance between the working attachment and the operator's cab or objects in the vicinity of the machine): min. 1.5 m.

Adjust the stick cylinder shut-down function in such a way that there is a sufficient safety distance, even if the working tool is oscillating or if shut-down is delayed.

Fig. 3-27

Menu: Stick cylinder shut-down

Note!

When adjusting the shut-down points, observe the following: The control system determines the stick position based on decimal measurements.

The menu does therefore not indicate angle values. The stick position is indicated by a value (value) that is not directly related to a real measurement.

The value increases as the stick is extended and decreases as the stick is retracted.

Setting the shut-down point for retraction:

Fig. 3-28

Menu: Shut-down point for retraction

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Control, operation

Operating manual

Operating and control elements

Move the elevating operator's cab (optional equipment) to its most forward extended position.

Move the boom upwards to the stop.

Retract the stick to the desired shut-down point.

Press the UP or DOWN arrow button to select the shut-down point for retraction (min. limit).

Press the Menu button.

The teach min. position menu is displayed.

The shut-down point min. limit (in example: 85) and the position of the stick act. value (in example: 93) are displayed.

Press the Menu button again.

The new value is saved (store min. value).

The shut-down point min. limit now corresponds to the position of the stick act. value.

Setting the shut-down point for extension:

Fig. 3-29

Menu: Shut-down point for extension

Extend the stick to the desired shut-down point.

Press the UP or DOWN arrow button to select the shut-down point for extension (max. limit).

Press the Menu button.

The teach max. position menu is displayed.

The shut-down point max. limit (in example: 177) and the position of the stick act. value (in example: 160) are displayed.

Press the Menu button again.

The new value is saved (store max. value).

The shut-down point max. limit corresponds now to the position of the stick act. value.

Note!

The menu options teach min. position and teach max. position cease to be displayed 15 seconds after the last actuation of a button. If the new shut-down points are not confirmed within this time, the previously set settings remain valid.

To exit the menu: Press the BACK button.

The display returns to the operator's menu.

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R 934 C Litronic / 11692682

Operating manual

Control, operation Operating and control elements

Menu: automatic central lubrication system (optional equipment) This menu is only available in machines that are equipped with an automatic central lubrication system.

It allows for the adjustment of the automatic lubrication, based on the actual use of the machine. The amount of applied grease is determined by the selected mode.

There are 3 different modes:

Mode

Use

Lubrication

H

Heavy-duty use (Heavy duty)

Large amount of grease

N

Normal use (Normal duty)

Medium amount of grease

L

Light use (Light duty)

Small amount of grease

The currently selected mode is highlighted.

Fig. 3-30

Automatic central lubrication menu

Selecting mode Press the UP or DOWN button.

The selection is blacked out (H, N or L).

Press the Menu button.

The arrow denotes the new mode selected.

To exit the menu: Press the BACK button.

The display returns to the operator's menu.

Menu: Purge mode This menu is only displayed when the diesel engine is shut down. It can be used to start the diesel engine in purge mode.

This is necessary when the fuel tank has been driven empty, or if the fuel system has been emptied.

First bleed the empty fuel system manually. Some air remains however in the fuel high pressure system. This air can only escape when the diesel engine is started.

The purge mode assists this process. The fuel high pressure system is automatically bled, so that the diesel engine starts better.

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Control, operation

Operating manual

Control

Fig. 3-31

Purge menu

Press the Menu button.

The purge mode is activated (purge = ON) Start the diesel engine. For detailed instructions, see chapter "Fuel system maintenance".

3.2 Control 3.2.1

Entering and exiting the operator's cab Caution!

Risk of injury when operator's cab is entered or exited without due regard to the safety instructions!

When entering and exiting the operator's cab, ensure that the safety lever is in its top position.

Always access and descend from the machine using the provided climbing aids.

Ensure that your body is resting on at least 3 points: Hold on to the machine with both hands when lifting a foot, and stand on both feet when letting go with one hand.

Do not use control elements as handles.

Never jump from the machine.

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R 934 C Litronic / 11692682

Operating manual

Control, operation Control

3.2.1.1

Mounting, descending

Fig. 3-32

A: Elevating operator's cab, with catwalk

Position the uppercarriage in travel direction (i.e. parallel to the undercarriage).

Always mount the machine/descend from the machine facing it.

3.2.1.2

Accessing, exiting

Fig. 3-33

B and C: Operator's cab without catwalk

1

Door handle

2

Locking mechanism

3

Inside door handle

4

Lever of locking mechanism

Accessing cab: Press the door lock on the door handle 1 and open the door.

If you wish to leave the door open, open it fully (swivel by 180° backwards) and secure it with the locking mechanism 2.

Always enter the cab facing the machine, and sit down on the operator seat.

Secure the safety belt.

Adjust the operator's seat.

Exiting cab: Park the machine and push the safety lever upwards.

Push down the door handle 3 at the door lock.

Open the door fully and secure it with the locking mechanism 2.

Face the machine when descending from it.

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3 - 31

Control, operation

Operating manual

Control

Releasing door locking mechanism: The door is secured by the locking mechanism 2.

Move the lever 4 beside the operator's cab frame outwards.

The door is now released.

Close the door.

3.2.2

Adjusting vertical position of the operator's cab (optional equipment) The height of the operator's cab can be adjusted steplessly.

Danger!

Risk of collision of elevated operator's cab with obstacles!

There is a risk of injury, if the elevated cab's paths of travel are obstructed or inclined. The stability of the machine might be compromised when the operator's cab is lifted.

Do not move the machine while the operator's cab is elevated, and if the paths of travel are obstructed or inclined.

Adjust the cab height only when the machine is standing still.

During the adjusting procedure, ensure that no persons are standing in the danger area of the machine.

Danger!

If the operator's cab is inadvertently lowered, there is a serious risk of injury or even death.

Familiarise yourself with the emergency operating devices of the cab so that you can take appropriate measures, if the need arises.

Ensure that no persons are standing in the danger area of the cab (i.e. under it).

Keep a safe distance to moving parts while the operator's cab is being lowered.

Danger!

There is an increased risk of injury when repair and maintenance work is to be carried out while the operator's cab is elevated.

If at all possible, carry out such work when the operator's cab is lowered.

If it is necessary to carry out work on the elevated cab, prop it up with suitable supports.

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R 934 C Litronic / 11692682

Operating manual

Control, operation Control

Fig. 3-34

Height adjustment of the operator's cab

The machine is in ready mode.

The engine is running.

The safety lever is moved down.

The servo control is active.

Press the UP or DOWN button to lift a or lower b operator's cab.

3.2.3

Emergency lowering of the operator's cab In the event of a failure of the diesel engine or the control system of the elevating operator's cab, it can be lowered manually by releasing the operating pressure.

Emergency lowering of the operator's cab:

Fig. 3-35

Emergency lowering valve at cab base

Move the lever 1 to position b.

The operator's cab is gradually lowered as long as the lever is held in position b.

Emergency lowering from outside the operator's cab: Danger!

Risk of injury from crushing when operator's cab is lowered!

When lowering the operator's cab, ensure that no persons are standing in the danger area of the lift frame and keep a safe distance from all moving parts.

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3 - 33

Control, operation

Operating manual

Control

Fig. 3-36

Emergency lowering valve on lift frame

Move the lever 1 to position b.

The operator's cab is gradually lowered as long as the lever is held in position b.

Note!

While the lever is in position b, the operator's cab cannot be lifted.

After lowering the cab, return the lever to position a.

3.2.4

Safety lever

Fig. 3-37

Safety lever

To prevent inadvertent movements of the machine, the left control console is equipped with a safety lever.

Caution!

When entering or exiting the operator's cab, always ensure that the safety lever is in its top position (arrow).

When the safety lever is tilted up, a number of machine functions are disabled or otherwise modified: – Actuation of the pilot control units (e.g. joysticks or pedals) does not result in movement of the machine.

– The slewing gear brake is applied.

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R 934 C Litronic / 11692682

Operating manual

Control, operation Control

– It is now not possible to release the slewing gear brake.

By moving the safety lever to its bottom position, the initial switching statuses are reestablished, and the pilot control units are enabled.

Before commencing work with the machine, take place on the operator's seat and move the safety lever to its bottom position.

3.2.5

Operator seat Danger!

The adjustment of the operator seat could result in an inadvertent actuation of control elements, moving the machine or the attachment.

This can lead to injury to persons or damage to property.

Do not adjust the operator seat while driving the machine.

Park the machine and apply the parking brake.

Move the safety lever up.

Fig. 3-38

Operator seat

1

Operator seat heating

2

3

Backrest adjustment

4

Mechanical / pneumatic lumbar support* Armrest height adjustment

5

Armrest adjusting wheel

6

Horizontal suspension*

7

Horizontal adjustment with control consoles

8

Display for weight settings*

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Control, operation

Operating manual

Control

9

Manual/automatic adjustment for body weight and seat height* 11 Horizontal adjustment

10 Shock absorber*

13 Seat inclination 15 Armrests

14 Safety belt 16 Headrest

12 Seat depth

* Model variant

Adjusting seat to body weight/seat height (in models with manual adjusting mechanism): Sit down on the seat.

Adjust the seat height/body weight by pulling or pushing the lever 9 to the stop.

Check the display 8.

• green = settings correct • yellow = correction required If necessary: Adjust the settings by pulling or pushing the lever 9 to the stop.

Adjusting seat to body weight (in models with automatic adjusting mechanism)*: Before adjusting the body weight settings, set the shock absorber* to "soft".

Sit down on the seat.

Pull the lever 9 briefly upwards.

The seat is automatically adjusted to suit the body weight of the operator.

Adjusting seat height (in models with automatic adjusting mechanism)*: Before adjusting the height, set the shock absorber to "soft".

Caution!

Risk of damage to compressor.

Do not run the compressor continuously for more than 1 minute.

Adjust the seat height by pulling or pushing the lever 9 to the stop.

Adjusting seat depth: Lift the button 12.

Sit on the seat and move it horizontally to the desired position.

To adjust the angle of inclination of the seat, press the button 13.

Sit on the seat and move it to the desired angle.

Horizontal adjustment: Pull up the lever 11.

Adjust the operator seat in horizontal direction.

Release the lever. Ensure that the lever engages properly in the desired position (audible click).

Carry out the following check: After locking, it must be impossible to move the operator seat to a different position.

Horizontal adjustment with control consoles: Pull up the lever 7.

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R 934 C Litronic / 11692682

Operating manual

Control, operation Control

Adjust the operator seat together with the control consoles in horizontal direction.

Release the lever. Ensure that the lever engages properly in the desired position (audible click).

Carry out the following check: After locking, it must be impossible to move the operator seat to a different position.

Adjusting backrest: Pull up the lever 3.

Sit on the seat and move the backrest to the desired position.

Release the lever. Ensure that the locking lever engages in the desired position.

Carry out the following check: After locking, it must be impossible to move the backrest to a different position.

Adjusting lumbar support (in models with mechanical adjusting mechanism): Adjust the height and curve of the lumbar pad by turning the hand wheel 2 at the back of the seat.

Adjusting lumbar support (in models with pneumatic adjusting mechanism)*: Adjust the curve of the upper and lower section of the backrest upholstery by pressing the two switches 2 at the rear of the seat.

Adjusting shock absorber*: The shock absorption level can be adjusted to suit the actual road or terrain conditions.

Turn the handle 10 to the desired position and release it.

• Position 1 = hard • Position 2 = medium • Position 3 = soft Adjusting horizontal cushioning*: Under certain operating conditions, you can improve the operator comfort by adjusting the horizontal cushioning mechanism. This helps reduce impact stress in travel direction on the operator as these impacts are better cushioned by the seat.

Move the handle 6 to the desired position.

• Position 1 = horizontal cushioning OFF • Position 2 = horizontal cushioning ON After the handle has been moved to position 1, ensure that is engages properly in this position: push the seat back until you hear an audible click.

Adjusting armrests: Turn the hand wheel 5 until the armrests are in the desired position.

If required, the height can be adjusted individually for each armrest: Remove the cover cap 4 from the seat covering.

Loosen the hex (wrench size 13 mm).

Set the armrest to the desired position.

Tighten the hex nut (25 Nm).

Replace the cover cap on the hex nut.

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3 - 37

Control, operation

Operating manual

Control

Adjusting headrest: Adjust the headrest 16 by pulling it from the engaging mechanism.

Adjust the headrest angle by pushing it forward or back.

To remove the headrest, move it to the upper stop and then pull it with force from the seat.

Seat heating: Actuate the switch 1 to switch on the seat heating.

• Position 0 = seat heating OFF • Position 1 = seat heating ON * Model variant

3.2.6

Windscreen

Fig. 3-39

Windscreen

The windscreen can be placed into 2 positions.

– Position a: windscreen closed.

– Position b: windscreen is fully opened (attached to the roof of the operator's cab).

Pull the latch 1 inwards and down.

The windscreen is released.

Move the windscreen with the bracket 2, engage it in one of the windscreen positions (a or b) and engage the latch 1.

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R 934 C Litronic / 11692682

Operating manual

Control, operation Control

3.2.7

Sun blind

Fig. 3-40

Sun blind for windscreen and cab roof

The operator's cab is equipped with two sun blinds, one for the windscreen and one for the glass panel in the cab roof.

Windscreen Pull the sun blind down, holding it by the cross bar 1.

The sun blind can be individually adjusted.

Press the switch 2 (red).

The sun blind is automatically rolled up.

Cab roof Pull out the sun blind and engage it in the holders provided.

To open the sun blind, remove it from the holders and let it roll up slowly.

3.2.8

Emergency exit through rear window

Fig. 3-41

Emergency exit through rear window

Pull the latch 1 at the inside of the rear window to remove the rubber insert 2.

In the event of an emergency, pull out the rubber insert 2 along the entire circumference of the panel and push out the window.

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3 - 39

Control, operation

Operating manual

Control

3.2.9

Inside lighting

Fig. 3-42

Inside lighting

The inside lighting is switched on/off with a rocker switch.

Set the rocker switch to position 1.

The light is switched on.

Set the rocker switch to position 0.

The light is switched off.

Switch position 2 is not assigned a function.

3.2.10

Fire extinguisher (optional equipment)*

Fig. 3-43

Fire extinguisher / first aid kit

The fire extinguisher is stored in a recess in the bottom right corner of the operator's cab. *Operator instructions

3.2.11

Windshield wiper

3.2.11.1

Windshield wiper With the ignition turned on, the windshield wipers are activated by pressing the switch S14.

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R 934 C Litronic / 11692682

Operating manual

Control, operation Control

Press switch.

Intermittent function.

LED I in the switch lights up.

Press switch again.

Continuous operation.

LED C in the switch lights up.

LED I in the switch turns off.

Press switch again.

Windshield wiper is turned off.

LED C in the switch turns off.

Adjusting the interval time for the intermittent function The interval time for the intermittent function can be set when the ignition is on by pressing switch S14.

Press the switch until the windshield wiper is turned off (LED I in switch turns off) Press and hold switch.

LED I in the switch blinks.

Release the switch when the desired interval time has been reached.

The interval time can be set to between 2 and 10 seconds.

3.2.11.2

Windshield washing system With the ignition is turned on, press the button S11 to activate the electric windshield washing system.

Press and hold button down.

Water will be sprayed onto the front windshield through nozzles.

The windshield wiper runs in continuous operation.

Release the button.

The water flow stops.

The windshield wiper continues to run continuously for approx. 3 seconds.

3.2.11.3

Windshield washing fluid container

Fig. 3-44

Windshield washing fluid container

The container for the windshield washing fluid is located at the rear of the cab.

Open the cover (see arrow) to refill the container with commercially available windshield washing fluid.

Quantity: see Lubrication Chart

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3 - 41

Control, operation

Operating manual

Control

3.2.11.4

Window wiper on the cab roof (option)

Fig. 3-45

Window wiper on cab roof

With the ignition turned on, press the switch S218 in the right control panel to activate the windshield wiper on the cab roof.

Press switch S218.

The windshield wiper on the cab roof runs continuously.

Press switch S218.

The windshield wiper on the cab roof is turned off.

3.2.12

Lighting

Fig. 3-46

Positions of lighting devices

1

Parking light/travel light lamp

2

Attachment headlight

3

Front roof light*

4

Beacon*

5

Rear roof light*

6

Rear light*

7

Tail light

*

Optional equipment

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Operating manual

Control, operation Control

Parking and travel light (dipped light) The switch S22 is assigned several functions that are operated by repeat actuation: – 1. Parking light on.

– 2. Travel light on.

– 3. Lighting off.

When the parking or travel light is on, the tail light is also on.

Attachment headlight, front roof light (optional equipment) The switch S10 is assigned several functions that are operated by repeat actuation: – 1. Attachment light on.

– 2. Attachment light off.

– 3. Attachment light and roof light on.

– 4. Attachment light and roof light off.

Beacon (optional equipment) The beacon is switched on with the switch S41.

Rear roof light, rear light (optional equipment) The rear roof light is switched on with the switch S275.

Press the switch.

Lights are on.

The indicator light in the switch is on.

Press the switch again.

Lights are off.

The indicator light in the switch is off.

3.2.13

Radio mute mode (optional equipment) The switch S422 enables the operator to switch the radio speakers to mute.

Press the switch S422.

The speakers are switched to mute.

Press the switch S422 again.

The speakers are switched to normal volume again.

3.2.14

Heating and air-conditioning system The operator's cab is equipped with a heating and air-conditioning system as standard. The operator's cab can be heated, air-conditioned and ventilated.

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3 - 43

Control, operation

Operating manual

Control

Fig. 3-47

Air conditioning control unit

Control keys 1 - A/C operation (cooling) 2 - Increase cab temperature / fan speed 3 - Reduce cab temperature / fan speed 4 - Control ON / OFF 5 - Fan speed manual / automatic 6 - REHEAT function 7 - Heating operation manual / automatic 8 - Fresh air operation / recirculated air mode 9 - Rear wall ventilation flap OPEN / SHUT 10 - Right control console ventilation flap OPEN / SHUT 11 - Windscreen and legroom ventilation flap OPEN / SHUT 12 - Windscreen ventilation flap OPEN / SHUT Display screens 13 - Recirculated air 14 - REHEAT function 15 - Air conditioning (cooling) 16 - Rear wall ventilation flap OPEN 17 - Right control console ventilation flap OPEN 18 - Windscreen ventilation flap OPEN 19 - Legroom ventilation flap OPEN 20 - Automatic operation 21 - Fan speed indicator bar for manual operation 22 - Fan speed symbol for manual operation 23 - Heating operation symbol for manual operation 24 - Heating performance indicator bar for manual operation 25 - Specified value / error code 26 - Temperature unit (°) A flashing error code F1-F5 will be displayed if the control unit identifies an error.

Note!

In the event of an error, please contact the LIEBHERR customer service centre.

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R 934 C Litronic / 11692682

Operating manual

Control, operation Control

Note!

To avoid the starter and battery from overloading, only switch on the airconditioning system after starting the diesel engine.

If the machine is to be used for a lengthy period of time without switching on the air conditioning system, operate the compressor every 2 weeks by pressing REHEAT key 6.

Switch on the control unit:

Fig. 3-48

Control unit self-test

Switch on the system by pressing key 4.

The software version will be displayed for approximately 12 seconds while the control unit performs its self-test.

The heating and air conditioning in the cab are in operation. Heating performance and fan speed are automatically controlled when the AUTO (20) symbol is displayed.

Adjusting the cab temperature:

Fig. 3-49

Example: increase the temperature

The desired cab temperature is displayed on-screen.

Press key 2 to increase the temperature.

Press key 3 to reduce the temperature.

Example: Press key 2 five times to increase the cab temperature by 5 °C. The set temperature value will remain stored until the next change is made.

To start cooling, switch on a/c operation (key 1).

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Control, operation

Operating manual

Control

Manually adjusting the heating performance:

Fig. 3-50

Manually adjusting the heating performance

Press key 7 to manually adjust the heating performance.

Symbol 23 (manual heating operation) and symbol 24 (heating performance indicator bar) are displayed, the text "AUTO" disappears.

Symbol 23 flashes for 5 seconds; during this time the heating performance can be manually adjusted.

Use keys 2 or 3 to increase/reduce heating performance.

Press key 7 twice in quick succession to restart automatic mode.

Symbols 23 and 24 are no longer displayed The text "AUTO" is displayed; automatic heating operation is activated.

Switching a/c operation on and off:

Fig. 3-51

A/C operation and REHEAT function

Press key 1.

A/C operation is switched on, symbol 15 is displayed.

The compressor will now be switched on by the control unit as required. It automatically controls the speed (rpm) of the heating and air conditioning unit.

Press key 1 again.

A/C operation is switched off, symbol 15 is no longer displayed.

Press REHEAT key 6 if you need to defog the cab.

Symbol 14 is displayed.

The REHEAT function automatically switches off again after 10 minutes.

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Operating manual

Control, operation Control

Recirculated air and fresh air, fan speed:

Fig. 3-52

Adjust the air supply and fan speed

The heating and air conditioning system can be switched to either recirculated or fresh air mode.

Press key 8 to open / close the fresh air flap.

Symbol 13 indicates that the fresh air flap is closed.

Symbol 13 is no longer displayed when the fresh air flap is open.

Manually adjusting the fan speed: Press key 5 to manually set the fan speed.

Manual fan speed mode is activated, the text "AUTO" disappears.

Symbol 22 (manual fan operation) flashes for 5 seconds; during this time fan performance can be manually adjusted.

Use keys 2 or 3 to increase/reduce fan performance.

Symbol 21 (fan performance bar indicator) changes accordingly Press key 5 twice in quick succession to restart automatic mode.

Symbols 21 and 22 are no longer displayed.

The text "AUTO" is displayed; automatic fan speed operation is activated.

Changing the air supply:

Fig. 3-53

Location of front air outlets (Fig. left) and outlets on rear cab wall (Fig. right)

The air outlets are located on the seat bracket a, right control console b, windscreen c and rear cab wall d. Opened ventilation flaps are indicated by an arrow on the display.

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3 - 47

Control, operation

Operating manual

Control

To obtain optimum comfort: During heating operation, open the air outlets in the legroom area a, on right control console b and (if required) for windscreen c.

During a/c operation, open the air outlets in the rear cab wall d and right control console b.

The best heating or air conditioning performance is achieved when using the recirculated air function.

The air flow is regulated by pressing keys 9 - 12 and using the rotating and lockable air outlets.

Fig. 3-54

Air outlet symbols

Press key 9.

Symbol 16 is displayed.

Air outlets d are opened.

Press key 9 again to re-close the ventilation flaps.

Symbol 16 is no longer displayed.

Air outlets d are closed.

Open / close ventilation flap on control console: Press key 10.

Symbol 17 is displayed.

Air outlet b is opened.

Press key 10 again to re-close the ventilation flaps.

Symbol 17 is no longer displayed.

Air outlet b is closed.

Open / close the ventilation flap for the windscreen and legroom: Press key 11.

Symbols 18 and 19 are displayed Air outlets a and c are opened.

Press key 11 again to re-close the ventilation flaps.

Symbols 18 and 19 are no longer displayed Air outlets a and c are closed.

Open / close windscreen ventilation flap: Press key 12.

Symbol 18 is displayed.

Air outlet c is opened.

Press key 10 again to re-close the ventilation flaps.

Symbol 18 is no longer displayed.

Air outlets c are opened.

Switching the temperature display: The displayed temperature can be switched from ° Celsius to ° Fahrenheit.

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R 934 C Litronic / 11692682

Operating manual

Control, operation Operation

Press and hold key 8.

Press key 3 The temperature is displayed in ° Fahrenheit.

Repeat this procedure to switch the temperature display to ° Celsius.

Auxiliary heater operation (option):

Fig. 3-55

Auxiliary heater operation

Switch on the auxiliary heater When the air conditioning system is switched on: the text SH (auxiliary heater) is displayed for several seconds.

The air conditioning system switches itself off and cannot be switched on again during auxiliary heater operation.

The air conditioning system is ready for operation again once the auxiliary heater has been switched off and the run-on time has expired.

3.3 Operation 3.3.1 3.3.1.1

Safety instructions Bringing the machine into service – Before starting the machine, perform a thorough walkaround inspection.

– Visually check the machine for loose bolts, cracks, wear, leaks and damage.

– Never start or operate a damaged machine.

– Make sure to correct any problems immediately.

– Verify that all hoods, covers and doors are closed, however, the locks should remain unlocked.

– Verify that all safety signs are in place.

– Make sure that all windows, as well as the inside and outside mirrors are clean.

Secure all doors and windows to prevent unintentional movement.

– Before operating the machine, adjust the operator’s seat, the mirror, the armrests and the other items to ensure comfortable and safe working conditions.

– The noise protection devices on the machine must be in working order.

– Never operate the machine without the cab.

3.3.1.2

Starting the machine – Before start up, check all indicator lights and instruments for proper function, bring all controls into neutral position and insure that the safety lever is in the raised position.

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Operation

– Blow the horn briefly prior to starting the diesel engine, in order to warn persons located near the machine.

– Only start the machine from the driver’s seat.

– Start the diesel engine according to the regulations in the operating instructions, if you have not received any other instructions.

– Lower the safety lever and check all indicators, gauges, warning devices and controls for their proper indication.

– Only operate the diesel engine in a well-ventilated area, if the area is enclosed. If necessary, open doors and windows in the building to provide ample fresh air.

– Bring the engine and hydraulic oil to operating temperature. Low oil temperatures cause a slow reaction of the controls.

– Check that all attachment functions are operating properly.

– Carefully take the machine to an open area and check all control functions.

3.3.1.3

Shutting down the machine – Park the machine on level and stable ground whenever possible. Otherwise, chock or block wheels when parking on a slope.

– Lower the attachment so that it rests on the ground.

– Move all control elements into the neutral position. Set the parking and slewing gear brake.

– Switch off the diesel engine according to the operating instructions and move the safety lever up, prior to leaving the driver’s seat.

– Lock the machine, as well as all hoods, covers and doors; remove all keys and secure the machine against any unauthorized use.

3.3.1.4

Towing the machine – Always observe the correct procedure: See chapter “Towing the machine” in this operating manual.

– The machine may only be towed in exceptional circumstances, such as moving a disabled machine from a hazardous location.

– Before pulling or towing the machine, check all cables, hooks and couplers for safety and stability.

– Towing equipment must have sufficient tensile strength and must be attached to the undercarriage at the designated tiedown attachment points.

– Never allow anyone to remain in the area of the towing devices.

– During the towing procedure, keep within the required transport position, the permissible speed and distance.

– Proceed as outlined in the operating manual when putting the machine back into service.

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Operating manual

Control, operation Operation

3.3.2 3.3.2.1

Starting machine General instructions Note!

When using the machine above a certain height above sea level and at low ambient temperatures, the performance and the service life of the diesel engine with turbo charger is considerably reduced.

Under such conditions, there is an increased risk of overheating of the coolant circuit and the hydraulic oil.

To prevent damage to the diesel engine, the output of the engine is automatically in line with the elevation above sea level and the ambient temperature.

Simultaneously observe the coolant circuit and the hydraulic oil cooling system.

3.3.2.2

Tasks to be completed prior to machine start Caution!

A fire can only be extinguished, if it is accessible.

Before starting the machine, open all locks of the hydraulic excavators panels.

In the event of a fire, these doors can than be opened without delay to extinguish the fire.

Position of the locks: see chapter "Maintenance".

Caution!

When the tasks listed below are completed and the machine is already at operating temperature, there is risk of injury from scalding by hot coolant or oil.

Before completing the tasks described below, read the respective sections in chapter "Maintenance".

Before starting the machine, carry out the following routine procedure: – Check oil level in engine*.

– Check coolant level of diesel engine*.

– Check oil level in hydraulic tank*.

– Remove water from fuel system*.

– If necessary, remove ice and snow from the cooling air and combustion air intake openings. * For instructions on how to complete these tasks, refer to chapter "Maintenance".

3.3.2.3

Deactivating the electronic immobiliser (optional equipment) On request, the machine can be equipped with an electronic immobiliser.

Prior to start-up the electronic system checks whether the ignition key code is correct. If this is the case, the control system is enabled.

The machine is delivered with two sets of keys (blue and red):

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Control, operation

Operating manual

Operation

Fig. 3-56 1

Keys in different colours

Programmed ignition key (blue)

2

Master key (red)

Note!

The red master key cannot be used to start the machine. It is only used for the programming and deprogramming of additional blue ignition keys.

It is very important that the red master key is kept in a safe place (e.g. machine owner's office) and only the blue key is handed over to the machine operator.

Start the machine with a blue programmed key.

Safety functions The electronic immobiliser is automatically activated after five seconds, provided that the diesel engine is shut down and the ignition key is removed.

If more than five keys with different codes are inserted into the ignition within a period of one minute, the immobiliser remains activated for 15 minutes. During this period, it is not possible to start the machine with any other key.

Manipulation protection The electronic immobiliser cannot be deactivated by manual manipulation to the machine.

Deprogramming keys If a programmed key is lost, the remaining programmed keys must be deprogrammed and reprogrammed.

For detailed information (functions, deletion of program, programming of keys, troubleshooting), see the user manual of the manufacturer.

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Operating manual

Control, operation Operation

3.3.2.4

Switching on the electrical system Switch on the main battery switch:

Fig. 3-57

Battery main switch

Turn battery main switch to position 1 (ON).

Switching on the ignition:

Fig. 3-58 0 2

Ignition switch

Neutral position Ignition position

1 P

Contact position Parking position

Turn battery main switch to position 1 (ON).

Turn the ignition key to contact position 1.

The ignition is switched on.

As soon as the system is switched on, it completes a self-test of the control panel keyboard and the indicating instruments: All indicator lights, with the exception of the two LEDs of the switch S22 (travel light) are briefly on.

The LIEBHERR logo is shown on the monitoring display.

During the self-test, observe the indicating instruments.

Note!

If the system fails to complete a self-test of the control panel keyboard and the indicating instruments, check whether the battery main switch is in the "ON" position.

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Control, operation

Operating manual

Operation

Service interval indication

Fig. 3-59

Service interval request

After the self-test is completed, the system indicates with a graphic sign whether a service check is due. This icon is shown temporarily, replacing the operating hours indicator.

The service check symbol disappears after about 8 seconds.

3.3.2.5

Starting the diesel engine Note!

Incorrect starting can damage the diesel engine!

Only operate the starter, if the diesel engine is off.

Do not operate the starter for periods of more than 20 seconds.

If the machine fails to start after 20 seconds of starter operation: Wait at least 1 minute until the next start attempt.

Turn the ignition key to position 0 before starting the engine again.

After three unsuccessful start attempts: identify the cause of the failure and eliminate it.

Engine starting process: Turn ignition key to ignition position 2.

As soon as the engine is running, release the ignition key.

The indicator lights H2 and H12 must be off (H23 is switched off after a short delay).

A buzzer signal is audible while the engine oil pressure is built up.

Starting engine at low ambient temperatures: Depending on the coolant and ambient temperature, the intake air is automatically fed through a heating flange for pre-heating.

If the Pre-heating ON symbol is displayed, leave the ignition key in position 1 until the Pre-heating END symbol appears. The motor can now be started.

Leave the ignition key in position 1.

The Pre-heating ON symbol is displayed on the screen.

The symbol remains displayed on the main screen for approx. 20 seconds.

After the Pre-heating END symbol is displayed (for 2 seconds), turn the ignition key to the ignition position 2.

As soon as the engine is running, release the ignition key.

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Operating manual

Control, operation Operation

Starting engine at ambient temperatures below -18 °C If the machine is to be started at temperatures below -18 °C, we recommend equipping the machine with one or several starter aids available from LIEBHERR (see starting aids).

3.3.2.6

Warm-up phase for diesel engine and hydraulic system Diesel engine If the engine coolant is cold (temperature below 20 °C), the speed is automatically set to step 3.

This process is continued until the engine coolant temperature reaches 20 °C, or for maximum 3 minutes.

Slowly increase the engine load until the second green LED (from the left) at the indicator P2 is on.

Note!

The engine is damaged if it is operated for a prolonged time at idle speed.

Shut down the diesel engine, if the machine is not operated.

Hydraulic system If the hydraulic oil is cold (temperature below 8 °C), the pump performance is automatically limited.

As soon as the hydraulic oil temperature rises to above 8 °C, the machine can be operated at full power.

3.3.2.7

Power selection (MODE) and speed adjustment

Fig. 3-60

Speed adjustment and mode functions

The display P4 (LED chain) indicates the preselected engine speed. The chain represents 10 speed steps.

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Operating manual

Operation

Selecting engine power (mode): By pressing the switch S86, you can select between 4 different modes. The active mode is indicated by the letter below the LED. – L: LIFT mode (speed step 5 - extremely sensitive lifting of loads) – F: FINE mode (speed step 10 - grading work) – E: ECO mode (speed step 8 - economic operation) – P: POWER mode (speed step 10) After the diesel engine is started, the speed preselection is set to step 1 (lower idle speed of diesel engine). If preheating of the diesel engine is required, it is set to step 3.

If necessary, allow the engine to heat up first.

Actuate the mode switch S86.

The selected mode is applied together with the associated speed and power.

The respective LED is permanently on.

In modes E (maximum torque) and P, the diesel engine operates at maximum power. In modes L and F, the hydraulic output is reduced.

The selected mode is stored when the engine is shut down, and is indicated by a flashing LED above the switch at the next start-up.

Note!

The best combination of engine speed and hydraulic power can only be chosen by means of the modes.

Changing the engine speed with the arrow keys might not have the desired result.

Before starting work, select the mode suitable for the task in hand.

Adjusting engine speed with the arrow keys: Increase speed: Press switch S258.

Speed is increased by one step.

The speed indicator P4 changes accordingly (increasing).

Reduce speed: Press switch S229.

The speed is reduced by one step.

The speed indicator P4 changes accordingly (decreasing).

A flashing LED above the switch S86 indicates an intermediate step in the selected mode. This indicates that the engine speed does not correspond to the selected mode.

Before continuing with the work, adjust the mode.

3.3.2.8

To be observed after start-up Danger!

Risk of asphyxiation from exhaust gases.

In confined rooms, do not start the engine unless you have ensured sufficient ventilation.

Open doors and windows in the window to provide ample fresh air.

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Control, operation Operation

Caution!

Risk of injury, if function check is not carried out properly.

Run the diesel engine until the engine and hydraulic oils have reached operating temperature. At low oil temperature, the steering responds only slowly.

Move the machine to an open space to test the function of the travel and the slewing gear brake.

Check the operating devices of the attachment to ensure that they work properly.

3.3.3

Switching off the diesel engine Caution!

Risk of damage to the turbo charger!

Do not suddenly shut down the engine from full-load speed.

First reduce the engine speed to lower idle speed by pressing the arrow key S229.

As a result only the LED to the very left in the indicator P4 remains on (engine speed).

Let the diesel engine run for minimum 30 seconds in idle mode.

Turn the ignition key to position 0 to shut down the engine.

Remove the ignition key.

3.3.4

Starting aids Danger!

Risk of explosion when using starting aids containing ether in diesel motors with pre-heating devices.

Never use starting aids which contain ether.

3.3.4.1

Fuel preheating S26 (optional extra) The fuel filter is electrically heated during fuel preheating. This will prevent the fuel filter salting up at low temperatures.

Fuel preheating should be activated at least 5 minutes before starting in low outdoor temperature conditions.

Press switch S26 on the right control panel before starting. The ignition must be switched on.

The fuel filter is heated electrically.

The indicator light in the switch illuminates.

3.3.4.2

Coolant / engine oil / hydraulic oil preheating (optional extra) Coolant, motor oil and hydraulic oil may be electrically preheated or maintained at a steady temperature (independent heating).

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Control, operation

Operating manual

Operation

The vehicle is fitted with an electrical cabinet containing the electrical connections to operate and control the heating. It is located to the side of the operator cab. The electrical heating is supplied from a stationary power connection.

This will considerably shorten the diesel engine cold running phase particularly at low temperatures. This will protect the diesel engine and reduce fuel consumption.

Danger!

There is a fault current shock hazard, e. g. due to defective insulation, if the static power supply is not fitted with a fault current circuit breaker !

If no fault current cirucit breaker is fitted, the circuit between human and equipment is not interrupted when a fault current occurs. This may result in electric shocks.

Preheating must be via a socket fitted with a residual current current breaker that has a rated current less than 30 mA. Otherwise do not connect the preheating system!

Danger!

The use of unsuitable electrical cables may result in injury resulting from burning cables!

Electrical cables with insufficient cross-section for the preheating current may become too hot. This represents a fire hazard.

Use connection cables with a minimum cross-section of 1.5 mm2.

Extension cables must have at least the same cross-section (1.5 mm2) as the connection cable.

Fully unwind the cable if you are using a cable reel.

Caution!

The electrical connections are located to the side of the operator cab.

Before driving off ensure that the connection cable is no longer attached to the hydraulic excavator.

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Operating manual

Control, operation Operation

Fig. 3-61

Coolant / engine oil / hydraulic oil preheating

1

Coolant preheating indicator light

5

On / off rotary switch for preheating hydraulic oil

2

Engine oil preheating indicator light

6

3

Fuse

7

On / off rotary switch for preheating engine oil Socket for power cable

4

Hydraulic oil preheating indicator light

8

On / off rotary switch for preheating the coolant

Plug the power cable into socket 7 in the electrical cabinet.

Connect the power cable to the stationary connection (110 - 120 V / 220 240 V AC).

Turn rotary switch 5 hydraulic oil-preheating to the "ON" position.

Hydraulic oil preheating has now been switched on.

Indicator light 4 illuminates.

Turn rotary switch 8 coolant preheating to the "ON" position.

Coolant preheating is now switched on.

Indicator light 1 illuminates.

Turn rotary switch 6 engine oil preheating to the "ON" position.

Engine oil preheating has now been switched on.

Indicator light 2 illuminates.

After starting the engine, disconnect the power cable from the machine.

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Operating manual

Operation

3.3.5

Jump start procedure Danger!

When connecting to jump start batteries, old batteries can be subject to increased gas formation.

Wear safety glasses and protective gloves during the jump start procedure and avoid open flames and creating any sparks in the vicinity of the discharged vehicle battery. DANGER OF EXPLOSION! Only use jump start cables with a sufficient cross section. Always follow the established jump starting procedure.

3.3.5.1

Connecting the batteries First connect the cable to the positive terminal (+) of the discharged battery and then to the positive terminal (+) of the jump start battery.

Connect the second cable to the negative terminal (-) of the discharged battery and then to the negative terminal (-) of the jump start battery.

Start the engine as described above.

Caution!

Before removing the jump start cable, be sure to bring the Diesel engine of the jump started machine into low idle.

For safety reasons, turn on a large user, such as work headlights, uppercarriage lighting etc. to avoid overvoltage. The electronics could otherwise be damaged.

3.3.5.2

Disconnecting the batteries First remove the cable from the negative terminal (-) of the jump start battery and then from the negative terminal (-) of the discharged battery.

Remove the second cable from the positive terminal (+) of the jump start battery and then from the positive terminal (+) of the discharged battery.

Check the electrical functions of the machine.

For battery care and maintenance, see the chapter "Battery care".

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Control, operation Operation

3.3.6 3.3.6.1

Travel operation Travelling straight ahead

Fig. 3-62

Travelling straight ahead

1

Idler

5a / 5b Pedal for left travel gear

2

Sprocket wheel

6a / 6b Pedal for right travel gear

Caution!

Before setting the machine to travel mode, align the uppercarriage to the undercarriage to ensure that the idler 1 is at the front and the sprocket wheel 2 is at the rear of the machine.

Forward travel: Push both pedals forward (5a and 6a).

Reverse travel: Caution!

Before travelling backwards, ensure that no persons or obstacles are in the path of the machine.

Push both pedals down (5b and 6b).

3.3.6.2

Turning at standstill

Fig. 3-63

Turning at standstill

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Operating manual

Operation

Turning left (A): Push the left pedal down (5b).

Simultaneously push the right pedal forward (6a).

Turning right (B): Push the right pedal down (6b).

Simultaneously push the left pedal forward (5a).

3.3.6.3

Turning machine with one chain

Fig. 3-64

Turning machine with one chain

Turning left (A): Push the right pedal forward (6a).

Turning right (B): Push the left pedal forward (5a).

Note!

If possible, avoid turning backwards to protect the travel gear components against wear.

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Control, operation Operation

3.3.6.4

Steering travel gear by hand

Fig. 3-65

Manual steering of travel gear

For manual steering, the machine must be driven with great sensitivity.

Insert the hand levers (1 and 2) supplied with the tool into the pedals for the travel gears.

The travel gears can now be operated by hand.

Note!

For safety reasons, manual steering of the travel gear is mandatory when driving the machine onto or from a low-loader.

3.3.6.5

Speed regulation The travel speed is adjusted with the switch S21. The travel motors can be operated at 2 speed positions: – Normal travel (position 1): Maximum drawing pull at moderate speed.

– Fast travel (position 2): Reduced drawing pull at maximum speed.

Press the switch S21 down.

Switching over from normal to fast travel speed is activated.

The indicator light in the switch is lit.

During travel, the system switches automatically between normal and fast travel, provided that the ground conditions permit this. On difficult terrain, the system switches automatically to normal travel.

Press the switch S21 up.

Switching over from normal to fast travel speed is deactivated.

The indicator light in the switch is off.

When the switch S21 is not actuated, the travel motors remain always in speed position 1.

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Operating manual

Operation

3.3.6.6

Slowing down machine The hydrostatic travel drive acts as an operating brake.

Release the travel gear pedals.

The pedals automatically return to their neutral positions.

The travel gear decelerates.

The machine is slowed down.

When the travel gear pedals are in neutral position, the hydrostatic drive system of the machine prevents it from moving.

Approx. 5 seconds after the pedals have been set to neutral position, the parking brake is applied automatically. The attachment can still be moved.

Caution!

Sudden release of the pedals causes the machine to be halted abruptly.

Prior to starting the machine, put on the seat belt.

3.3.7

Travel warning device (option)

Fig. 3-66

Travel warning device

Actuate the travelling pedal 7.

The travel warning device turns on automatically.

An acoustical signal (warning tone) will be emitted.

Deactivating the travel warning device: Actuate the rocker switch S55 in left joystick 4.

The travel warning device is turned off.

Note!

The travel warning device can only be turned off 10 seconds after starting to travel.

If the accelerator pedal is actuated again, the travel warning device is reactivated.

3.3.8

Drive deactivation (optional extra) If the machine is equipped with an adjustable-height cab, it is possible to have a drive deactivation device fitted.

This device means that when the cab is raised: – driving motions are not possible.

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Control, operation Working with the machine

– the driving direction switch S30 does not function.

– the symbols "Drive forwards" and "Drive in reverse" do not appear on screen.

3.4 Working with the machine 3.4.1 3.4.1.1

Safety Instructions Working with the machine – Before starting to work, familiarize yourself with the specific conditions of the job site and any local regulations. These include: the obstacles in the working or movement area, the load carrying capacity of the ground and required safeguards for the job site to protect machines and personnel from public highway traffic.

– Always keep an adequate safety distance to overhangs, edges, embankments and an unsecured substrate.

– Be particularly cautious in conditions of reduced visibility and changing ground conditions.

– Always locate any underground utilities before you dig. Observe the required clearance distances to any underground utilities.

– Familiarize yourself with the location of power lines and use caution when working near them. Observe the required clearance distances to any power lines.

– In the case of contact with a power line: • do not move the machine or its attachment, • do not leave the operator’s platform, • warn people in the vicinity not to approach or touch the machine, • have the power turned off.

– Before moving the machine, always ensure that the attachments are safely secured.

– When traveling on public roads, observe all traffic regulations, insure that your equipment has all required lighting and marking, and observe any applicable load limitations.

– Always turn on the lights in conditions of poor visibility or darkness.

– Do not permit any passengers on the machine (except on two way excavators).

– Operate the machine only when seated and with the seat belt fastened.

– Report any problems or needed repairs and make sure that all required repairs are carried out immediately.

– Insure that the intended work area is clear of all personnel before beginning work.

– Before starting to work, always check the brake system as outlined in the operating manual.

– Never leave the operator’s seat as long as the machine is still moving.

– Never leave the machine unattended while the diesel engine is running.

– Know the loads to be handled and be aware of any stability limitations these loads may create.

– The maximum approved passable incline / traverse slope of the machine depends on the attached equipment as well as the substrate.

– For travel, move the uppercarriage parallel to the undercarriage and hold the load as close as possible to the ground.

EXCEPTION: see WHEN LOADING AND UNLOADING

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Working with the machine

– Adjust the travel speed to suit local conditions.

– Avoid working movements which could cause the machine to tip over.

– If possible, always work downhill or uphill, never sideways on a slope.

– Travel downhill at the permitted speed or you could lose control over the machine.

– Travel down grades at the appropriate speed to maintain control of the machine.

Shift to a lower gear to allow the engine to control the maximum speed of the machine.

– When loading a truck, make sure that the truck driver leaves the cab, even if a rock protection is present.

– Always use the safety devices intended for their specific use for demolition work, clearings, hoisting operations, etc.

– For terrain which is difficult to gain an overview of and whenever necessary, ask for assistance of a guide. Have only one person signal you.

– Only permit experienced personnel to secure loads and signal the machine operator. The guide must position himself within view of the operator or be in voice contact with him.

– Depending on the attachment combination, there can be a danger of collision between the working tool and the operator’s cab, the cab protection or the boom cylinders. To avoid damage, utmost attention is required when the bucket teeth enter this range.

3.4.1.2

Use in material handling applications, specifically when travelling with raised loads and attachments – Material handling applications, especially using a grapple, may require travel with suspended loads. Doing this will shift the machine centre of gravity and reduce stability.

The following practices and precautions should be observed: • Match your travel behaviour to the changed machine characteristics and surrounding conditions.

• Reduce the travel speed to avoid sudden braking or steering manoeuvres.

• Avoid sudden speed changes, such as braking, acceleration, changes in travel direction.

• Turn the uppercarriage only if the undercarriage is not travelling.

• Turn the uppercarriage only after taking on the load.

• Move the machine only after you have taken on the load, lifted it and turned the uppercarriage in travel position.

• If so required to the job site conditions, ensure, that you have appropriate windscreen protection.

The protective screen (FOPS) must be installed if there is a danger of falling objects from overhead.

• Do not exceed the grapple rated load. Know the density and weight of materials being handled.

– The working sequences when working with machines with grapples require a properly instructed and trained operator.

– The work application is only permitted after the machine operator has received sufficient training and practical experience.

3.4.1.3

Application of machines with tower elevation – Due to the tower elevation, the centre of gravity of the machine will shift upward in vertical direction. The travel and work behaviour of the machine will thereby be strongly influenced, for example reduction of dynamic stability.

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Control, operation Working with the machine

– Due to the elevated centre of gravity, the machine must be aligned in horizontal direction before starting to work. In horizontal direction, the centre of gravity of the uppercarriage is above the centre of the undercarriage, which improves stability.

– The machine can rock despite levelling and tip over!

For that reason, the following rules must be strictly observed: When driving the machine: • Driving with loads is not permitted.

• Swing the uppercarriage parallel to the undercarriage (transport position).

• Pull the attachment as close as possible to the machine.

• Only then may the outriggers be retracted and the machine be driven.

• Check the roadway to ensure that the ground is solid and even! Potholes and uneven road surfaces endanger the stability of the machine.

• Match your travel behaviour to the changed machine characteristics (higher centre of gravity) and surrounding conditions.

• Reduce the travel speed to avoid sudden braking or steering manoeuvres.

• Avoid sudden speed changes, such as braking, acceleration, changes in travel direction.

• Travel up or down grades perpendicular (at right angles) to the slope.

• Special care must be taken when driving through narrow passages - drive slowly!

In material handling operation: • Wheel model: Before moving (turning) the uppercarriage from transport position, the machine must be supported on outriggers and horizontally aligned.

• Make sure to check the placement surface of the outriggers (load carrying capacity of ground). Sinking of an outrigger below ground level would result in devastating consequences!

• Carry out all movements with increased caution.

• When swinging a load, first bring the attachment as low and close to the machine as practical. Note: be aware of the hazard of grapple swing when moving a load toward the operator cab.

• Avoid abrupt slow down or acceleration of the attachment or uppercarriage.

• Never lift a heavier load than stated in the load chart.

3.4.1.4

Additional notes for machines with fixed cab raiser – To enter and exit the machine, park the machine on level ground. Position the uppercarriage to the undercarriage in such a way that the steps and ladders are aligned.

– When entering or leaving the machine, always face the machine and use the three points of contact with the machine.

– When you can reach the door handle with your free hand, open the door first before climbing higher. Note that factors such as wind, can make it more difficult to open the door. For that reason, always guide the door by hand when opening the door. Make sure that the door is properly latched open.

– Continue to climb up and immediately sit on the operator’s seat in the cab. Then close the door and fasten the safety belt.

– Proceed with the same care when exiting and climbing down as when entering and climbing up the machine.

– Park the machine only on firm and level ground. Position the uppercarriage to the undercarriage in such a way that the steps and ladders are aligned.

– Release the safety belt. When exiting, face the machine and use the three-point support. Climb down until you can close the door safely. Always guide the door by hand when closing the door.

– Finally climb down to the ground.

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Operating manual

Working with the machine

3.4.1.5

Protection from vibrations – The vibration impact on mobile construction machinery is usually the result of the manner of utilization. Especially the following parameters have a significant influence: • Terrain conditions: Unevenness and potholes; • Operating techniques: Speed, steering, braking, control of operating elements of the machine during travel as well as working.

– The machine operator determines the vibration impact to a great part, since he himself selects the speed, the gear ratio, the working manner and the travel route.

This results in a wide range of various vibration impacts for the same machine type.

The full body vibration impact for the machine operator can be reduced if the following recommendations are observed: – Select the appropriate machine, equipment parts and auxiliary devices for the corresponding tasks.

– Keep the seat in good order and adjust it as follows: • The seat adjustment and the suspension should be made according to the weight and the size of the operator.

• Check the suspension and the adjustment mechanism regularly and make sure that the characteristics of the seat remain as specified by the seat manufacturer.

– Check the maintenance condition of the machine, especially regarding: Tire pressure, brakes, steering, mechanical connections, etc.

– Do not steer, brake, accelerate and shift or move and load the attachment of the machine in a jerky manner.

– Match the machine speed to the travel route to avoid vibration impacts.

• Decrease the speed when driving on pathless terrain; • Drive around obstacles and avoid very impassable terrain.

– Keep the quality of the terrain where the machine is working and travelling in good order: • Remove large rocks and obstacles; • Fill furrows and holes; • To establish and retain suitable terrain conditions, keep machines available and allow for sufficient time.

– Travel longer distances (i.e. on public roads) with suitable (medium) speed.

– For machines, which are frequently used for travel, consider use of auxiliary ride control systems, and also monitor speed to minimize buildup of "pitching" vehicle movement.

3.4.2

Sensor controlled low idle automatic This device automatically reduces the engine RPM to low idle after several seconds if no hydraulic functions are actuated by the joystick or the pedals. This saves fuel and reduces noise. Touching the joystick or operating the pedals resets the engine RPM to its original setting.

Actuate the sensor controlled low idle automatic by pressing switch S20.

Press switch.

Sensor controlled low idle automatic is activated.

LED in the switch lights up.

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Press switch again.

Sensor controlled low idle automatic is deactivated.

LED in the switch turns off.

Note!

The sensor controlled low idle automatic is turned off if the magnetic system is activated via switch S46 and the servo control S35 is turned off.

To set the reset time to low idle after the joysticks have been released: Press and hold switch.

LED in the switch blinks.

The desired time span is reached.

Release the switch.

LED in the switch lights up.

The sensor controlled low idle automatic is activated.

In each case, when a hydraulic function is actuated, the engine RPM which was previously set using the electric throttle control function will be reset automatically.

Caution!

The sensor controlled low idle automatic must be turned off when starting the Diesel engine and when travelling downhill. The LED in the switch may not light up.

3.4.3

Operating working attachment

Fig. 3-67

Operating working attachment

Caution!

The machine is equipped with PCSA controls as standard.

On request, the machine can be fitted with a different control system (e.g.

LIEBHERR control). For such machines, observe the instructions in the respective separate operating manual.

The left joystick (1) controls the stick and swivelling movements: – Movement in direction a and b: Stick is extended or retracted.

– Movement in direction c and d: Uppercarriage is swivelled to the left or right.

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Control, operation

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Working with the machine

The right joystick (2) controls the boom and grapple movements: – Movement in direction e and f: Grapple is closed or opened.

– Movement in direction g and h: Boom is lifted or lowered.

Moving the stick: The stick is moved by operating the left joystick 1.

Pulling the joystick backward a: Stick moves in direction a Pushing the joystick forward b.

Stick moves in direction b Moving the boom: The boom is moved by operating the right joystick 2.

Pulling the joystick backward g: The boom is lifted.

Pushing the joystick forward h: Boom is lowered.

Operating the grapple: Danger Risk of accident!

It is strictly forbidden to guide the attachment tool by hand.

Moving the joystick to the left e: Grapple is closed.

Moving the joystick to the right f: Grapple is opened.

Operating tilting system (optional equipment)

Fig. 3-68

Operating tilting system

The tilting system of the industrial stick is operated with the right joystick 2.

Moving the joystick to the left e: The working tool is tilted inwards.

Moving the joystick to the right f: The working tool is tilted outwards.

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Combined movements: Diagonal movement of a joystick results in a combination of the associated working movements. Operators can thus complete different attachment movements simultaneously.

3.4.4

Swivelling the uppercarriage The uppercarriage can be swivelled, if the slewing gear brake is released (LED in switch S17 is off).

The uppercarriage is swivelled by operating the left joystick 1.

Move the joystick to the left c: The uppercarriage is swivelled to the left.

Move the joystick to the right d: The uppercarriage is swivelled to the right.

3.4.5

Halting the uppercarriage The uppercarriage can be hydraulically slowed down in its movement and halted.

The mechanical slewing gear brake enables the operator to secure the halted uppercarriage in any desired position.

Hydraulic braking: Move the left joystick 1 to its neutral position: The uppercarriage is slowed down hydraulically.

Move the left joystick 1 in the opposite direction: The uppercarriage is stopped with the maximum hydraulic force.

Mechanical slewing gear brake: Caution!

The mechanical slewing gear brake can be damaged, if it is applied during a swivelling movement.

Therefore apply the slewing gear brake only when the uppercarriage is stationary.

Press the switch S17: The slewing gear brake is applied.

The LED in the switch is on.

Press the switch S17 again: The slewing gear brake is released.

The LED in the switch is off.

Checking the mechanical slewing gear brake: Ensure that the uppercarriage is stationary.

Press the switch S17.

The slewing gear brake is applied.

The LED in the switch is on.

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Move the left joystick 1 to the right and then to the left stop.

The uppercarriage must not swivel.

The slewing gear brake is working properly.

Positioning slewing gear brake (optional equipment):

Fig. 3-69

Positioning slewing gear brake

The positioning slewing gear brake is used for the progressive and precise slowing down of the uppercarriage.

Note!

Frequent use of the positioning slewing gear brake results in increased wear.

Do not use the positioning slewing gear brake as an operating brake, but only for special halting and parking manoeuvres of the slewing gear.

The uppercarriage should normally be slowed down hydraulically.

Operate the pedal 1.

The uppercarriage is slowed down in its movement.

3.4.6

Lowering the working attachment when diesel engine is shut off

Fig. 3-70

Lowering attachment when the diesel engine is off

In the event of an emergency, the attachment can be lowered even if the diesel engine is not running.

Turn the ignition key to contact position 1.

Turn the switch S75 to position 1 The symbol of the oscillating axle locking device ("locked") is shown on the screen.

The oscillating axle is permanently locked.

Operate the joysticks or pedals until the attachment is fully lowered.

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Note The attachment can be lowered with the residual pressure in the control oil unit.

This reserve is however limited and allows only for a limited number of operations of the pilot control units.

Therefore use the joysticks only to lower the attachment and do not attempt to complete other movements.

3.4.7

3.4.7.1

Electronic stick cylinder shut-down function (optional equipment) Function and purpose When the boom is moved, it can reach great heights and outreaches. The stick with attached load might collide with the operator's cab or impact on other objects.

There is even a risk of collision with the operator's cab or the object, which would likely result in injury to the operator, and damage to the working attachment or the attached load.

In order to assist the machine operator, the range of movement of the stick is limited by the electronic stick cylinder shut-down system.

The movement range of the stick cylinder is determined by two shut-down points that can be adjusted through the operator's menu. The shut-down points of the stick and the boom settings determine the reach of the working attachment.

3.4.7.2

Use of stick cylinder shut-down function The stick cylinder shut-down function remains permanently on and cannot be switched off during machine operation. If the stick is to be moved beyond a shutdown point, the stick cylinder shut-down function can be overridden.

Danger!

The stick cylinder shut-down function is an auxiliary tool designed to assist the machine operator!

For functional reasons, the stick cannot be brought to a sudden stop. The faster it is moved, the longer its braking distance. The machine might vibrate or swing! Risk of accident!

Please note that the machine operator is responsible for the correct adjustment of the relevant settings!

Adjust the stick cylinder shut-down function in such a way that there is a sufficient safety distance, even if the working tool is oscillating or if shut-down is delayed.

Avoid fast movements of the stick when it is moved near the shut-down limits.

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Control, operation

Operating manual

Working with the machine

Fig. 3-71

Shut-down points: Retracting stick (min), extending stick (max)

The following operating statuses are shown on the main screen:

Symbol

Description Stick cylinder shut-down Shut-down point reached when stick is being retracted.

Overriding stick cylinder shut-down function The shut-down point for retracting is overridden and the stick can be retracted without restrictions.

Stick cylinder shut-down Shut-down point reached when stick is being extended.

Overriding stick cylinder shut-down function The shut-down point for extending is overridden and the stick can be extended without restrictions.

Stick cylinder shut-down, fault If two symbols are shown at the same time, there is a fault in the system.

Possible causes: – Incorrect shut-down point settings, or settings of the two shut-down points identical.

Remedy: Readjust the settings for stick cylinder shut-down. For detailed instructions, see chapter "Operator's menu", submenu "stick cylinder shut-down".

– Electrical fault.

Contact the LIEBHERR customer service department. In the event of an electrical failure, you have the option to override the stick cylinder shut-down function with "emergency operation". For detailed instructions, see chapter "Malfunctions, emergency operation".

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3.4.7.3

Overriding stick cylinder shut-down function Danger!

When the function is overridden, the stick can be moved freely and without limits in all directions. Risk of accident!

When overriding the stick cylinder shut-down function, operate the machine with extreme caution.

Press the button S403.

The stick cylinder shut-down function is overridden. The buzzer sounds.

For the next 10 seconds, the stick can be moved without restrictions.

After the 10 seconds have lapsed, the stick can only be moved in one direction to return it to the permissible working range.

Carefully move the stick into the permissible working range.

The buzzer is automatically switched off as soon as the stick is again within the permissible working range.

3.4.7.4

Adjusting the stick cylinder shut-down function For detailed instructions, see chapter "Operator's menu", submenu "stick cylinder shut-down".

3.4.8 3.4.8.1

Mechanical stick cylinder shut-down function Function and purpose When the boom is moved, it can reach great heights and outreaches. There is a risk that the stick with attached load might come very close to the operator's cab.

There is even a risk of collision with the operator's cab or the object, which would likely result in injury to the operator, and damage to the working attachment or the attached load.

In order to assist the machine operator, the range of movement of the stick is limited by the mechanical stick cylinder shut-down system.

3.4.8.2

Use of stick cylinder shut-down function The stick cylinder shut-down function remains permanently on and cannot be switched off during machine operation. If the stick is to be moved beyond a shutdown point, the stick cylinder shut-down function can be overridden.

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Danger!

The stick cylinder shut-down function is an auxiliary tool designed to assist the machine operator!

For functional reasons, the stick cannot be brought to a sudden stop. The faster it is moved, the longer its braking distance. The machine might vibrate or swing! Risk of accident!

Please note that the machine operator is responsible for the correct adjustment of the relevant settings!

Adjust the stick cylinder shut-down function in such a way that there is a sufficient safety distance, even if the working tool is oscillating or if shut-down is delayed.

Avoid fast movements of the stick when it is moved near the shut-down limits.

3.4.8.3

Overriding stick cylinder shut-down function Danger!

Risk of injury and damage to equipment!

While the stick cylinder shut-off function is overridden, there is a risk that the attachment might collide with the operator's cab.

When overriding the stick cylinder shut-down function, operate the machine with extreme caution.

After the stick shut-down function has stopped the movement of the stick: The stick cylinder shut-down function can be overridden by pressing the switch S216.

Press the switch S216.

The indicator light in the switch is on.

The stick cylinder shut-down function is overridden.

Carefully move the stick beyond the shut-down point into the danger range.

3.4.8.4

Adjusting the limit switches

Fig. 3-72

Elevating operator's cab

Safety distance (distance between working attachment and operator's cab): min. 1.5 m.

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Adjust the stick cylinder shut-down function in such a way that there is a sufficient safety distance, even if the working tool is oscillating or if shut-down is delayed.

Move the elevating operator's cab (optional equipment) to its most forward extended position.

Fig. 3-73

Stick cylinder shut-down point

Move the boom upwards to the stop.

Retract the stick all the way to the desired shut-down point (MIN).

Switch off the diesel engine and push the safety lever upwards.

Fig. 3-74

Adjusting the limit switch

Loosen the screws 1.

Move the connecting link 2 until the outer edge enters the stress field of the limit switch 3.

Tighten the screws 1.

Test the stick cylinder shut-down function.

If required, readjust the settings and test the function again.

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Control, operation

Operating manual

Working with the machine

3.4.9

Adjustment of attachment tool The machine can operate a range of attachment tool (additional consumers) with various pressure and flow rate settings. The respective selections are made in the operator's menu (see "Tool Control" menu).

Caution!

If an incorrect operating mode is chosen, the attachment tool might be damaged or its functions might be restricted.

Make sure that you have all the necessary information regarding the technical data of the attachment tool.

Use the attachment tool exclusively with the prescribed settings (Tool Control).

In the operator's menu, select the pressure and flow settings required for the attachment tool you wish to operate (see chapter "Tool Control").

3.4.10

Operating the attachment tool (by pedals, push buttons) Danger!

The working attachment can cause serious or even fatal injury to persons.

Ensure that no persons are standing inside the danger zone of the machine.

It is strictly forbidden to guide the attachment tool by hand.

Danger!

If a large or wide attachment tool (e.g. grapple) is swivelled towards the operator's cab, it might collide with the cab or even break through it, causing danger to the machine operator.

Always keep a safe distance between the moving attachment tool and the operator's cab.

3.4.10.1

Working functions

Fig. 3-75

Operating attachment tool by pedals

The working function of the attachment tool is controlled by pedals.

Example: hydraulic hammer Press the foot pedal k down.

The hydraulic hammer is operated.

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Example: sorting grapple, scrap shears Press the foot pedal k down.

The attachment tool closes.

Press the foot pedal m down.

The attachment tool opens.

3.4.10.2

Rotating and adjusting

Fig. 3-76

Press the push button at the joystick to rotate and adjust the attachment tool

1 2

Rotator (e.g. for rotating grapple) Lock bolts of a hydraulic quick-change adapter system

3 A

Swivelling ditch cleaning bucket Actuation at left joystick (standard equipment)

B

Actuation at right joystick (optional equipment)

C R/L

Actuation at left and right joystick (optional equipment) Push button/direction of movement

Press the push buttons at the joystick to turn the attachment tool or to adjust it. The buttons are located at the right or left joystick (depending on machine equipment).

The rotating function corresponds to the "rotate grapple" function used for grapples and other attachment tools.

Press the switch S19.

The auxiliary function (grapple rotator) is activated.

The LED in the switch is on.

Press and hold the button L. The attachment tool turns (swivels) to the left.

The lock bolts are extended.

Press and hold the button R. The attachment tool turns (swivels) to the right.

The lock bolts are retracted.

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Control, operation

Operating manual

Working with the machine

3.4.11

Changeover of control (optional equipment)

Fig. 3-77

Changeover of control

Depending on the selected mode, the attachment tool and the tilting system are operated by the pedals (movement m and k) or with the joystick (movement e and f).

By changing over the control, the functions of the pedals are assigned to the joystick and vice versa.

To change from one control mode to the other, turn the key switch S405 in the right control console.

Turn the key switch S405 to position 1.

The indicator light H322 is on.

Control changeover is activated.

Turn the key switch S405 back to position 0.

The indicator light H322 is off.

Control changeover is deactivated.

Function

Changeover off (0)

on (1)

Tilting system

e+f

m+k

Attachment tool

m+k

e+f

Operate the attachment tool and the tilting system according to the selected control mode.

3.4.12

Operating attachment tool (mini joystick control, optional equipment) Danger!

The working attachment can cause serious or even fatal injury to persons.

Ensure that no persons are standing inside the danger zone of the machine.

It is strictly forbidden to guide the attachment tool by hand.

Danger!

If a large or wide attachment tool (e.g. grapple) is swivelled towards the operator's cab, it might collide with the cab or even break through it, causing danger to the machine operator.

Always keep a safe distance between the moving attachment tool and the operator's cab.

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Control, operation Working with the machine

3.4.12.1

Working functions

Fig. 3-78

Mini joystick, operating attachment tool

The working functions of the attachment tool are controlled by means of a mini joystick located on the right joystick.

The further the mini joystick is moved in a particular direction, the faster the attachment tool is moved.

In this control mode, it is not necessary to activate the attachment tool with a separate switch as these functions are automatically activated when the servo control is switched on.

Example: hydraulic hammer Push the mini joystick to the left 1.

The hydraulic hammer is operated.

Example: sorting grapple, scrap shears Push the mini joystick to the left 1.

The attachment tool closes.

Push the mini joystick to the right 2.

The attachment tool opens.

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Control, operation

Operating manual

Working with the machine

3.4.12.2

Rotating and adjusting

Fig. 3-79

Rotation and adjustment of attachment tool by means of mini joystick

1

Rotator (e.g. for rotating grapple)

2 3

Lock bolts of a hydraulic quick-change adapter system Swivelling ditch cleaning bucket

L/R

Direction of movement

The mini joystick on the left joystick is used to rotate or change the attachment tool.

The rotating function corresponds to the "rotate grapple" function used for grapples and other attachment tools.

The further the mini joystick is moved in a particular direction, the faster the attachment tool is moved.

In this control mode, it is not necessary to activate the attachment tool with a separate switch. as these functions are automatically activated when the servo control is switched on.

Push mini joystick to the left L. The attachment tool turns (swivels) to the left.

The lock bolts are extended.

Push the mini joystick to the right R. The attachment tool turns (swivels) to the right.

The lock bolts are retracted.

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3.4.13

Changeover of joystick control (optional equipment)

Fig. 3-80

Changeover of control

Depending on the selected mode, the attachment tool is operated with the mini joystick (movement 1 and 2) or with the joystick (movement e and f).

To change from one control mode to the other, turn the key switch S405 in the right control console.

Turn the key switch S405 to position 1.

The indicator light H322 is on.

Control changeover is activated.

Turn the key switch S405 back to position 0.

The indicator light H322 is off.

Control changeover is deactivated.

If the control is changed over, the tilting system is disabled.

Function

Changeover off (0)

on (1)

Tilting system

e+f

-

Attachment tool

1+2

e+f

Operate the attachment tool according to the current control mode.

3.4.14

Magnetic system (option) With a magnetic system, optional equipment such as magnets for transferring scrap can be operated. The magnetic system is turned on by pressing switch S46 on the right control panel and is operated electronically using a button in the joystick.

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Operating manual

Installation and removal of attachment parts

Fig. 3-81

Operating the magnetic system

Press switch S46.

The magnetic system function is turned on.

The engine RPM P4 increases to level 8.

The sensor controlled low idle automatic S20 no longer functions.

Danger!

The magnet can loose its load in the event of a loss of current.

Always ensure that no one is standing beneath the load.

Do not press push button S6L or switch S55 unintentionally.

Control in the right joystick: Press the left push button S6L. The magnet is activated.

Press the left push button S6L again.

The magnet is deactivated.

Control in left joystick (American version): Push switch S55 up.

The magnet is activated.

Push switch S55 down .

The magnet is deactivated.

3.5 Installation and removal of attachment parts 3.5.1 3.5.1.1

Safety Instructions Installation and removal of attachment parts – Equipment and attachment parts made by other manufacturers or those which do not have LIEBHERR’s general approval for installation may not be installed on the machine without prior written approval by LIEBHERR. LIEBHERR must be provided with the required technical documentation necessary for this purpose.

– Set the machine on a level and stable ground prior to any work with attachments.

– Lock the uppercarriage with the locking pin to the undercarriage.

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– Do not position yourself under a raised attachment that has not been adequately and securely supported.

– Never place yourself under a machine while it is elevated.

– Remove hydraulic system pressure before working on any attachments (as described in this operating manual).

– Do not attempt to lift heavy parts. Use suitable lifting devices with sufficient load carrying capacity.

– Insure any lifting system or lifting device that is used is in good repair and adequately rated for the component or machine to be supported. Always wear work gloves when handling wire cables.

– When working on the equipment: Switch off the diesel engine, remove the key and turn the safety lever upward.

– During repairs: Make sure that the hydraulic lines are properly attached and that all fittings and connections are properly tightened.

– As soon as an attachment part is removed and supported, cover or cap the openings in the hydraulic circuit to prevent dirt infiltration. Permit only authorized persons near the machine or the lifting device.

3.5.1.2

Removal and installation of attachment pins – Never use your fingers to align pin bores. If possible, always use a hydraulic pin pulling device to push out the pins on the attachment.

– If pins must be removed with a sledge hammer, use a punch and a guide tube held by another person.

– To drive out a pin, install the impact screw from the tool box in the threaded bore of the pin and hit the screw only.

– For the installation of a pin retained with castle nut and cotter pin, drive the pin in first to the stop, then install the castle nut by hand until contact and tighten it only to the point where the cotter pin can be installed.

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Control, operation

Operating manual

Installation and removal of attachment parts

3.5.2

Installation and removal of digging tool

Fig. 3-82

Installation and removal of digging tools

The following is a description of the installation and removal of digging tools. Digging tools include backhoe bucket, ditch cleaning buckets or ripper.

3.5.2.1

Removing the digging tool Position the attachment in such a way that the entire bottom part of the digging tool is laying on the ground.

Unscrew the locking plate 5 and remove the locking plate 6 and knock out pin 3 and pin 4.

If necessary, raise the attachment slightly when knocking out pin 4 to relieve it.

3.5.2.2

Installing a new digging tool Position the digging tool to be installed in such a way that its entire flat bottom is laying on the ground.

Start the engine and move the attachment until the bucket stick bearing and the bearing points 1 of the digging tool are aligned.

Guide in pin 4 and secure it with plate 6.

Extend the bucket cylinder slowly until the bore hole in the connecting link 7 is located precisely between the bearing points 2.

Guide in pin 3 and secure it with plate 5.

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Grease all lube points on pins 3 and 4 until clean grease emerges on the corresponding bearing points.

3.5.2.3

Bucket cylinder operation Two hydraulic lines on the stick are used either for bucket cylinder operation or grapple operation.

The lines are switchable via a valve block 15: – a - Bucket cylinder operation (for digging tools) – b - Grapple operation (for grapple, scrap cutter etc.)

Turn the both square head bolts on valve block 15 in such a way that the markings are positioned transverse to the travel direction (position a, bucket cylinder operation).

Note!

If the machine is equipped with a hydraulic quick change adapter and LIKUFIX, it is not necessary to switch between bucket cylinder operation and grapple operation. There is no valve block 15.

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Control, operation

Operating manual

Installation and removal of attachment parts

3.5.3

Attachment of grapple to bucket stick

Fig. 3-83

Attaching grapple to bucket stick

Danger!

Risk of injury Ensure that the machine operator follows the instructions of the instructor when moving the equipment.

Two workers are required to attach or remove the grapple.

3.5.3.1

Attaching grapple Before attaching a clamshell grab or multiple grab, ensure that the necessary hydraulic lines for grapple operation are mounted to the bucket stick.

The grapple must be in a stable position (grabs fully opened).

If necessary, dismantle the digging bucket.

Move the attachment in order to position the bucket stick between the bearing points of the grapple suspension 1.

Insert the bolts 2 and secure them with the plate 3.

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Caution!

The hydraulic lines are under pressure.

Before connecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick and press the buttons of the "Rotate grapple" function).

Move the safety lever up.

Connect the hydraulic hoses 4 and 5 (for the supply of the grab cylinders) to the pipelines.

For grapples with hydraulic rotator, also connect the hydraulic hoses 6 and 7 to the pipelines for this auxiliary equipment.

3.5.3.2

Attachment of connecting link

Fig. 3-84

Securing of connecting link

After the grapple has been removed, secure the connecting link 1. There are various ways to do this (depending on the machine equipment).

Fully retract the bucket tilt cylinder 6.

Attach the holder 5 to the change lever 2.

Insert the securing device 3 in the connecting link 1 and mount it to the holder 5.

Insert securing plugs 4 on both sides.

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Installation and removal of attachment parts

3.5.3.3

Changeover to grapple operation

Fig. 3-85

Valve block for tilt cylinder operation / grapple operation

Two hydraulic lines on the bucket stick are used for the operation of the tilt cylinder or the grapple.

The lines are switchable by means of a valve block: – a - Tilt cylinder operation (for digging buckets) – b - Grapple operation (for grapples, scrap shears, etc.)

Note If the machine is equipped with a quick-change adapter and LIKUFIX, there is no need for this changeover. The valve block is therefore omitted.

Turn the two square head screws on the valve block until the marks are aligned in the direction of travel (position b, grapple operation).

Complete all working movements several times without load (opening and closing grapple, moving grapple to the right and left) in order to let any trapped air escape from the hydraulic circuits.

3.5.3.4

Removing grapple If necessary, remove the securing device 3 from the connecting link.

Fully open the grabs and place the grapple in a vertical position on level ground.

Caution!

The hydraulic lines are under pressure.

Before disconnecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick and press the buttons of the "Rotate grapple" function).

Move the safety lever up.

Disconnect the hydraulic hoses from the pipelines on the bucket stick.

Immediately seal open lines to prevent dirt from entering the system.

Prop up the grapple to ensure that it cannot topple over.

Unscrew the plate 3 and carefully drive out the bolt 2. To do this, you might have to start the diesel engine and lift the attachment slightly from the ground.

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3.5.4

Attachment of grapple to industrial stick

Fig. 3-86

Attaching grapple to industrial stick

Danger!

Risk of injury!

Ensure that the machine operator follows the hand signal instructions of the instructor when moving the equipment.

Two workers are required to attach or remove the grapple.

3.5.4.1

Attaching grapple Before attaching a clamshell grab or multiple grab, ensure that the necessary hydraulic lines for grapple operation are mounted on the stick.

The grapple must be in a stable position (grabs fully opened).

Move the attachment in order to position the industrial stick between the bearing points of the grapple suspension 1.

Insert the bolts 2 and secure them with the plate 3.

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Caution!

The hydraulic lines are under pressure.

Before connecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick and press the buttons of the "Rotate grapple" function).

Move the safety lever up.

Connect the hydraulic hoses 4 and 5 (for the supply of the grab cylinders) to the pipelines.

For grapples with hydraulic rotator, also connect the hydraulic hoses 6 and 7 to the pipelines for this auxiliary equipment.

Complete all working movements several times without load (opening and closing grapple, moving grapple to the right and left) in order to let any trapped air escape from the hydraulic circuits.

3.5.4.2

Removing grapple Fully open the grabs and place the grapple in a vertical position on level ground.

Caution!

The hydraulic lines are under pressure.

Before disconnecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick and press the buttons of the "Rotate grapple" function).

Move the safety lever up.

Disconnect the hydraulic hoses from the pipelines on the stick.

Immediately seal open lines to prevent dirt from entering the system.

Prop up the grapple to ensure that it cannot topple over.

Unscrew the plate 3 and carefully drive out the bolt 2. To do this, you might have to start the diesel engine and lift the attachment slightly from the ground.

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Operating manual

Control, operation Installation and removal of attachment parts

3.5.5 3.5.5.1

Multi-coupling system (optional equipment) Overview

Fig. 3-87

Overview

1

Stick

2

Coupling

3

Hand lever

4

Locking mechanism

5 7

Securing mechanism Coupling plate of working tool

6 8

Protective cover Multi-function lever

9

Pressure release device

The multi-coupling system allows you to connect and disconnect several hydraulic lines at the same time. The working tool can thus be quickly connected to the stick.

Fig. 3-88

Securing mechanism

A safety pin retains the locking lever, thus preventing inadvertent opening of the coupling. The coupling is properly secured when the safety pin is engaged. The locking lever is only released by the safety pin after the pressure has been fully released. The coupling can then be opened.

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3.5.5.2

Pressure release device

Fig. 3-89

Pressure release device of the coupling

Caution!

The hydraulic lines are under pressure! The hand lever could thus be moved back with force, causing injury to the operator.

Before connecting/disconnecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick and press the buttons of the "Rotate grapple" function).

Open the pressure release device of the coupling.

The pressure release device of the coupling is operated with the multi-function lever from the toolbox.

Attach the multi-function lever and turn it as follows: A = Pressure release device closed (operation) B = Pressure release device open (opening/closing coupling)

3.5.5.3

Working tool

Fig. 3-90

Positioning grapple

When opening or closing the coupling, ensure that the working tool is in a stable position. The grapple must be positioned between the machine and the stick (see Fig. 3-90). This allows for better access to the coupling.

Before connecting the coupling, attach the working tool to the machine (see respective chapter).

Remove the working tool from the machine only when the coupling has been opened.

Check the coupling parts for dirt and clean them if necessary with a clean oilsoaked cloth.

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After connection with the coupling, test the working tool functions.

3.5.5.4

Opening coupling

Fig. 3-91

Opening pressure release device, releasing locking mechanism and moving hand lever down

Complete pressure release from the machine (joystick).

Attach the multi-function lever and open the pressure release device of the coupling.

Pull the locking mechanism upwards and move the hand lever down.

The coupling is opened.

Pull out the coupling plate (or protective cover).

3.5.5.5

Closing coupling

Fig. 3-92

Inserting the coupling plate, moving hand lever up and closing pressure release device

Fully insert the coupling plate (or protective cover) in the coupling to the stop.

Move the hand lever up.

The coupling is closed, and the lines are connected.

Ensure that the safety pin is engaged.

Close the pressure release device of the coupling.

Remove the multi-function lever.

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3.5.6

Industrial stick with mechanical quick-change adapter (optional equipment) The industrial stick with mechanical quick-change adapter allows for the fast and easy exchange of working tools.

3.5.6.1

Safety information – First familiarise yourself with the functions and operation of the quick-change adapter (without attached working tools).

– Before locking or releasing the quick-change adapter, tilt the safety lever upwards.

– When attaching and removing working tools, ensure that no persons are located in the working area of the tool.

– During mounting and removing, move the working tool only at minimum speed, and only if absolutely necessary.

– Position the working tool as little above the ground as is necessary before starting the locking or release procedure, in order to avoid dangerous movements.

– If required, use a pedestal or working platform to reach the locking bolts and connections. Do not stand on the working tool.

– Check the locking screw every day to ensure that it is properly tightened.

– The quick-change adapter is equipped with an integrated safety load hook for the safe attachment of lifting tackle, such as cables or chains. To use lifting tackle, you must use a suspension system with a safety load hook.

– Switch on the magnet system (optional equipment) while attaching or removing the working tool.

3.5.6.2

Positioning option

Fig. 3-93

Example: Load hook in frame (bearing block)

Working tools that are prone to tilting or cannot be placed on the ground must be secured. For attachment and removal use suitable equipment (e.g. frames, etc.).

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3.5.6.3

Overview

Fig. 3-94

3.5.6.4

Industrial stick with mechanical quick-change adapter

1 3

Locking bolt (extended) Crank

2 4

Locking screw Load hook

5

Stick

6

Suspension at the working tool

Releasing and locking

Fig. 3-95

Releasing and locking

Turn the locking screw anticlockwise and remove it (A).

Insert the crank into the locking bolt and turn it anticlockwise until both locking bolts are inserted to the stop (B).

The quick-change adapter is released.

Remove or attach the working tool.

Insert the crank into the locking bolt and turn it clockwise until both locking bolts are screwed out to the stop (C).

The quick-change adapter is locked.

Turn the locking screw clockwise (D).

The quick-change adapter is secured.

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3.5.6.5

Attaching working tool The working tool must be securely positioned on the ground or secured in a frame.

Switch off the magnet system (if installed).

Fig. 3-96

Releasing and attaching working tool

Screw out the locking screw.

Release the quick-change adapter.

Move the industrial stick in such a way that the load hook can be engaged at the bolts of the suspension.

Lift the attachment a little of the ground so that it is suspended freely.

The suspension is centred in the quick-change adapter.

Danger!

Prior to locking, there is no secured connection between the working tool and the quick-change adapter. The working tool can therefore become dislodged, causing serious injury.

Approach the quick-change adapter with great care.

Tilt the safety lever upwards in order to secure the working tool against inadvertent movement.

Fig. 3-97

Locking

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Lock the quick-change adapter.

When properly mounted, the working tool is secured with the pins.

Screw in the locking screw.

If installed: Loosen the locking screw 1 (optional equipment) at the suspension (unless the locking screw is loosened, the working tool cannot be moved freely).

Caution!

The hydraulic lines are under pressure.

Before connecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick).

Connect all hydraulic or electrical lines (e.g. for the attachment of a grapple).

The safe mounting of the working tool must be checked with a proper visual inspection.

Danger!

An improperly locking quick-change adapter might inadvertently become released during operation!

Ensure that the locking bolts are secured with locking screw.

Check the locking screw every day to ensure that it is properly tightened.

3.5.6.6

Dismantling working tool

Fig. 3-98

Releasing

Lift the working tool a little of the ground so that it is suspended freely.

If in place: Tighten the locking screw 1 (optional equipment) at the suspension (without tightening the screw, the suspension would tilt to the side during removal, so that it would be difficult to take it up at the next attachment).

Caution!

The hydraulic lines are under pressure.

Before disconnecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick).

Disconnect all hydraulic or electrical lines to the working tool (e.g. for the removal of a grapple).

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Danger!

Risk of injury!

After the working tool is released, it is fully disconnected from the machine. There is a risk that the working tool becomes inadvertently dislodged.

Ensure that the working tool cannot be moved by a third party while you carry out this task.

Position the working tool as little above the ground as is necessary before starting the release procedure, in order to avoid dangerous movements.

Screw out locking screw.

Release the quick-change adapter.

Fig. 3-99

Disconnecting working tool

Place the working tool on the ground or on a frame.

Move the industrial stick in such a way that the load hook is disengaged from the bolt of the suspension.

Move the attachment away from the working tool.

3.5.7

Industrial stick with hydraulic quick-change adapter (optional equipment) The industrial stick with hydraulic quick-change adapter allows for the fast and easy exchange of attachment tools.

3.5.7.1

Safety information – First familiarise yourself with the functions and operation of the quick-change adapter (without attached tool).

– When attaching and removing attachment tools, ensure that no persons are standing in the working area of the attachment.

– During mounting and removing, move the attachment tool only at minimum speed, and only if absolutely necessary.

– If the buzzer and the "quick-change adapter" icon are on and you are NOT carrying out an intended locking or release procedure, immediately shut down the machine. If these indicating elements are not on when you are carrying out an intended locking or release procedure, immediately stop the procedure.

This can occur if a lock bolt has inadvertently become dislodged, or if a

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mechanical, hydraulic or electrical fault occurs. Only resume operation after the defective part has been repaired or replaced.

– The quick-change adapter is equipped with an integrated safety load hook for the safe attachment of lifting tackle, such as cables or chains. To use lifting tackle, you must use a suspension system with a safety load hook.

– While attaching or removing attachment tools, ensure that the magnet system (optional equipment) is switched off.

3.5.7.2

Disconnecting option

Fig. 3-100 Example: load hook in frame (bearing block) Attachment tools that are prone to tilting or cannot be placed on the ground must be secured. For attachment and removal, use suitable equipment (e.g. frames, etc.).

3.5.7.3

Overview

Fig. 3-101 Industrial stick with hydraulic quick-change adapter A Industrial stick 1

3.5.7.4

B Suspension device of attachment tool 2 Half shell at suspension tackle

Lock bolt

Operation and function control To operate the quick-change adapter, you must simultaneously actuate two control elements (two-hand operation). With one hand, start the quick-change adapter. Use the other hand to control the movement of the lock bolts.

During release, the "quick-change adapter" icon is displayed on the screen. This icon, together with a buzzer warning sound, indicates that the quick-change adapter is not locked.

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Releasing and locking of adapter by means of push buttons (standard equipment):

Fig. 3-102 Releasing and locking of adapter by means of push buttons* *

In machines with optional equipment, the quick-change adapter can be controlled by operating the left or right joystick.

This is only possible, if the auxiliary function is activated (switch 19, LED on).

Press and hold the button S47.

The quick-change adapter is activated.

Press and hold the button R. A buzzer sound is emitted.

The lock bolts are retracted.

The "quick-change adapter" icon appears on the screen.

The quick-change adapter is released.

Press and hold the button L. The buzzer is off.

The lock bolts are extended.

The "quick-change adapter" icon on the screen disappears.

The quick-change adapter is locked.

Locking and releasing quick-change adapter with the mini joystick (optional equipment):

Fig. 3-103 Locking and releasing quick-change adapter with the mini joystick

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The mini joystick on the left joystick is used to operate the lock bolts.

Press and hold the button S47.

The quick-change adapter is activated.

Push the mini joystick to the right R and hold it there.

A buzzer sound is emitted.

The lock bolts are retracted.

The "quick-change adapter" icon appears on the screen.

The quick-change adapter is released.

Push the mini joystick to the left L and hold it there.

The buzzer is off.

The lock bolts are extended.

The "quick-change adapter" icon on the screen disappears.

The quick-change adapter is locked.

3.5.7.5

Attaching tools The attachment tool must be safely positioned on the ground or secured in a frame.

The attachment tool must be in such a position that the openings of the half shells face upwards or away from the machine.

Switch off the magnet system (optional equipment).

Fig. 3-104 Releasing adapter and attaching tool Release the quick-change adapter.

Release all buttons.

Move the industrial stick in such a way that the front side is inserted between the half shells of the suspension tackle.

If positioned correctly, the lock bolts are aligned with the bores of the grapple suspension.

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Fig. 3-105 Locking Lock the quick-change adapter.

Release all buttons.

If in place: Loosen the locking screw 1 (optional equipment) at the suspension (unless the locking screw is loosened, the attachment tool cannot be moved freely).

Caution!

The hydraulic lines are under pressure!

Before connecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick).

Connect the hydraulic or electrical lines as required (e.g. for the attachment of a grapple).

Check the attachment tool for proper fixture by carrying out a visual inspection.

3.5.7.6

Removing attachment tool The attachment tool must be in a stable position.

If required, a support structure (frame) must be used.

Danger!

After the attachment tool is released, it is not any more secured to the machine. The attachment tool might thus become dislodged and cause serious injury.

Before releasing the quick-change adapter, place the attachment tool on the ground.

Switch off the magnet system (optional equipment).

Fully open the jaws of grapples.

Place the attachment tool without load on the ground or in a suitable frame.

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Fig. 3-106 Tightening the locking screw, disconnecting the lines and releasing quick-change adapter If in place: Tighten the locking screws 1 (optional equipment) at the suspension system.

The tightened locking screw ensures that the suspension system cannot tilt to the side while the tool is being attached.

Caution!

The hydraulic lines are under pressure!

Before disconnecting the hydraulic lines, depressurise them using the joysticks (switch off diesel engine, turn ignition key to contact position, operate the joysticks).

Disconnect all hydraulic or electrical lines to the attachment tool (e.g. for the removal of a grapple).

Release the quick-change adapter.

Release all buttons.

Fig. 3-107 Disconnecting attachment tool Move the industrial stick in such a way that the front side is disengaged from the half shells.

Attach a different tool.

- alternatively Lock the quick-change adapter without attaching a tool to switch off the buzzer.

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3.5.7.7

Acknowledging buzzer signal (warning signal) After the working tool has been removed, the buzzer (warning signal) sounds as long as the system is not locked.

If the overload warning system is switched on, the warning buzzer can be acknowledged.

If no working tool is to be mounted, it is useful to deactivate the warning signal. This is also recommended to ensure that another buzzer sound (i.e. from the overload warning system) is actually audible.

Press the switch S349.

The buzzer is switched off.

The "quick-change adapter" icon remains displayed.

Note!

The acoustic warning signal is automatically reactivated when the system is locked again.

In order to activate the warning buzzer, lock the system once.

The "quick-change adapter" icon on the screen disappears.

The buzzer and warning sound are on at the next release process.

3.5.8

LIKUFIX MH 40 quick-coupling system (optional equipment) The LIKUFIX MH 40 quick-coupling system allows for the fast and efficient exchange of attachment tools without having to leave the operator's cab. Hydraulic and electrical connections are thereby automatically disconnected and connected.

3.5.8.1

Safety information – First familiarise yourself with the functions and operation of the quick-coupling system (without attached tools).

– When attaching and removing attachment tools, ensure that no persons are standing in the working area of the attachment.

– During mounting and removing, move the attachment tool only at minimum speed, and only if absolutely necessary.

– If the buzzer and the "quick-change adapter" icon are on and you are NOT carrying out an intended locking or release procedure, immediately shut down the machine. If these indicating elements are not on when you are carrying out an intended locking or release procedure, immediately stop the procedure.

This can occur if a lock bolt has inadvertently become dislodged, or if a mechanical, hydraulic or electrical fault occurs. Only resume operation after the defective part has been repaired or replaced.

– The quick-coupling system is equipped with an integrated safety load hook for the safe attachment of lifting tackle, such as cables or chains. To use lifting tackle, you must use a suspension system with a safety load hook.

– While attaching or removing attachment tools, ensure that the magnet system (optional equipment) is switched off.

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3.5.8.2

Disconnecting option

Fig. 3-108 Example: load hook in frame (bearing block) Attachment tools that are prone to tilting or cannot be placed on the ground must be secured. For attachment and removal, use suitable equipment (e.g. frames, etc.).

3.5.8.3

Overview

Fig. 3-109 LIKUFIX MH 40 quick-coupling system

3.5.8.4

A Top section (at attachment)

B Bottom section (at attachment tool)

1

Lock bolt

2

Check pin

3 5

LIKUFIX at machine Guide bolt

4 6

LIKUFIX at attachment tool Protective cover / top section

7

Protective cover / bottom section

Operation and function control To operate the quick-coupling system, you must simultaneously actuate two control elements (two-hand operation). With one hand, start the quick-coupling system. Use the other hand to control the movement of the lock bolts.

The check pin (see Fig. 3-109) is an auxiliary tool that indicates the position of the lock bolts.

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– Check pin visible (extended): The quick-coupling system is released.

– Check pin retracted: The quick-coupling system is locked.

During release, the "quick-change adapter" icon is displayed on the screen. This icon, together with a buzzer warning sound, indicates that the quick-change adapter is not locked.

Releasing and locking of coupling system by means of push buttons (standard equipment):

Fig. 3-110 Releasing and locking of coupling system by means of push buttons* *

In machines with optional equipment, the quick-coupling system can be controlled by operating the left or right joystick.

This is only possible, if the auxiliary function is activated (switch 19, LED on).

Press and hold the button S47.

The quick-coupling system is activated.

Press and hold the button R until the check pins are fully extended.

A buzzer sound is emitted.

The check pins are visible.

The "quick-change adapter" icon appears on the screen.

The quick-coupling system is released.

Press and hold the button L until the check pins are fully retracted.

The buzzer is off.

The check pins are retracted.

The "quick-change adapter" icon on the screen disappears.

The quick-coupling system is locked.

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Locking and releasing coupling with the mini joystick (optional equipment):

Fig. 3-111 Locking and releasing coupling with the mini joystick The mini joystick on the left joystick is used to operate the lock bolts.

Press and hold the button S47.

The quick-coupling system is activated.

Push the mini joystick to the right R and hold it in that position until the check pins are fully extended.

A buzzer sound is emitted.

The check pins are visible.

The "quick-change adapter" icon appears on the screen.

The quick-coupling system is released.

Push the mini joystick to the left L and hold it in that position until the check pins are fully retracted.

The buzzer is off.

The check pins are retracted.

The "quick-change adapter" icon on the screen disappears.

The quick-coupling system is locked.

3.5.8.5

Attaching tools The attachment tool must be safely positioned on the ground or secured in a frame.

Switch off the magnet system (optional equipment).

Fig. 3-112 Releasing, lowering top section

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Release the quick-coupling system.

Release all buttons.

If necessary, adjust the position.

Slowly lower the top section and place it carefully on the bottom section.

Continue lowering the top section until the guide bolts are fully inserted in the bores provided.

Fig. 3-113 Locking Lock the quick-coupling system.

Release all buttons.

Check the attachment tool for proper fixture by carrying out a visual inspection.

3.5.8.6

Removing attachment tool The attachment tool must be in a stable position.

If required, a support structure (frame) must be used.

Danger!

After the attachment tool is released, the upper and bottom sections are not any more secured to each other. The attachment tool might thus become dislodged and cause serious injury.

Before releasing the quick-coupling system, place the attachment tool on the ground.

Switch off the magnet system (optional equipment).

Fully open the jaws of grapples.

Place the attachment tool without load on the ground or in a suitable frame.

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Fig. 3-114 Releasing, lifting top section Release the quick-coupling system.

Release all buttons.

Slowly lift the top section.

Attach a different tool.

- alternatively To switch off the buzzer, lock the quick-coupling system without attaching a tool.

3.5.8.7

Acknowledging buzzer signal (warning signal) After the working tool has been removed, the buzzer (warning signal) sounds as long as the system is not locked.

If the overload warning system is switched on, the warning buzzer can be acknowledged.

If no working tool is to be mounted, it is useful to deactivate the warning signal. This is also recommended to ensure that another buzzer sound (i.e. from the overload warning system) is actually audible.

Press the switch S349.

The buzzer is switched off.

The "quick-change adapter" icon remains displayed.

Note!

The acoustic warning signal is automatically reactivated when the system is locked again.

In order to activate the warning buzzer, lock the system once.

The "quick-change adapter" icon on the screen disappears.

The buzzer and warning sound are on at the next release process.

3.5.9

Hydraulic quick-change adapter (optional equipment) The hydraulic quick-change adapter allows for the fast and efficient exchange of attachment tools without having to leave the operator's cab.

When operated in conjunction with the LIKUFIX quick-coupling system (optional equipment), the connecting lines are automatically connected and disconnected.

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3.5.9.1

Safety information – First familiarise yourself with the functions and operation of the quick-change adapter (without attached tools).

– When attaching and removing tools, ensure that no persons are standing in the working area of the attachment.

– During mounting and removing, move the attachment tool only at minimum speed, and only if absolutely necessary.

– Position the attachment tool as little above the ground as is necessary before starting the locking or release procedure, in order to avoid dangerous movements.

– If the buzzer and the "quick-change adapter" icon are on and you are NOT carrying out an intended locking or release procedure, immediately shut down the machine. If these indicating elements are not on when you are carrying out an intended locking or release procedure, immediately stop the procedure.

This can occur if a lock bolt has inadvertently become dislodged, or if a mechanical, hydraulic or electrical fault occurs. Only resume operation after the defective part has been repaired or replaced.

– Check the attachment tool every day to ensure that it is properly secured. In addition to the above check, carry out a dummy run with the attachment tool: Tilt the attachment tool in and out (without load), lifting it only as far as this is necessary to check proper connection (e.g. pin in bolt eye).

– The lifting capacity of the quick-change adapter or the integrated load lift hook might be greater or smaller than that of the basic machine. Always observe the load capacity values of the machine.

– While attaching or removing attachment tools, ensure that the magnet system (optional equipment) is switched off.

3.5.9.2

Overview

Fig. 3-115 Hydraulic quick-change adapter

3.5.9.3

1

Lock bolt (extended)

3

Load lift hook

2

Mounting hook for attachment tool

Operation and function control To operate the quick-change adapter, you must simultaneously actuate two control elements (two-hand operation). With one hand, activate the quick-change adapter.

Use the other hand to control the movement of the lock bolts.

During release, the "quick-change adapter" icon is displayed on the screen. This icon, together with a buzzer warning sound, indicates that the quick-change adapter

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is not locked.

Releasing and locking of quick-change adapter by means of push buttons (standard equipment):

Fig. 3-116 Releasing and locking of adapter by means of push buttons* *

In machines with optional equipment, the quick-change adapter can be controlled by operating the left or right joystick.

This is only possible, if the auxiliary function is activated (switch 19, LED on).

Press and hold the button S47.

The quick-change adapter is activated.

Press and hold the button R. A buzzer sound is emitted.

The lock bolts are retracted.

The "quick-change adapter" icon appears on the screen.

The quick-change adapter is released.

Press and hold the button L. The buzzer is off.

The lock bolts are extended.

The "quick-change adapter" icon on the screen disappears.

The quick-change adapter is locked.

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Locking and releasing attachments with the mini joystick (optional equipment):

Fig. 3-117 Locking and releasing quick-change adapter with the mini joystick: The mini joystick on the left joystick is used to operate the lock bolts.

Press and hold the button S47.

The quick-change adapter is activated.

Push the mini joystick to the right R and hold it there.

A buzzer sound is emitted.

The lock bolts are retracted.

The "quick-change adapter" icon appears on the screen.

The quick-change adapter is released.

Push the mini joystick to the left L and hold it there.

The buzzer is off.

The lock bolts are extended.

The "quick-change adapter" icon on the screen disappears.

The quick-change adapter is locked.

3.5.9.4

Attaching tools

Fig. 3-118 Positioning attachment The attachment tool must be placed on the ground in a stable position.

Switch off the magnet system (optional equipment).

Position the stick and the attachment tool.

Fully retract the bucket tilt cylinder.

Release the quick-change adapter.

Release all buttons.

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Fig. 3-119 Taking up attachment tool, step 1 Position the quick-change adapter in such a way that the attachment tool can be taken up with the mounting hooks.

Fig. 3-120 Taking up attachment tool, step 2 Lift the attachment tool a little from the ground and fully extend the bucket tilt cylinder until the bearing plate of the attachment tool touches the stop of the quick-change adapter.

The bores of the quick-change adapter and the attachment tool must be properly aligned.

Danger!

Risk of injury!

After the attachment tool is released, it is not any more secured to the machine. The attachment tool might thus become dislodged and cause serious injury.

Position the attachment tool as little above the ground as is necessary before starting the locking procedure, in order to avoid dangerous movements.

Lock the quick-change adapter.

Release all buttons.

Caution!

The hydraulic lines are under pressure!

Before connecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick).

Connect all hydraulic or electrical lines (e.g. for the attachment of a grapple).

Check the attachment tool for proper fixture by carrying out a visual inspection.

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3.5.9.5

Removing attachment tool The attachment tool must be in a stable position.

If the working tool cannot be placed in an upright position, it must be removed in a lying position.

Switch off the magnet system (optional equipment).

Caution!

The hydraulic lines are under pressure!

Before disconnecting the hydraulic lines, depressurise them using the joysticks (switch off diesel engine, turn ignition key to contact position, operate the joysticks).

Disconnect all hydraulic or electrical lines from the attachment tool (e.g. for the removal of a grapple).

Fully extract the bucket tilt cylinder.

Place the attachment tool in a slightly elevated position from the ground.

Fig. 3-121 Aligning attachment tool for release Danger!

Risk of injury!

After the attachment tool is released, it is not any more secured to the machine. The attachment tool might thus become dislodged and cause serious injury.

Position the attachment tool as little above the ground as is necessary before starting the release procedure, in order to avoid dangerous movements.

Release the quick-change adapter.

Release all buttons.

Fig. 3-122 Placing the attachment tool on the ground Slowly retract the bucket tilt cylinder and lower the attachment tool to the ground.

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Attach a different tool.

- alternatively Lock the quick-change adapter without attaching a tool to switch off the buzzer.

3.5.10

Hydraulic quick-change adapter with LIKUFIX (optional equipment) The LIKUFIX quick-coupling system allows for the fast and efficient exchange of working tools without having to leave the operator's cab. Hydraulic and electrical connections are thereby automatically disconnected and connected.

Fig. 3-123 Quick-change adapter with LIKUFIX 1

Protective cover of quick change adapter

2

3

LIKUFIX hydraulic coupling at quick- 4 change adapter

Protective cover of working tool LIKUFIX hydraulic coupling at working tool

For mounting and dismantling instructions, see chapter "Hydraulic quick-change adapter". Please observe the following additional instructions: Before attaching the device, remove the protective covers.

Always keep the hydraulic couplings clean.

Before connecting the tool, check the connections for dirt. If necessary, clean all coupling parts and sealing surfaces with a clean cloth and oil.

When connecting or disconnecting the hydraulic coupling, proceed slowly and with the necessary care.

Tilt the quick change adapter at the attachment so that the coupling plates can easily be connected due to the weight of the working tool.

After completion of the work, and especially before transport, mount the protective covers.

Note!

If the hydraulic coupling cannot be easily connected to each by their own weight, check whether a foreign object (stone, etc.) is jammed between the parts. If this is the case, clean the coupling parts to prevent damage through subsequent coupling.

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3.5.10.1

Acknowledging buzzer signal (warning signal) After the working tool has been removed, the buzzer (warning signal) sounds as long as the system is not locked.

If the overload warning system is switched on, the warning buzzer can be acknowledged.

If no working tool is to be mounted, it is useful to deactivate the warning signal. This is also recommended to ensure that another buzzer sound (i.e. from the overload warning system) is actually audible.

Press the switch S349.

The buzzer is switched off.

The "quick-change adapter" icon remains displayed.

Note!

The acoustic warning signal is automatically reactivated when the system is locked again.

In order to activate the warning buzzer, lock the system once.

The "quick-change adapter" icon on the screen disappears.

The buzzer and warning sound are on at the next release process.

3.5.11

Mechanical quick-change adapter (optional equipment) The mechanical quick-change adapter allows for the fast and easy exchange of working tools.

3.5.11.1

Safety information – First familiarise yourself with the functions and operation of the quick-change adapter (without attached working tools).

– Before locking or releasing the quick-change adapter, tilt the safety lever upwards.

– Ensure that the working tool cannot be moved by a third party while you carry out this task.

– When attaching and removing working tools, ensure that no persons are located in the working area of the tool.

– During mounting and removing, move the working tool only at minimum speed, and only if absolutely necessary.

– Position the working tool as little above the ground as is necessary before starting the locking or release procedure, in order to avoid dangerous movements.

– If required, use a pedestal or working platform to reach the locking bolts and connections. Do not stand on the working tool.

– Check the locking screw every day to ensure that it is properly tightened. In addition to the above check, carry out a dummy run with the working tool: Tilt the working tool in and out (without load), lifting it only as far as this is necessary to check proper connection (e.g. pin in bolt eye).

– The lifting capacity of the quick-change adapter or the integrated load lift hook might be greater or smaller than that of the basic machine. Always observe the load capacity values of the machine.

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3.5.11.2

Overview

Fig. 3-124 Mechanical quick-change adapter

3.5.11.3

1 3

Locking bolt (extended) Crank

5

Load lift hook

2 4

Locking screw Mounting hook for working tool

Releasing and locking

Fig. 3-125 Releasing and locking Turn the locking screw anticlockwise and remove it (A).

Insert the crank into the locking bolt and turn it anticlockwise until both locking bolts are inserted to the stop (B).

The quick-change adapter is released.

Remove or attach the working tool.

Insert the crank into the locking bolt and turn it clockwise until both locking bolts are screwed out to the stop (C).

The quick-change adapter is locked.

Turn the locking screw clockwise (D).

The quick-change adapter is secured.

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3.5.11.4

Attaching working tool

Fig. 3-126 Positioning attachment The working tool must be placed on the ground in a stable position.

Position the stick and the working tool.

Fully retract the bucket tilt cylinder.

Screw out locking screw.

Release the quick-change adapter.

Fig. 3-127 Taking up working tool, step 1 Position the quick-change adapter in such a way that the working tool can be taken up with the mounting hooks.

Fig. 3-128 Taking up working tool, step 2 Lift the working tool a little from the ground and fully extend the bucket tilt cylinder until the bearing plate of the working tool touches the stop of the quick-change adapter.

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The bores of the quick-change adapter and the working tool must be properly aligned.

Danger!

Prior to locking, there is no secured connection between the working tool and the quick-change adapter. The working tool might become dislodged and cause serious injury.

Approach the quick-change adapter with great care.

Position the working tool as little above the ground as is necessary before starting the locking procedure, in order to avoid dangerous movements.

Lock the quick-change adapter.

Screw in the locking screw.

Caution!

The hydraulic lines are under pressure.

Before connecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick).

Connect all hydraulic or electrical lines (e.g. for the attachment of a grapple).

The safe mounting of the working tool must be checked with a proper visual inspection.

3.5.11.5

Dismantling working tool The working tool must be in a stable position.

If the working tool (e.g. grapple) cannot be placed in an upright position, it must be removed in a horizontal position.

Caution!

The hydraulic lines are under pressure.

Before disconnecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick).

Disconnect all hydraulic or electrical lines to the working tool (e.g. for the removal of a grapple).

Fully extract the bucket tilt cylinder.

Place the working tool in a slightly elevated position from the ground.

Fig. 3-129 Aligning working tool for release

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Danger!

Risk of injury!

After the working tool is released, it is fully disconnected from the machine. The working tool might become dislodged and cause serious injury.

Approach the quick-change adapter with great care.

Position the working tool as little above the ground as is necessary before starting the release procedure, in order to avoid dangerous movements.

Screw out locking screw.

Release the quick-change adapter.

Fig. 3-130 Placing the working tool on the ground Slowly retract the bucket tilt cylinder and lower the working tool to the ground.

Move the attachment away from the working tool.

3.6 General working methods 3.6.1

Tips for the proper operation of the machine preventing damage and wear In order to prolong the service life of the machine and to prevent avoidable damage, observe the following instructions: – Do not use the machine for work where its attachment is used to hammer against a hard material to remove it. Repeated impact of the working attachment against hard materials results in damage to the steel structure and the machine components.

– Under certain circumstances, where a particular type of boom, stick and working tool are combined, there is a risk that the tool collides with the operator's cab. This can result in damage to the operator's cab, and the operator might suffer injury.

– The use of the slewing gear for drilling material is not permitted.

– Do not lift the machine by propping it up with the attachment. If this happens by accident, slowly lower the machine back onto the ground. Do not lower the machine quickly onto the ground, and do not attempt to dampen this movement with the hydraulics, as this can damage the machine.

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Control, operation General working methods

Caution!

Incorrect operation of the attachment (e.g. backhoe bucket, concrete crusher, scrap shear, hydraulic hammer, swivelling rotator, stick extension) might result in an excessive load of the attachment.

The load on the attachment is greatest – when the hydraulic cylinders are fully retracted (in end position) – when the hydraulic cylinders are fully extended (in end position) – when the attachment is fully extended There is a risk of damage to parts of the equipment, to the hydraulic cylinders and to the machine.

Do not fully extend or retract the hydraulic cylinders.

When the hydraulic cylinders are near the end positions (limit range), move them only slowly and with great caution.

When swivelling the attachment, maintain a minimum distance of 10° to the end position to the tilt cylinder.

Fig. 3-131 Permissible working range for hydraulic cylinders 1

Possible swivel range

2

Permissible working range with 10 ° distance to end position

3

Limit range

4

Boom or stick

5

Hydraulic cylinder

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3.6.2

Preparation

Fig. 3-132 Safe working: observe machine range and danger zones Danger!

Risk to life and limb when the machine is swivelled.

Ensure that no persons are standing inside the danger area r of the machine.

Caution!

Risk of injury during work.

Always wear safety footwear. If required by the nature of the work to be carried out, wear hard hat and protective goggles.

Always wear the safety belt.

Before starting work, operate the horn to warn other workers.

Position the transport vehicle and the machine in such a way that the machine operator can properly supervise the transfer of the load.

If possible, position the machine at a higher point than the transport vehicle, in order to avoid unnecessary lifting of the load.

Lock the oscillating axle.

Extend the supports until the wheels are fully lifted from the ground.

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3.6.3

Working with grapples Danger!

Risk to life and limb or damage to the machine by swinging grapple: – The grapple can collide with and damage the operator's cab and injure the operator.

– The grapple can also injure other persons.

– A swinging grapple can also affect the stability of the machine.

Prevent the grapple from swinging near the operator's cab.

Ensure that the stick is in a position where the grapple cannot collide with the machine when the excavator travels or when the brakes are applied.

Move the joystick slowly and smoothly to prevent swinging of the grapple.

Ensure that the moving grapple cannot collide with persons.

Do not lift heavy loads with a fully extended boom and stick. Do not move loads to the far right or left.

Observe the load lift chart showing the permissible lift loads that can be attached to the end of the stick, depending on its actual extension.

3.6.4

Excavating and moving material with grapples Put the machine into its working position.

Fig. 3-133 Clamshell bucket: align stick, close jaws, lift excavated material Align stick (1): Open the claws fully.

Lower the stick vertically to excavated area.

Closing jaws (2): Danger!

When being closed, the clamshell bucket might lift the machine. As a result, the machine might inadvertently roll away.

Avoid situations where the machine could become unstable by lifting the equipment sufficiently before closing the grapple.

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Close the jaws.

Lift the stick only slightly in order to relieve the pressure on the ground.

To lift excavated material (3): Close the jaws.

Lift the boom.

Move the machine to the unloading area (e.g. transport vehicle).

Fig. 3-134 Releasing excavated material Swivel the stick as far possible in order to prevent any risk from the slewing bucket.

Open the jaws and release the excavated material.

3.6.5

Loading operation Danger!

There is always a risk that the hydraulic excavator might topple over! Sinking of an outrigger into the substrate could result in devastating consequences!

Make sure to check the placement surfaces of the outriggers (load-carrying capacity of ground).

Perform all movements with extra caution.

Observe the load lift chart: showing the permissible lift loads that can be attached to the end of the stick, depending on its actual extension.

Fig. 3-135 Taking up the load

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Note!

Maximum lifting capacity is given, when the load is taken up as closely as possible near the undercarriage.

Fig. 3-136 Loading operation Carefully lift the load.

Keep the load as close as possible to the undercarriage, while keeping a sufficient safety distance to the operator's cab (swinging grapple!). Move the load as low as possible above the ground.

Swivel the attachment carefully across the loading platform of the transport vehicle or across the unloading area.

Place the load on the platform/ground (open the grapple).

Danger!

Risk to life and limb from suspended loads that become dislodged during loading onto the transport vehicle.

Do not overload the transport vehicle and ensure that the load cannot fall from the platform.

While loading the vehicle, ensure that no persons are in the danger area of the excavator or in the transport vehicle.

Never swivel the attachment over the driver's cab.

Caution!

Especially when moving timber, it might be necessary to move the machine while the loaded attachment is lifted. In this case, the centre of gravity of the machine is shifted vertically and thus higher than normal. The travel behaviour of the machine is greatly affected by this.

Observe the instructions in chapter "Safe use of machine for goods handling".

3.6.6

Load lifting operation Load lifting operation includes all manoeuvres where loads attached to the machine with lifting tackle (cables, chains, etc.) are lifted, transferred and lowered, whereby

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the load must be attached manually to the machine. Loading operations thus also include lifting and lowering of pipelines, shaft rings and vessels.

Danger!

The machine may only be used for lifting operations, if it is equipped with the necessary safety devices and when these devices are in proper working order.

According to the European standard EN 474-5, machines used to lift loads must be equipped with the following safety devices: – Lifting tackle that allows for the safe attachment of a load (optional equipment) An example of a safe lifting tackle are lift hooks that are attached to the machine instead of the digging bucket. Load lift hooks may be replaced with safety hooks welded to the digging bucket.

– Overload warning system (optional equipment) If the actual load reaches or even exceeds the permissible load according to the load lift chart, the overload warning system must generate a visual and audible alarm signal to the machine operator.

– Pipe fracture safety valve at the boom cylinders The pipe fracture safety valve must conform to the requirements laid down in ISO 8643.

– Load lift chart in the operator's cab If one or more of the above requirements is not met, the machine may not be used for load lifting operations.

3.6.7

Use of quick-change adapter for load lifting operation

Fig. 3-137 Lifting operation with load hook 1

Load lift hook

3

Hook for working tool (not suitable for load lifting operation)

2

Lifting tackle

A Permissible swivelling range The quick-change adapter is equipped with two integrated load lift hooks for lifting operation.

The maximum lifting capacity of the individual load lift hooks is indicated at the quickchange adapter. The load capacity might be below or above that of the basic machine. Always observe the load capacity values of the machine.

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Load-lifting work can be carried out with or without an attached working tool. If a working tool is mounted and the machine is used to lift loads, we recommend fully retracting the locking pins. This prevents that the lifting tackle is deflected by the locking pins, as this could cause damage.

Danger!

If a load is lifted incorrectly, it might become dislodged, which in turn could result in serious accidents.

To lift loads, always use the load hooks 1 and never the hook for the working tool.

Adjust the quick-change adapter position so that the load hook 1 opens upwards and is within the permissible swivel range A. Attach the load to the load hook according to the instructions in chapter "lifting operation".

3.6.8 3.6.8.1

Overload warning system (optional equipment) General The overload warning system warns the machine operator with a visual signal (overload warning indicator light) and an acoustic signal (buzzer sound) when the permissible maximum load is reached.

The overload warning system therefore helps prevent dangerous situations where the permissible load moment is inadvertently exceeded. In the event of a warning signal, reduce the extension of the attachment or lower the load to the ground without increasing the extension.

Even if the overload warning system is used, it remains the responsibility of the machine operator to ensure that only loads of a known weight that is below the maximum permissible load of the machine are lifted. Also observe the applicable statutory accident prevention regulations.

The permissible maximum load depends on the machine equipment (undercarriage, attachments) and is shown on the load table in the operator's cab.

When the machine is standing on firm and level ground, the above values allow for the swivelling of the uppercarriage by 360°.

The load capacity values in the table correspond to max. 75 % of the tip load or 87 % of the hydraulic lifting force according to ISO 10567.

If the overload warning system is defective, it is prohibited to lift loads. The system must be repaired by a specialist technician.

Note!

The load capacity values might vary, depending on the mounted tools and attachments.

Note!

The overload warning system must be tested prior to the commissioning of the machine and then every year by a specialist technician, in accordance with the testing and setting installations in the service manual.

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3.6.8.2

Operating principle The overload warning system consists of a pressure switch connected to the piston side of the hoist cylinders.

If the hydraulic pressure in the hoist cylinders reaches the limit value, the pressure switch generates a signal. This signal switches on the overload warning indicator light and triggers a buzzer sound.

The limit value is set within the range of the stability factors.

3.6.8.3

Commissioning Danger!

The overload warning system does not disable the machine when the permissible load moment is exceeded. The operator is only informed that the limit value is exceeded.

When the overload warning system has been triggered, do not exceed the load or outreach.

Press the switch S18 down.

The overload warning system is activated.

The indicator light in the switch is on.

3.6.8.4

Function test Before each shift, the machine operator must check whether the overload warning system is working properly: Lift the boom and extend the hoist cylinders to the stop.

Continue moving the joystick in direction "lifting boom".

The overload warning indicator light must be on.

The buzzer must sound.

3.7 Parking and exiting machine Shut down the diesel engine.

Turn the ignition key to contact position.

Release the pressure from the pressure lines by carefully moving the joystick several times.

Move the safety lever up.

The parking brake is applied.

The slewing gear brake is applied.

Remove the ignition key.

Close all doors, hoods and covers of the machine and lock them.

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Control, operation Transport

3.8 Transport 3.8.1

Safety instructions – Insure that the transporting vehicle or truck trailer is rated for the intended machine weight and size.

– Park the machine on a level surface and chock the track chains and/or wheels.

– During transport, remove parts of the attachment that create an over width or length condition, if necessary.

– Clean the undercarriage. The undercarriage must be swept clean, meaning, the chains / wheels must be free of snow, ice and sludge prior to driving onto the transporting vehicle.

– Align the machine precisely with the loading ramp.

– Attach the manual lever for sensitive driving (crawler excavator) to the driving pedals.

– Have another person guide and signal the operator.

– On wheel models equipped with an uppercarriage locking mechanism, the uppercarriage must be secured to the undercarriage with the locking pin after loading onto the trailer.

– Secure the machine and any loose components with tiedowns in accordance with any applicable national regulations.

– Release all pressure lines (as described in this operating manual), remove the ignition key and pull the safety lever up prior to leaving the machine.

– Close all cab and panel doors.

– Verify that no one remains on the machine during the transport.

– Investigate the travel route, specifically in reference to limits for width, height and weight prior to the transport.

– Pay special attention when driving under electrical lines and bridges and when passing through tunnels.

– Use the same care for unloading as for loading.

3.8.2 3.8.2.1

Transport of the machine on a low-loader Preparation Prior to loading the excavator onto a low-loader, make the following preparations: Hold wheel chocks ready.

Remove dirt, ice and snow from the tyres, ramps and loading platforms.

Remove the stick and/or working attachment, if required.

If the transport vehicle is to be accessed over a ramp or similar device, ensure that the maximum permissible angle is not exceeded. Maximum angle of inclination W <= 10°

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Fig. 3-138 Loading ramp

3.8.2.2

Loading the machine onto a low-loader If necessary, disconnect the semi-trailer from the tractor vehicle.

Rotate the operator's cab to be positioned over the sprocket wheel.

Align the machine to the loading ramp.

Note Employ a trained person (signaller) to guide the machine operator during this manoeuvre.

Hin

Establish contact with the signaller.

Slowly drive the machine onto the low-loader.

Swivel the uppercarriage by 180°.

Lower the boom.

Turn the ignition key to contact position and depressurise all pressure lines by carefully operating the joysticks repeatedly in all directions.

Remove the ignition key and tilt the safety lever upwards.

Close all doors, hoods and covers of the machine and lock them.

Fold in the rear mirror.

Connect the semi-trailer to the tractor vehicle and lift the low-loader.

3.8.2.3

Secure the machine:

Fig. 3-139 Securing the machine Before moving the low-loader, the machine must be secured against shifting.

Danger!

Shifting of the machine on the low-loader can result in serious accidents.

Secure the machine against shifting.

Place chocks at the wheels and secure the equipment with cables and chains.

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Using tension chains, secure the machine by attaching the chains to the points labelled as tie-down points (see Fig. 3-139).

Secure the cables and chains at the provided points on the low-loader.

Transport route: Ge

Danger!

Risk of serious accidents when the vehicle collides with low bridges, overhead lines, etc.

Special attention must be paid when driving under power lines.

Reconnoitre the route before starting the journey.

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4 Malfunctions Malfunctions are indicated by indicator lights or icons on the monitoring display. In certain cases, an acoustic warning signal is issued. Additional information that facilitates the elimination of the problem is provided by error codes.

Malfunctions are frequently caused by incorrect operation of the machine or improper maintenance.

Each time you encounter a malfunction, read the relevant chapter in the operator’s manual.

Identify the cause of the malfunction and eliminate it or have it eliminated.

Note!

If you are unable to identify the cause of the malfunction, contact the LIEBHERR service department.

Do not carry out any work for which you are not qualified.

When contacting the LIEBHERR service department, describe the malfunction and all associated circumstances in as much detail as possible.

Quote the machine type, the serial number and the year of manufacture of your equipment.

4.1 Error code list General error codes Error code

Effect

Cause

Remedy

E 002

Engine oil pressure not monitored

Pressure switch, short circuit, earth contact or wire break

Check engine oil level, contact LIEBHERR customer service

Coolant temperature not monitored

Water level sensor, short circuit, earth contact or wire break

Check coolant level, contact LIEBHERR customer service

Coolant temperature not monitored

Temperature sensor, short circuit, earth contact or wire break

Check cooler for dirt, contact LIEBHERR customer service

E 003 E 004 E 005 E 006 E 007 E 009

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Malfunctions

Operating manual

Error code list

General error codes Error code

Effect

Cause

Remedy

E 010

Hydraulic oil level not monitored

Hydraulic oil level sensor, short circuit, earth contact or wire break

Check hydraulic oil level, contact LIEBHERR customer service

Hydraulic oil temperature not monitored

Hydraulic oil temperature sensor, short circuit, earth contact or wire break

Check cooler for dirt, contact LIEBHERR customer service

Pump distribution gear (if installed): gear oil temperature not monitored

Temperature sensor, short circuit, earth contact or wire break

Contact LIEBHERR customer service

Speed sensor, short circuit, earth contact or wire break

Switch diesel engine and hydraulic pump to emergency mode, contact LIEBHERR customer service

E 024

Diesel engine speed not monitored; diesel engine speed cannot be changed through keyboard; reduced hydraulic power

E 027

Insufficient hydraulic power

Cable defect at the amplifier for the performance regulation of the hydraulic pump

Switch hydraulic pump to emergency mode, contact LIEBHERR customer service

E 033

Maximum fan speed

Fan control, cable defective

Contact LIEBHERR customer service

E 036

Flow reduction for hydraulic attachments is not working properly

Cable defect at the amplifier for the flow regulation of the hydraulic pump

Do not operate flow-reduced attachments, contact LIEBHERR customer service

E 039

Flow reduction for hydraulic attachments is not working properly

Cable defect at the amplifier for the flow regulation of the second hydraulic pump

Do not operate flow-reduced attachments, contact LIEBHERR customer service Contact LIEBHERR customer service

E 011 E 012 E 013 E 014 E 015 E 016 E 017 E 018 E 022 E 023

E 042

Slewing gear fine control not working

Cable defect at valve

Monitoring of hydraulic oil cooling does not work

Cable defect at valve

No power reduction at slewing gear

Cable defect at valve

Performance regulation of hydraulic pump not working properly

Cable defect at valve

E 045

Insufficient pressure for attachment

Tool Control, cable defect at pressure control valve

Contact LIEBHERR customer service

E 046

Engine speed cannot be adjusted through the keyboard

Speed-adjustment servo motor faulty

Switch diesel engine to emergency mode, contact LIEBHERR customer service

E 053 E 054

Stick cannot be moved

Angle sensor, short circuit, earth contact or wire break

Contact LIEBHERR customer service

E 056

Fine control of slewing gear not responding

Pressure sensor, earth contact or wire break

Check pressure switch at the left pilot control unit, contact LIEBHERR customer service

Engine power reduced

Temperature sensor of intercooling air, earth contact or short to plus

Check wiring, contact LIEBHERR customer service

E 057 E 058 E 063 E 065 E 070

not assigned

E 072

No information re. intercooling air available

Intercooling pressure sensor, short circuit or wire break

Check wiring, contact LIEBHERR customer service

Diesel engine cannot be started

Starter, earth contact or wire break

Check wiring, contact LIEBHERR customer service

-

PLD hardware failure

Contact LIEBHERR customer service

E 073 E 074 E 075 E 078 E 079 E 081 E 082

PLD software failure In the event of a failure of both speed sensors, the engine cannot be started

Speed sensor Speed1 Speed sensor Speed2

Contact LIEBHERR customer service

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Malfunctions Error code list

General error codes Error code

Effect

Cause

Remedy

E 084

Failure of pre-heating and afterheating function

Cold-starting aid, short circuit, malfunction or wire beak

Check engine control unit, heating flange, cable harness, contact LIEBHERR customer service

E 087

-

Speed difference between Speed1 and Speed2

Contact LIEBHERR customer service

E 088

Engine power reduced

Fault in ambient air pressure sensor

Check wiring and sensor

E 089

Machine cannot be started

Cable defect, water in fuel filter

Check cabling between engine control unit and sensor, remove water from fuel filter

E 090 E 091

Fuel temperature is not transmitted, engine performance is reduced

Fuel temperature sensor, earth contact, wire break or short to plus

Check cabling between engine control unit and sensor

E 098

-

Fault in cable connection D+ to PLD electronics

Check alternator and alternator wiring, contact LIEBHERR customer service

E 085 E 086

E 099 E 100

Alternator defective -

E 101

Speed signal Speed1 Speed signal Speed2

Check speed transducer and cabling of engine control unit, contact LIEBHERR customer service

E 102

Engine cannot be started

Crank shaft synchronisation failed

Switch ignition on and off, check speed transducer, contact LIEBHERR customer service

E 103

-

Speed sensor of cam shaft defective

Check wiring to speed transducer, check speed sensor, contact LIEBHERR customer service

E 104

No speed signal from cam shaft

E 105

Engine cannot be started

Cam shaft synchronisation failed

Check speed sensor, contact LIEBHERR customer service

E 109

-

CAN1 hardware failure

Check cabling, plugs and CAN assemblies, contact LIEBHERR customer service

E 110

No CAN1 data (timeout)

E 111

-

Injector A1 defective

E 112

-

Injector A1 BIP fault

E 113

-

Injector A2 defective

E 114

-

Injector A2 BIP fault

E 115

-

Injector A3 BIP defective

E 116

-

Injector A3 BIP fault

E 117

-

Injector A4 BIP defective

E 118

-

Injector A4 BIP fault

E 119

-

Injector B1 BIP defective

E 120

-

Injector B1 BIP fault

E 121

-

Injector B2 BIP defective

E 122

-

Injector B2 BIP fault

E 123

-

Injector B3 BIP defective

E 124

-

Injector B3 BIP fault

E 125

-

Injector B4 BIP defective

E 126

-

Injector B4 BIP fault

E 127

-

Bank1 parameters missing

E 128

-

Bank2 parameters missing

E 135

-

5V reference 1 defective

E 136

-

5V reference 2 defective

E 137

-

5V reference 3 defective

E 138

-

5V reference 4 defective

Check cabling, plugs and engine control unit, contact LIEBHERR customer service

Check cabling, plugs and engine control unit, contact LIEBHERR customer service

Contact LIEBHERR customer service Contact LIEBHERR customer service

copyright by R 934 C Litronic / 11692682

4-3

Malfunctions

Operating manual

Error code list

General error codes Error code

Effect

Cause

Remedy

E 302

Input through keyboard not possible

No code plug

Contact LIEBHERR customer service

E 303

Engine speed cannot be adjusted through the keyboard, hydraulic performance is reduced

No CAN bus connection between keyboard and control system

Switch diesel engine and hydraulic pump to emergency mode, contact LIEBHERR customer service

E 305

Malfunctions, e.g. of travel brake, slewing gear brake, servo control

No CAN bus connection between keyboard and ESP01 printed circuit board (message is also displayed, if ESP01 is not ready for operation)

Switch controls to emergency mode, contact LIEBHERR customer service

E 306

Malfunctions, e.g. in travel direction switch, gear shifting system, oscillating axle locking mechanism, accessory kits

No CAN bus connection between keyboard and ESP02 printed circuit board (message is also displayed, if ESP02 is not ready for operation)

Contact LIEBHERR customer service

E 307

Speed adjustment not possible

No CAN bus connection between keyboard and PLD diesel engine regulating unit (message is also displayed, if PLD regulator is not ready for operation)

Contact LIEBHERR customer service

E 308

No or incorrect display

No CAN bus connection of keyboard to display, or keyboard defective

Contact LIEBHERR customer service

E 309

Software incompatibility between keyboard and display

E311

Main screen is blank

No CAN bus connection to control system

Contact LIEBHERR customer service

E 314

Diesel engine switches to emergency mode

Timeout of PLD

Contact LIEBHERR customer service

E 319

Engine speed cannot be adjusted through the keyboard, hydraulic performance reduced

Hardware coding does not match software coding

Switch diesel engine and hydraulic pump to emergency mode, contact LIEBHERR customer service

Failure of idle automatic at left joystick, diesel engine remains at lower speed

Handle sensor, short circuit, earth contact or wire break

Deactivate idle automatic, contact LIEBHERR customer service

Failure of idle automatic at right joystick, engine remains at lower speed

Handle sensor, short circuit, earth contact or wire break

Deactivate idle automatic, contact LIEBHERR customer service

E 450

Engine speed reduction at lowering of attachment (pressure-less lowering)

Pressure sensor, short circuit, earth contact or wire break

Contact LIEBHERR customer service.

E 454 E 455

Possible incorrect actuation of slewing gear brake

Slewing gear speed sensor, slewing gear, short circuit, earth contact or wire break

Contact LIEBHERR customer service

E 456

Incorrect fuel level indication

Fuel sensor, short circuit, earth contact or wire break

Visual check of fuel level, contact LIEBHERR customer service Do not execute any work that requires stroke limitation; if necessary, switch stroke limitation to emergency mode; contact LIEBHERR customer service

E 321 E 322 E 442 E 443 E 445 E 446

No known machine type received from keyboard Unknown hardware coding

E 458 E 905

Stroke limitation fails to work

Failure of angle sensor of boom

E 906

Stroke limitation fails to work

Failure of basic boom angle sensor

E 907

Stroke limitation fails to work

Failure of stick angle sensor

E 911

Control system failure

Fault in EEPROM record

Contact LIEBHERR customer service

copyright by

4-4

R 934 C Litronic / 11692682

Operating manual

Malfunctions Error code list

General error codes Error code

Effect

Cause

Remedy

E 914

Boom cylinder cannot be moved

No release signal for boom cylinder to control system

E 916

Boom cylinder cannot be moved

No release signal for boom cylinder preliminary shut-down to control system

Do not execute any work that requires stroke limitation; if necessary, switch stroke limitation to emergency mode; contact LIEBHERR customer service

E 917

Boom regulating cylinder cannot be moved

No release signal for boom regulating cylinder to control system

E 918

Boom regulating cylinder cannot be moved

No release signal for boom regulating cylinder to control system

E 919

Stick cylinder cannot be moved

No release signal for stick cylinder to control system

E 929

Working attachment cannot be operated

Stroke limitation, failure in power supply to sensor

The faults and errors listed below are indicated by symbols on the screen or by indicator lights. The respective error codes are not shown in the EC field of the operator menu. The only way to read them is the list-S-Exxx menu.

Error codes combined with symbols / indicator lights Error code

Symbol *

Effect

Cause

What you can do

E 501

Indicator light H2 on, acoustic warning signal

Oil pressure of diesel engine too low

Set the diesel engine to low idle speed and switch it off after 30 seconds.

E 502

Symbol is displayed, acoustic warning signal

Coolant level too low

Set the diesel engine to low idle speed and switch it off after 30 seconds; locate leak and seal it.

E 503

Symbol and P2 are on at the same time, acoustic warning signal

Coolant overheating

Set the diesel engine to low idle speed and switch it off after 30 seconds; check radiator for dirt; check coolant level; contact LIEBHERR customer service.

E 504

Symbol is displayed, acoustic warning signal

Hydraulic oil level too low

Set the diesel engine to low idle speed and switch it off after 30 seconds; locate leak and seal it; add hydraulic oil.

E 505

Symbol is displayed, acoustic warning signal

Hydraulic oil overheating

Set the diesel engine to low idle speed and switch it off after 30 seconds; check radiator for dirt; contact LIEBHERR customer service.

E 506

Symbol is displayed, acoustic warning signal

Oil temperature in pump distribution gear too high

Set the diesel engine to low idle speed and switch it off after 30 seconds; check hydraulic oil cooler for dirt; contact LIEBHERR customer service.

E 509

Indicator light H24 on, acoustic warning signal

Flow indication of steering system: no hydraulic oil or steering pump defective

Contact LIEBHERR customer service.

E 510

Indicator light H23 on, acoustic warning signal

Accumulator pressure of working brake too low (< 100 bar)

Load pressure accumulator while diesel engine is on. If problem persists: contact LIEBHERR customer service.

copyright by R 934 C Litronic / 11692682

4-5

Malfunctions

Operating manual

Error code list

Error codes combined with symbols / indicator lights Error code

Effect

Cause

What you can do

E 511

Symbol *

Symbol is displayed.

Overvoltage at control keyboard

Contact LIEBHERR customer service.

E 512

Problems at start-up of hydraulic excavator; symbol is displayed

Battery voltage too low, undervoltage at PLD

Contact LIEBHERR customer service.

E 513

Control system shuts down hydraulic excavator; battery gasses, symbol is displayed

Battery voltage too high, overvoltage at PLD

Contact LIEBHERR customer service.

E 514 E 515

Central lubrication system lubrication control without function, symbol is displayed

Signal to frequency valve continues after the set monitoring time has lapsed.

Perform interim lubrication, contact LIEBHERR customer service.

E 516

Diesel engine cannot be started, or engine shut-down

Emergency-stop EDC error, engine control has detected an internal error

Contact LIEBHERR customer service.

E 517

Diesel engine shuts down; symbol is displayed

Injector fault

Contact LIEBHERR customer service.

E 518

Diesel engine shuts down; symbol is displayed

Start synchronisation error

Contact LIEBHERR customer service.

E 519

Symbol is displayed, acoustic warning signal

Engine speed: warning threshold exceeded

Contact LIEBHERR customer service.

E 520

Diesel engine shuts down; symbol is displayed, acoustic warning signal

Engine speed: safety threshold exceeded

Contact LIEBHERR customer service.

E 521

Diesel engine shuts down; symbol is displayed

Both speed transducers defective

Contact LIEBHERR customer service.

E 522

Diesel engine shuts down; symbol is displayed, acoustic warning signal

Low lubricant pressure (safety threshold exceeded)

Contact LIEBHERR customer service.

E 523

Symbol is displayed, acoustic warning signal

Coolant overheating (7>seconds); safety threshold exceeded

Let machine cool down, e.g. in F mode; check radiator for dirt; check coolant level; contact LIEBHERR customer service.

E 524

Symbol is displayed, acoustic warning signal

Intercooling air overheating (7>seconds); safety threshold exceeded

Check radiator for dirt, contact LIEBHERR customer service.

E 525

Symbol is displayed, acoustic warning signal

Engine fault in emergency mode

Set the diesel engine to low idle speed and switch it off after 30 seconds. Contact LIEBHERR customer service.

E 526

Symbol is displayed, acoustic warning signal

Fuel temperature: warning threshold exceeded

Check radiator for dirt. Contact LIEBHERR customer service.

copyright by

4-6

R 934 C Litronic / 11692682

Operating manual

Malfunctions Error code list

Error codes combined with symbols / indicator lights Error code

Effect

Cause

What you can do

E 527

Symbol *

Symbol is displayed, acoustic warning signal

Fuel temperature: safety threshold exceeded

Set the diesel engine to low idle speed and switch it off after 30 seconds. Contact LIEBHERR customer service.

E 528

Symbol is displayed

Water in fuel filter

Remove the water from the fuel filter.

E 530

Diesel engine shuts down; symbol is displayed, acoustic warning signal

Internal error in engine control unit

Attempt restart; if not successful, contact LIEBHERR customer service.

E 532

Symbol is displayed

Fuel pressure: warning threshold exceeded

Check fuel filter, tank; contact LIEBHERR customer service.

E 533

Symbol is displayed

Fuel pressure: safety threshold exceeded

Set the diesel engine to low idle speed and switch it off after 30 seconds. Contact LIEBHERR customer service.

E 534

Symbol is displayed.

Fuel pressure: warning threshold exceeded

Contact LIEBHERR customer service.

E 535

Symbol is displayed

Fuel pressure: safety threshold exceeded

Contact LIEBHERR customer service.

E 536

Symbol is displayed

Fuel pressure Rail 1; warning threshold exceeded

Contact LIEBHERR customer service.

E 537

Symbol is displayed

Fuel pressure Rail 1; safety threshold exceeded

Contact LIEBHERR customer service.

E 538

Symbol is displayed

Fuel pressure Rail 2; warning threshold exceeded

Contact LIEBHERR customer service.

E 539

Symbol is displayed

Fuel pressure Rail 2; safety threshold exceeded

Contact LIEBHERR customer service.

E 597

Engine power reduced; symbol displayed, acoustic warning signal

Intercooling air temperature: warning threshold exceeded

Let machine cool down, e.g. in F mode; check radiator for dirt; contact LIEBHERR customer service.

*

screen symbol or indicator light

In machines equipped with a hydraulic quick-change adapter (optional equipment), an additional warning symbol is shown in the SY field: Quick-change adapter symbol This symbol, together with a buzzer warning sound, indicates that the quick-change adapter is not properly locked.

If the symbol is displayed, immediately halt operation, unless you wish to release the adapter. If the symbol is not displayed while the quick-change adapter is being released, also immediately stop the procedure.

copyright by R 934 C Litronic / 11692682

4-7

Malfunctions

Operating manual

Troubleshooting

The alarm signals can be triggered if a locking pin has inadvertently become dislodged, or by mechanical or hydraulic damage. The alarm signals might also be caused by defects in the electrical system (e.g. at the proximity switch or buzzer).

Only resume operation after the defective part has been repaired or replaced.

4.2 Troubleshooting 4.2.1

Diesel engine and fuel system

Error / fault Diesel engine fails to start

Engine starts, but stops immediately or runs irregularly

Cause

Remedy

Fuel tank nearly/completely empty

Add fuel and bleed fuel system

Underpressure in the tank

Open the tank lid and close it again

Fuel filter dirty

Clean or change filter and bleed the fuel system; drain off fuel / clean tank

Ambient temperature below 0 °C

For operation and control under extreme conditions, see operating manual

Starter failure

Check line connections, service starter

Batteries flat

Recharge / replace batteries

Fuel tank empty (underpressure in tank)

Add fuel and bleed fuel system

Fuel filter dirty

Clean or change filter and bleed fuel system (tank)

In winter: engine oil viscosity too high

Use an engine oil that is suitable for the respective ambient temperature

Dry air filter contaminated

Clean or change

Air in fuel system

Bleed fuel system

Bleeding valve in fuel tank blocked

Clean

Fuel line kinked

Check line and repair, if required

Diesel engine emits grey or black fumes

Dry air filter contaminated

Clean or change

White steam emitted by diesel engine

Water in combustion room

Consult customer service department

Diesel engine does not reach full speed

Speed not set to maximum value

Set speed to maximum value

Injection unit settings incorrect

Consult customer service department

Dry air filter contaminated

Clean or change

Insufficient fuel supply

Clean or replace fuel filter; check lines, drain water from tank

copyright by

4-8

R 934 C Litronic / 11692682

Operating manual

Malfunctions Troubleshooting

Error / fault

Cause

Diesel engine too hot

Remedy

Insufficient amount of coolant

Add coolant, check for tightness

Water pump defective

Repair

Thermostats fail to work

Replace thermostats

Radiator dirty

Cleaning radiator

Insufficient oil pressure in diesel engine Note!

Immediately switch off the diesel engine!

Oil level too low

Correct oil level

Oil pressure indicator defective

Change oil pressure switch

Diesel engine uses too much oil

Leakage on diesel engine

Retighten screws; replace seals, if required

Oil in coolant or coolant in oil

Consult customer service department

Unusual noises / noise at exhaust air side

4.2.2

Leakage in exhaust gas system

Check / repair exhaust gas system

Hydraulic system

Error / fault

Cause

Remedy

Unusual noises / noise from hydraulic pumps Note!

Immediately switch the engine to its lower idle speed and shut it down!

Stop valve at the hydraulic tank closed

Open stop valve

Hydraulic pumps take in air

Check oil level in the hydraulic tank, check suction lines for leakage

Engine stalls

No performance adjustment

Activate emergency mode; consult customer service department

Hydraulic oil temperature too high

Radiator dirty

Cleaning radiator

Fan or fan control defective

Eliminate fault / consult customer service department

Hydraulic oil level too low

Oil loss

Repair leak, replace hoses, add oil through the return filter

Travel function not available

Safety lever moved up

Move safety lever down

Slewing gear failure

Servo control not working

Move the safety lever down

Slewing gear brake activated

Move safety lever down Release slewing gear brake

No working movement

Servo control not working

Move safety lever down

No servo pressure

Consult customer service department

No pump high pressure

Consult customer service department

copyright by R 934 C Litronic / 11692682

4-9

Malfunctions

Operating manual

Troubleshooting

4.2.3

Travel gearbox

Error / fault

Cause

Remedy

Oil escaping at running rollers, support rollers or idler

Seal defective

Replace seal

Chain guide at idler defective

Excessive play of idler guide system at the running roller frame

Adjust pay of idler guide system

Chain jumps from guides

Insufficient chain tensions / chain wheel worn

Adjust chain tension

Correctly tightened chain becomes loose after short operation

Chain tensioning cylinder defective

Check chain tensioning cylinder; replace or reseal, if necessary (to be done by authorised specialist technician)

Running or support roller stiff

Drive extremely dirty

Clean drive

4.2.4

Electrical system

Error / fault

Cause

Remedy

Battery charging indicator light does not go off

V-belt of alternator loose or broken

Tighten or replace V-belt

Alternator defective

Replace alternator

Batteries are not sufficiently charged

Batteries defective

Replace batteries

Battery connections dirty / oxidised

Clean battery connections

Cable loose or defective

Connect or replace cable

Failure of indicator light or indicating instrument

Incandescent lamp burnt out; indicating instrument defective

Replace defective part

Failure of one or more instrument panel functions

Adapters disconnected or defective; earth connector disconnected; short circuit - fuse blown

Plug in or change adapter; eliminate cause of short circuit; replace fuse or reset automatic cut-out

Engine speed adjustment not possible

Excavator electronics for speed adjustment not working

Consult customer service department

Idle automatic is activated

Grab the joystick or deactivate the idle automatic Consult customer service department

No signal from speed sensor

Consult customer service department

Permanent sensor signal

Consult customer service department

Deactivate idle automatic

Activate idle automatic

Switch defective

Replace switch

Idle automatic without function; speed fails to drop Slewing gear brake cannot be released with switch

copyright by

4 - 10

R 934 C Litronic / 11692682

Operating manual

Malfunctions Fuses and relays

4.2.5

Heating and air-conditioning system

Error / fault

Cause

No warm air escaping from heating system

Heating blower not working

Low air circulation rate in operator's cab

4.2.6

Remedy

Stop valves of coolant line on the diesel engine closed

Open stop valve

Engine not at operating temperature

Heat engine to operating temperature

No power

Check fuse and cable; replace if required

Blower motor defective

Replace blower motor

Ambient air filter / recirculation air filter contaminated

Clean air intake openings; replace ambient air filter

Air outlets closed

Open air outlets

Working attachment

Error / fault

Cause

Remedy

Cylinder responds to load

Piston seal on cylinder defective

Service cylinder

Excessive bearing play in attachment

Bearing points worn

Replace bearing components

Grapple / bucket cannot be moved

Valve block at tilt cylinder connected incorrectly

Change connections to valve block

Attachment cannot be rotated, swivelled or operated

Auxiliary function not activated

Activate respective additional function

Lines not connected

Connect lines

4.3 Fuses and relays Danger!

Incorrect or bridged fuses do not provide the protection required for the protection of the machine operator and the electrical equipment.

Use only original fuses.

Never bridge electrical fuses.

If necessary, order replacement fuses from LIEBHERR. Before exchanging a fuse or relay, set the battery main switch to position 0 (OFF).

copyright by R 934 C Litronic / 11692682

4 - 11

Malfunctions

Operating manual

Fuses and relays

4.3.1

Fuse box E50

Fig. 4-1

Fuse box E50

The E50 fuse box is located behind the left side door above the batteries.

Remove the lid of the fuse box and replace it after the fuse has been replaced.

F19

100 A

Pre-heating

F20

50 A

Main fuse

F22

7.5 A

Warning light system

F31

7.5 A

Heating and a/c system terminal 15

F33

7.5 A

Refuelling pump*

F34

Reserve

F35

Reserve

F36

20 A

Refuelling pump*

F36-2

15 A

Stroke limitation / stick cylinder shut-down*

F37

20 A

Heating and a/c system terminal 30

F109

50 A

Optional equipment and auxiliary headlight*

F110

50 A

Engine control terminal 30

F115

7.5 A

Emergency operation terminal 15

F116

7.5 A

Engine control terminal 30

F117

7.5 A

Engine control terminal 15

F122

7.5 A

Engine control, preheating monitoring

F133

7.5 A

Elevating operator's cab*

F253

25 A

Attachment light

K66-1

Stroke limitation / stick cylinder shut-down*

K66-2

Stroke limitation / stick cylinder shut-down*

K127

Relay of emergency operation / speed control

K128

Relay of starting engine emergency operation

K288

Main relay terminal 15

K302

Relay of pre-heating

K415

Relay of attachment light

* optional equipment

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4 - 12

R 934 C Litronic / 11692682

Operating manual

Malfunctions Fuses and relays

4.3.2

ESP02 printed circuit board

Fig. 4-2

Fuses and ESP02 relay board

The ESP02 board is located in the left control console and is accessible when the operator's cab door is open.

Remove the cover of the control console and replace it after the fuse has been replaced.

F1

2A

Left parking and tail light

F2

2A

Right parking and tail light

F3

7.5 A

Reserve

F4

15 A

Servo control and safety lever for kits

F5

15 A

Special functions SF2, SF3 and SF4*, reserve

F6

15 A

Special function SF1*, 1st gear, oscillating axle locking, brake light

F7

15 A

Headlight

F8

7.5 A

Parking brake, servo control, creeper gear

F9

7.5 A

Windscreen wiper

F10

7.5 A

Pre-heating, windscreen washer system, beacon*, rotating grapple*

F11

15 A

Reserve

F12

15 A

Reserve

copyright by R 934 C Litronic / 11692682

4 - 13

Malfunctions

Operating manual

Emergency operation

F13

15 A

Excavator control

F14

15 A

Emergency control

F15

7.5 A

Brake pressure switch

F16

7.5 A

Indicators

F17

15 A

Reserve

F18

15 A

Reserve

F19

7.5 A

Cigarette lighter

F20

15 A

Reserve

F21

15 A

Ignition lock, terminal 30

F22

7.5 A

Cab lighting, horn

F23

7.5 A

Travel light, right

F24

7.5 A

Travel light, left

F250

2A

Automatic cut-out for keyboard terminal 15

F251

2A

Automatic cut-out for keyboard terminal 30

K330

Relay / central lubrication system*

K332

Relay / left and right travel light

* optional equipment

4.4 Emergency operation 4.4.1

Purpose The emergency operation function is an auxiliary function that enables operators to restore machine functions that have failed. Depending on the situation, this auxiliary function might need to be activated, for example to remove a machine quickly from the construction site after a fault occurred.

When in emergency mode, various functions are directly controlled, so that the control and operating elements that are faulty are bypassed. The function is intended exclusively for temporary use in the event of an emergency and is not a substitute for proper repair.

The options available in emergency mode depend on the type and extent of the malfunction or fault. The following emergency mode functions are available:

Emergency operation

Purpose

Control

Short-term continuation of operation until repair can be performed (it is always recommended to carry out repairs without delay)

Gear shifting Hydraulic pump

Moving the machine away from the construction site or a dangerous position (immediate repair is required)

Shut-down systems, restrictions (functions that limit the range of movement of the machine) Disengaging transmission

Towing the machine to the workshop

For instructions on how to operate the machine in emergency mode, see next chapter.

copyright by

4 - 14

R 934 C Litronic / 11692682

Operating manual

Malfunctions Emergency operation

Danger!

In emergency mode, certain safety functions of the control system are disabled.

This can lead to accidents or damage to the machine.

Use emergency mode only for the intended purpose.

Inform all persons involved in the operation and maintenance of the machine that it is in emergency mode.

Immediately switch off the emergency mode when it is no longer required.

Have the machine repaired as quickly as possible.

4.4.2

Identifying solenoid valve For the emergency operation of functions, it is under certain circumstances necessary to interfere directly in the control of the machine and to switch solenoid valves manually.

The solenoid valves are numbered. The number (Y...) is found on the connecting cable of the solenoid valve and in the respective figure.

4.4.3

Emergency mode control In the event of a failure of the control electronics, certain machine components might not work properly.

Depending on the type and extent of the malfunction, it might be possible to reestablish proper operating conditions for the machine components: The emergency control feature includes three functions: – Emergency operation of diesel engine – Emergency speed adjustment – Emergency operation of control devices These functions may be combined with each other.

The control panel for emergency control is located in the rear section of the right control console.

Fig. 4-3

Control panel in the right control console

copyright by R 934 C Litronic / 11692682

4 - 15

Malfunctions

Operating manual

Emergency operation

Fig. 4-4

4.4.3.1

Control panel for emergency control

S71

Switch / emergency start / emergency operation of diesel engine

S72

Switch / speed adjustment

S73

Switch / emergency operation

H11

Indicator light / emergency operation

H60

Indicator light / diesel engine failure

Emergency operation of diesel engine In normal operating mode, the electronic devices of the diesel engine communicate with the control electronics of the machine. In the event of a malfunction or failure, it might not be possible to start the diesel engine or to control it properly. In such a case, the diesel engine must be started in emergency mode.

Press the switch S71 to the right.

Start the diesel engine with the ignition key.

The indicator light H11 is on.

The symbol n-min/MANU is shown at the display.

The diesel engine runs in emergency mode.

Switching back to normal operating mode is only possible after the diesel engine has been switched off and restarted again.

H

Note!

In emergency mode, communication between the diesel engine and the control electronics of the machine might be impaired. Error messages from the diesel engine might not be displayed. In addition, the following safety functions are disabled: – Automatic shut-down of the diesel engine in the event of insufficient engine oil pressure – Automatic shut-down of the diesel engine in the event of excessive coolant or intercooling air temperature Engine malfunctions are indicated as follows: – The indicator light H60 at the emergency control unit is on.

– Acoustic warning signal – Error code E 525

copyright by

4 - 16

R 934 C Litronic / 11692682

Operating manual

Malfunctions Emergency operation

If an engine failure is indicated in diesel engine emergency mode, or if the operating status is outside the permissible range (e.g. overheating), immediately shut down the diesel engine.

Do not operate the diesel engine in emergency mode for longer than is necessary in order to bring the machine to the repair workshop.

4.4.3.2

Emergency speed adjustment The emergency speed adjustment caters for the following failures: – Power selection (mode) with switch S86 – Speed adjustment by means of arrow buttons S228 and S229 If the diesel engine is in emergency mode, the engine speed can be adjusted by the switch S72. The operator can set the engine to an upper or a lower emergency speed.

Push the switch to left (tortoise icon): lower emergency speed Push the switch to right (hare icon): upper emergency speed Note!

If the diesel engine has been automatically switched to emergency mode, the current engine speed is maintained.

4.4.3.3

Emergency operation of control devices The emergency operation of the control devices caters for the failure of the following functions: – Servo control – Parking brake, slewing gear brake Danger!

In emergency mode, the servo control system, the parking brake and the slewing gear brake cannot be operated with the normal switches and buttons, but only with the safety lever.

In emergency mode, the machine might make unexpected movements when the safety lever is pushed down (instant release of slewing gear brake and parking brake). There is thus an increased risk of accidents!

Therefore, use emergency operation for control devices only when absolutely necessary.

Use the function only to complete the manoeuvres necessary to remove the machine from the danger zone.

Fig. 4-5

Emergency control screen

Move the safety lever up.

Press the switch S73 to the right.

Emergency control mode is now activated.

The emergency mode symbols are shown in the screen (see Fig. 4-5).

The servo control, the parking brake and the slewing gear brake can be operated with the safety lever.

copyright by R 934 C Litronic / 11692682

4 - 17

Malfunctions

Operating manual

Emergency operation

Move the safety lever down.

The parking brake and the slewing gear brake are released.

Servo control is activated.

4.4.4

Emergency operation of hydraulic pump In the event of a failure in the pump control, the performance of the hydraulic pumps is automatically reduced to a minimum.

For such a situation, the excavator is equipped with an emergency operation function for the hydraulic pump.

It overrides the control electronics so that the hydraulic pump can be operated at a reduced output rate.

Fig. 4-6

Control oil unit, hydraulic pump emergency operation

Switch off the diesel engine.

Disconnect the plug 1 from the proportional solenoid valve Y50.

Remove the cotter pin 2.

Move the lever 3 into a horizontal position (emergency position).

The hydraulic pump is switched to emergency operation.

Start the diesel engine.

4.4.5

Emergency operation of electric stick cylinder shut-down function Danger!

In emergency mode, the stick can be moved freely and without limits in all directions. Risk of accident!

When moving the stick cylinder in emergency mode, proceed with extreme caution.

copyright by

4 - 18

R 934 C Litronic / 11692682

Operating manual

Malfunctions Emergency operation

Fig. 4-7

Stick cylinder shut-down, solenoid valves

The solenoid valves of the electronic stick shut-down function are located at the rear of the control valve and can be operated manually (emergency operation).

Turn in the T-handles of the solenoid valves Y212 and Y233.

The electronic stick cylinder shut-down system is disabled.

The stick can be moved without restrictions.

4.4.6

Towing the machine Towing the machine is a dangerous manoeuvre, and the responsibility for any damage in connection with towing rests with the operator.

The machine may only be towed in exceptional situations, e.g. if the machine must be moved for safety reasons or if it must be repaired at the workshop.

Injuries to persons or damage to equipment caused by towing of the machine are not covered by the manufacturer's warranty.

Danger!

Incorrectly dimensioned towing rods or cables might break. Steel chains are generally prone to breaking during towing.

There is a serious risk of injury or damage to equipment.

Never use a chain for towing.

Tow the vehicle with a adequately dimensioned towing rod or cable.

Note!

When towing the machine, ensure that the brakes of the travel gear are released.

The diesel engine must be running in order to build up the necessary pressure.

If the diesel engine cannot be started or if there is a fault in the hydraulic system, the required pressure must be built up manually. For instructions, consult the LIEBHERR customer service department.

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4 - 19

Malfunctions

Operating manual

Emergency operation

Fig. 4-8

Towing the machine

Ensure that the towing rod or steel cable used for towing is of a sufficient tensile strength.

Attach the towing rod or steel cable to the eyelet on the undercarriage.

For machines that are not equipped with an eyelet (machines equipped with blade support): place the steel cable around the blade support.

Towing speed: max. 2 km/h

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5 Maintenance 5.1 Safety instructions 5.1.1

General safety instructions – Maintenance and repairs may only be carried out by trained expert technicians.

– Always note the frequency intervals for inspections as contained in this operating manual.

– Insure that an adequately equipped workshop is available to perform these tasks, and note the designated qualifications of the personnel responsible for each inspection.

– The maintenance and inspection schedule sets out precisely who should, or is allowed to carry out which jobs.

The machine operator (and his staff) are allowed to carry out certain jobs, but other jobs must be carried out only by qualified and trained staff.

– Spare parts must meet the technical requirements set forth by the manufacturer.

This is always ensured with original spare parts. Spare parts that do not meet the technical requirements of the manufacturer might impair the safety and proper operation of the machine.

– Wear task-appropriate personal protective equipment at all times. Example: In addition to a protective helmet and safety boots, for certain jobs protective goggles and gloves are also necessary.

– Keep unauthorized personnel away from the machine during maintenance.

– Secure a wide-ranging area for maintenance, as necessary.

– Inform the operator before starting to carry out special tasks and maintenance work. Make sure he knows the person who is in charge of the work.

– Perform all maintenance operations on the machine on a level and stable ground with the working equipment lowered and the diesel engine turned off, unless described otherwise in the operating manual.

– Hang a well visible warning label “do not switch on“ onto the ignition during maintenance operations, especially when working under the machine. Remove the ignition key and set the main battery switch to position 0.

– Re-torque all bolts at the completion of the maintenance procedure to the required torque specification.

– If the dismantling of safety equipment is necessary, the safety equipment must be re-attached and inspected directly upon conclusion of the operations.

5.1.2

Checking for cracks – Machines are subject to different loads, depending on application, job site, duration of use and conditions of use. The different load conditions result in different service lives for various machines components. This could lead to cracks and loose connections, particularly on load-bearing parts. This applies particularly to machines used in material handling or industrial applications or for machines with special equipment, such as demolition excavators. To ensure that operating safety is maintained, the machine must be checked regularly for cracks, loose connections or other visible damage.

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5-1

Maintenance

Operating manual

Safety instructions

– To check for cracks, it is necessary to keep the machine clean and to clean it regularly.

– The inspection must be carried out according to the inspection and maintenance schedule.

– It is advisable to carry out these inspections with the machine supported, on firm and level ground.

– Specific attention should be given to the following: • The steel structure undercarriage with axle and gear mounting, support, lower slewing ring seating with tower and slewing ring.

• The steel structure uppercarriage with bearing block for boom and boom cylinder, upper slewing ring seating, cab bearing, mounting of slewing gear and counterweight.

• Steel structure of working attachments, e. g. boom, stick, quick change adapter, digging tool and grapple.

• Hydraulic cylinder, axles, steering, pins and pin connections, steps, ladders and mounting elements.

– Check for cracks visually. If a crack is suspected or is in areas which are not easily visible, such as the slewing ring seating, then the dye penetration procedure should be used to check for cracks.

– Any damage found must be fixed immediately. Welding on load-bearing parts of earth moving machines, material handling and transport units may only be made by certified welders in accordance with acceptable welding practices. Contact LIEBHERR Service to discuss suitable measures.

5.1.3

Welding – Welding, cutting and grinding should only be done with the specific approval of LIEBHERR. Prior to any welding, cutting or grinding, clean the machine and surrounding area to remove dust and flammable materials.

– Insure adequate ventilation.

5.1.4

Fuels, lubricants and process chemicals – When handling oils, greases and other chemical substances, always observe the applicable safety regulations for the corresponding product.

– Ensure safe and environmentally friendly disposal of operating and service fluids as well as exchange parts.

– Handle hot operating and service fluids carefully (danger of burning and scalding).

5.1.5

Repair – Do not attempt to lift heavy parts. Use lifting devices with sufficient load carrying capacity. When replacing parts or large sub-assemblies, use appropriate and functioning lifting devices and adequate load carrying capacity to insure safe movement during installation. Never stand or work under suspended loads.

– Always wear work gloves when handling wire ropes.

– Only permit experienced personnel to secure loads and signal the crane operator.

The guide must position himself within view of the operator or be in voice contact with him.

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R 934 C Litronic / 11692682

Operating manual

Maintenance Safety instructions

– When working overhead, use appropriate safe access ladders and working platforms.

Do not use parts of the machine as climbing devices, if they are not designed for this purpose.

Wear a harness when working at great heights.

Keep handles, steps, railings, platforms, and ladders free of dirt, ice and snow.

– When working on the attachment (for example when replacing teeth), make sure the machine is properly supported. Never use metal-on-metal support.

– Never stand underneath a machine that has been raised with the aid of work equipment unless it has been properly and securely supported.

– Always support the machine in such a ways that any shifting weight will not endanger the stability of the machine and avoid metal to metal contact.

– Work on travel gears, brake and steering systems may only be carried out by specially trained expert personnel.

– If the machine must be repaired on an incline, block the track chains with chocks and secure the uppercarriage to the undercarriage with the locking pin.

– Only qualified, specially trained personnel may work on the hydraulic system.

– Do not check for hydraulic leaks with your hand. Use cardboard or similar material to detect leaks. Wear work gloves.

– Do not loosen any lines or bolts before lowering the equipment, turning off the diesel engine and relieving the hydraulic system. After the diesel engine has been turned off, you must move all pilot controls (right handed joystick and pedals) into all directions to reduce the control pressure and the dynamic pressure in the work cycles. Then release the pressure in the tank, as described in this operating manual.

5.1.6

Electrical system – Check the electrical system regularly.

All defects, such as loose connections, burnt out fuses and bulbs, burnt or damaged wires or cables must be repaired immediately by an electrician or specially trained personnel.

– Only use original fuses with the correct amperage.

– Only qualified technicians should attempt troubleshooting or repairs on high voltage systems.

– DO NOT work on energized attachments.

– When working on mid and high voltage components, shut off the voltage and connect the supply cable to the ground to discharge any stored energy.

– Check all disconnected parts if they are truly free of current, ground them and short circuit them. Insulate adjacent, current carrying parts.

– Disconnect the battery before working on the electrical system or before carrying out any arc welding work on the machine.

5.1.7

Pressure accumulator – Pressure accumulators contain stored energy and operate at high pressures.

Only specially trained personnel may work on pressure accumulators.

– Do not operate damaged pressure accumulators.

– You must reduce the pressure in the hydraulic system as described in this operating manual prior to working on a hydraulic accumulator.

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5-3

Maintenance

Operating manual

Safety instructions

– Do not weld or solder on the pressure accumulator and do not carry out any mechanical work on them.

– Fill the pressure accumulator only with nitrogen.

– The accumulator housing can become hot during operation, there is a danger of burning.

– New pressure accumulators must be charged to the required pressure for the application before use.

– The operating data (minimum and maximum pressure) is marked permanently on the pressure accumulators. Make sure that the marking remains visible.

5.1.8

Hydraulic hoses and lines – Hydraulic lines and hoses may never be repaired!

– All hoses, lines and fittings must be checked every two weeks for leaks and visible damage. Damaged parts must be replaced immediately. Remember that escaping high pressure oil can penetrate skin. Escaping oil can also cause fires.

– Even if hoses are properly stored and used, they undergo a natural aging process. For that reason, their service life is limited.

• Improper storage, mechanical damage and impermissible use are the most frequent causes of failure.

• Using hoses and lines close to the limit ranges of permitted use can shorten the service life (for example in high temperatures, frequent work cycles, extremely high impulse frequencies, multi shift operation).

– Hoses and lines must be replaced when the following conditions are found during inspection: • Damage to the outer layer as far as the intermediate layer (e.g. chafing, cuts and cracks); • Brittleness of the outer layer (hose material cracking); • Deformations, which differ from the natural shape of the hose or hose line, when under pressure or not under pressure, or in bends (e.g. separation of layers, blisters or bubbles); • Leaks; • Failure to follow installation instructions; • Damage or deformation of hose fittings, which reduce the strength of the fitting or the hose / fitting connection; • Hose slipping out of the fitting; • Corrosion on the fittings, which reduces function and strength; – When replacing hoses and lines, observe the following: • Use only original spare parts.

• Route and install hoses and lines properly, observe correct connection points.

• Always ensure that the hoses and lines are free of torsion when routing. On high pressure hoses, always attach the screws of half clamps or full flange on both ends of hose first and then tighten.

• When using high pressure hoses and lines with a bent fitting, always tighten the end with the bent fitting first when tightening the flanges, then the end with the straight fitting.

• Any existing mounting clamps in the centre of the hose may only be installed and tightened thereafter.

• Check daily to ensure that all clamps, covers and protective devices are properly mounted. This prevents vibration and damage during operation.

• Route the hoses and lines in such a way that chafing with other hoses or other structures is prevented.

• A minimum distance of approximately ½ of the outer hose diameter to the other parts is recommended. The distance should not be less than 10 to 15 mm (1/2 inch).

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Operating manual

Maintenance Maintenance access doors

• When replacing hoses and lines on movable parts (e.g. from boom to stick), check for hose interference and kinking over the complete range of motion.

5.1.9

Cab protection (FOPS) For certain machine applications LIEBHERR offers optional cab protection systems of various designs. These systems consist of a full length FOPS (falling objects protective structure) or a top guard and front guard to protect the operator's cab and windscreen area from falling objects (for example rocks or debris).

The full length FOPS wraps around the operator's cab, is mounted to the uppercarriage and is a stand-alone system.

The top and front guards are either bolted individually or in combination to the cab structure. In that case the operator's cab is also part of the cab protection system and is subject to the following instructions.

– Never operate a machine if one of these protections is damaged in any way.

– Damages may occur due to: • structural modifications or repairs (for example welding, cutting or drilling) • deformation after an accident • falling objects – Structural modifications or repairs of any kind are prohibited without the expressed, written approval of LIEBHERR.

5.2 Maintenance access doors 5.2.1

Overview of access doors

Fig. 5-1

Access doors on the machine

The machine has 5 access doors for maintenance. Some of the doors are secured by means of lockable handles or fittings. The locks integrated in the handles must be unlocked before commencing work.

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5-5

Maintenance

Operating manual

Maintenance access doors

Caution!

Access doors can close accidentally and trap the machine operator or maintenance personnel.

When you have opened the access doors, lock them using the retainer.

No.

Access doors

1

Centre hood

Access to: – Diesel engine – Radiator

2

Right hood

– Diesel engine – Control oil unit

3

Side door, left

– Radiator – Electric cabinet E50 – Batteries

4

Side door, front left

– Toolbox – Stowing compartment – Battery main switch

5

Side door, right

– Dry air filter – Control oil unit – Hydraulic pump

Tab. 5-1

5.2.2

Access doors

Door locking mechanism

Fig. 5-2

Door locking mechanism

To prevent the access doors from moving unintentionally (e.g. due to wind), open them fully and allow the door locking mechanism (see arrow) to latch.

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Operating manual

Maintenance Cleaning machine

5.2.3

Engine hood locking mechanism

Fig. 5-3

Engine hood locking mechanism

Release lock 1, open and push back the engine hood.

Secure the engine hood using mechanical retainer 2.

Caution!

The engine hood is by means of two gas pressure springs. These hold the engine hood open. The holding force of older gas pressure springs may diminish and could cause the engine hood to be lowered in an uncontrolled fashion.

Always additionally secure the engine hood using mechanical retainer 2.

5.3 Cleaning machine The machine should be cleaned before carrying out any maintenance or repair work.

In particular, the connections and screws should be cleaned of oil, fuel and residue of cleaning agents.

Note!

High-pressure water jet cleaners (steam cleaners) can damage the coating.

Do not use high-pressure water jet cleaners during the first two months after commissioning (or after recoating).

Observe the prescribed safety distances.

Before cleaning the machine: Before cleaning the machine with water or with a steam cleaner (high-pressure water jet cleaner), carry out the following tasks to protect the equipment against penetrating water.

Lubricate all bearing points, bolt connections and the slewing ring; if necessary, use the central lubrication system to do this.

Cover or seal all openings that must be protected against penetrating water for safety reasons (particularly at risk of damage are electric motors, electric components, switch cabinets, plug connections, measuring sensors and air filters).

copyright by R 934 C Litronic / 11692682

5-7

Maintenance

Operating manual

Care for rubber components

Cleaning: Use flint-free cleaning cloths.

Do not use aggressive detergents or flammable liquids.

When cleaning the engine compartment, ensure that the temperature sensor of the fire alarm and extinguishing systems (if installed) are not accidentally brought into contact with the hot cleaning solution, After cleaning: Remove all seals and covers.

Check all fuel, engine oil and hydraulic lines for leakage, loose connections, chaffing and damage.

Repair any defects without delay.

Lubricate all bearing points, pin connections and the slewing ring to remove any water that might have been penetrated.

If required, renew the preservation layer (anti-corrosion protection) on components and surfaces.

5.4 Care for rubber components The service life of rubber seals can be prolonged by treating them with a rubber care product.

Clean and regularly treat the rubber seals on doors and panelling elements with a care product. This helps prevent premature wear and protects the rubber seals during the cold season.

Recommended care products: Silicone, talcum powder, deer tallow

5.5 Fuels, lubricants and process chemicals 5.5.1

General information Observe the instructions for lubricants and process chemicals. Lubricate the machine and change the oils at the prescribed intervals. For more information, see lubrication chart and inspection and maintenance schedule.

Keep workplaces for these activities clean. This enhances the service life and reliability of the machine.

All work on the machine must be carried out while it is standing on firm and level ground.

Switch off the diesel engine, remove the ignition key and set the battery main switch to position 0 (OFF).

Clean lubricating nipples before adding grease.

Clean all filling points and the area around them before opening the caps and screws.

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Operating manual

Maintenance Fuels, lubricants and process chemicals

The oil should be changed while it is at operating temperature.

After each oil change or refilling, check the fill level in the respective unit (the specified fill levels are guide values).

Collect old oil and chemicals in suitable containers and dispose of them according to the applicable statutory regulations.

5.5.2 5.5.2.1

Filling volumes, lubrication chart Recommended lubricants

Designation

Recommended product

Symbol

Diesel engine

Liebherr Motoroil 10W-40 Liebherr Motoroil 10W-40 low ash Liebherr Motoroil 5W-30

29.0

Hydraulic system: Oil change volume

Liebherr Hydraulic Basic 68 Liebherr Hydraulic Basic 100 Liebherr Hydraulic HVI Liebherr Hydraulic Plus Liebherr Hydraulic Plus Arctic

384

Slewing gear mechanism

Liebherr Gear Basic 90 LS

8.6

Travel gear mechanism

Liebherr Gear Basic 90 LS

2x4.5

Pump distributor gear

Liebherr Gear Basic 90 LS

5.6

Central lubrication system, lubrication points on machine and tool attachments

Liebherr Universalfett 9900

-

Hinges, joints, locks

Engine oil

-

Volume [litre]*

-

* = guide values

5.5.2.2

Recommended fuels and process chemicals

Designation

Recommended product

Symbol

Volume (litre)*

Fuel tank

Conventional diesel fuel

580

Coolant

Liebherr Antifreeze Mix Liebherr Antifreeze Concentrate

40.0

Liebherr Antifreeze OS Mix Liebherr Antifreeze OS Concentrate Windscreen washer system

Conventional windscreen cleaning agent or denatured alcohol

-

3.0

* = guide values

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5-9

Maintenance

Operating manual

Fuels, lubricants and process chemicals

5.5.2.3

Lubrication chart

Fig. 5-4

Lubrication chart for type 1440

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Operating manual

Maintenance Specifications for fuels, lubricants and process chemicals

Symbol

Description Diesel engine, check oil level Gearbox or axle, check oil level Hydraulic tank, check oil level Carry out first oil change Change oil Lubricate machine Lube point Medium filling point Observe operating manual

Tab. 5-2

Key to lubrication chart

5.6 Specifications for fuels, lubricants and process chemicals 5.6.1

Diesel fuels

5.6.1.1

Specification The diesel fuels must meet the minimum requirements of the fuel specifications outlined below.

Approved specifications: – DIN EN 590 – ASTM D 975 (89a) - 1D and 2D The fuel supplier must submit a fuel certificate (fuel specification, sulphur content, lubricity, cetane number)

5.6.1.2

Sulphur content, lubricity The following restrictions apply: – Do not use fuels with a sulphur content of more than 1 % (10,000 mg/kg).

– When using engine oils conforming to specification E6 and standard oil change intervals (every 500 operating hours): Do not use fuels with a sulphur content of more than 0.005 % (50 mg/kg).

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Maintenance

Operating manual

Specifications for fuels, lubricants and process chemicals

– When using exhaust gas purification units (particle filters): Do not use fuels with a sulphur content of more than 0.005 % (50 mg/kg).

– Diesel engines with external exhaust gas return system: We recommend using fuels with a sulphur content of less than 0.005 % (50 mg/kg).

Additional information: see oil change intervals for operation under adverse conditions.

According to DIN EN 590, diesel fuels must have a lubricity determined by HFRR test (corrected wear scar diameter [wsd 1.4] at 60 °C) of maximum 460 µm The ASTM D 975 fuel standard does not specify that the fuels must undergo a fuel lubricity test. The required additives should be added by the supplier, who is responsible for the quality of the fuel.

5.6.1.3

Cetane number ASTM D 975 fuels must have a cetane number of minimum 45. A cetane number of more than 50 is preferable, especially at temperatures below 0 °C (32 °F).

5.6.1.4

Low temperature operation At low temperatures, paraffin crystals are formed in the diesel fuel. They increase the flow stress in the fuel filter so that the diesel engine might not be supplied with sufficient fuel.

Caution!

The use of an unsuitable fuel can cause damage to the diesel engine. Adding petroleum, normal car petrol or other substances damages the injection system.

Never add petroleum, car petrol or other additives to the diesel fuel.

At ambient temperatures of below -20 °C: use start-up aid (e.g. fuel filter heater).

For operation of the machine under arctic conditions: use special diesel fuels that offer adequate viscosity.

5.6.2 5.6.2.1

Lubricating oil for the diesel engine Quality Modern diesel engines must be lubricated with high-performance oils. They consist of a basic oil with special additives.

The lubricating oil requirements for LIEBHERR diesel engines are based on the following standards and regulations:

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Operating manual

Maintenance Specifications for fuels, lubricants and process chemicals

Designation

Specification

ACEA classification (Association des Constructeurs Européens d'Automobiles)

E4, E6, E7

API classification (American Petroleum Institute)

CH-4, CI-4

Caution: particle filter only permitted with E6

Caution: observe shorter oil change intervals Tab. 5-3

Lubricating oil specifications

If LIEBHERR oils are not available locally, use an oil that conforms to the specifications (before choosing an oil, contact our customer service department).

5.6.2.2

Viscosity The choice of the lubricating oil viscosity is based on the SAE classification (Society of Automotive Engineers). The SAE classification does not provide any indication as regards the quality of a lubricating oil. The relevant factor for the correct choice of SAE class is the ambient temperature.

Excessively high viscosity might lead to start-up problems. If the viscosity is too low, the oil's lubrication might not be sufficiently efficient.

The temperature ranges shown in the diagram are approximate ranges that might temporarily be exceeded.

Fig. 5-5

Temperature-based selection of the SAE class

For ambient temperatures of -20 °C (-4 °F) to +45 °C (+113 °F), we recommend the following diesel engine oils: Liebherr Motoroil 10W-40, specification ACEA E4 Liebherr Motoroil 10W-40 low ash, specification ACEA E6 For ambient temperatures of -30 °C (-22 °F) to +30 °C (+86 °F), we recommend the following diesel engine oils: Liebherr Motoroil 10W-30, specification ACEA E4

5.6.2.3

Adverse operating conditions affecting the oil change intervals Oil change intervals: see chapter "Inspection and maintenance schedule".

Subsequent oil changes depend on the climate, the sulphur content of the fuel and the oil grade. For details, see the table below.

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Maintenance

Operating manual

Specifications for fuels, lubricants and process chemicals

If the specified operating hours (h) per year are not reached, the diesel engine oil and the filter must be changed at least once every year.

A number of adverse factors (unfavourable operating conditions) affect the length of the maintenance interval.

Possible adverse factors: – Frequent cold starts – Sulphur content of fuel – Operating temperature If such factors apply, the oil and filter must be changed according to the table below.

Adverse factor

Oil quality CH-4, CI-4

Operating conditions

Sulphur content of fuel

Normal climate, to -10 °C

below -10 °C

E4 / E7*

Interval

to 0.5 %

250 h

500 h

between 0.5 % and 1 %

125 h

250 h

to 0.5 %

125 h

250 h

between 0.5 % and 1 %

not permissible

125 h

Adverse factor

Oil quality E6

Operating conditions

Sulphur content of fuel

Normal climate, to -10 °C

below -10 °C

Interval

to 0.005 %

500 h

between 0.005 % and 0.05 %

250 h

between 0.0501 % and 0.1 %

125 h

to 0.005 %

250 h

between 0.005 % and 0.05 %

125 h

between 0.0501 % and 0.1 %

not permissible

h= operating hours * TBN minimum 13 mg KOH/g

5.6.3

Coolants for diesel engine

5.6.3.1

General recommendations The cooling system works only properly when pressurised. It is therefore imperative that it is kept clean and sealed at all times, that the radiator sealing and operating valves work properly and that the required coolant level is maintained.

Corrosion inhibitors/antifreeze agents approved by LIEBHERR ensure proper protection against frost, corrosion and cavitation without causing damage to seals and hoses and without foaming.

Coolants that contain unsuitable corrosion inhibitors or antifreeze agents or that have been prepared incorrectly might cause failure of assemblies and component parts in the coolant circuit due to cavitation or corrosion. Heat-insulating deposits on components that conduct heat might result in overheating and consequently failure of the engine.

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Operating manual

Maintenance Specifications for fuels, lubricants and process chemicals

5.6.3.2

Water (fresh water) Clear and clean water free of particles that meets the following chemical requirements is suitable for use as a coolant.

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

Designation

Value / unit

Total alkaline earth metals (water hardness)

0.6 to 3.6 mmol/l (3 to 20 °dH)

pH at 20 °C

6.5 to 8.5

Chloride ion concentration

max. 80 mg/l

Sulphate ion concentration

max. 100 mg/l

Tab. 5-4

Fresh water quality

Designation

Value / unit

Total alkaline earth metals (water hardness)

0.6 to 2.7 mmol/l (3 to 15 °dH)

pH at 20 °C

6.5 to 8.0

Chloride ion concentration

max. 80 mg/l

Sulphate ion concentration

max. 80 mg/l

Tab. 5-5

Fresh water quality with use of DCA 4*

* = Diesel Coolant Additives

Water analysis results are available from the local authorities.

5.6.3.3

Mixing ratio for coolant The coolant must contain min. 50% corrosion inhibitor and antifreeze agent at all times of the year.

Mixing ratio Outdoor temperature to Water %

Corrosion inhibitor/antifreeze agent %

-37 °C

50 %

50 %

-50 °C

40 %

60 %

Tab. 5-6

Permissible mixing ratio (for all seasons)

Fig. 5-6

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

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Maintenance

Operating manual

Specifications for fuels, lubricants and process chemicals

A Ambient temperature B Corrosion inhibitor/antifreeze agent concentration in coolant

5.6.3.4

Permissible corrosion inhibitors/antifreeze agent Note!

Improper mixing of different products might negatively affect the properties of the coolant and cause damage to the cooling system.

Use only approved products. Do not mix different products.

Never mix products containing silicone with silicone-free products.

If the recommended LIEBHERR product is not available locally: Contact the LIEBHERR customer service department; choose product conforming to the "Coolant specifications for LIEBHERR diesel engines".

Concentrate Product name

Manufacturer

Liebherr Antifreeze Concentrate

Liebherr

Liebherr Antifreeze OS Concentrate

Liebherr

Ready-mixed corrosion inhibitor/antifreeze agent (premix) Product name

Manufacturer

Liebherr Antifreeze Mix

Liebherr

Liebherr Antifreeze OS Mix

Liebherr

Premix = ready-mixed product (50 % water and 50 % corrosion inhibitor/antifreeze agent)

5.6.3.5

Approved corrosion inhibitors without antifreeze agent Note!

Improper mixing of different products might negatively affect the properties of the coolant and cause damage to the cooling system.

Use only approved products. Do not mix different products.

Never mix products containing silicone with silicone-free products.

If the recommended LIEBHERR product is not available locally: Contact the LIEBHERR customer service department; choose product conforming to the "Coolant specifications for LIEBHERR diesel engines".

In exceptional circumstances and at ambient temperatures that are always above the freezing point, e.g. during use in tropical regions where there are no corrosion inhibitors/antifreeze agents available, the following inhibitors must be added to the coolant: – DCA 4 (Diesel Coolant Additives 4) – Caltex / Chevron / Havoline / Total product In this case, the coolant must be changed annually.

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Operating manual

Maintenance Specifications for fuels, lubricants and process chemicals

As part of routine maintenance work, check the concentration and correct it, if necessary.

Product name

5.6.4

Manufacturer

DCA 4 Diesel Coolant Additives

Fleetguard / Cummins Filtration

Caltex CL Corrosion Inhibitor Concentrate

Chevron Texaco

Chevron Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free (ELC)

Chevron Texaco

Havoline Extended Life Corrosion Inhibitor (XLI)

Chevron Texaco

Total WT Supra

Total, Paris

Hydraulic oil Hydraulic oils must meet the requirements outlined below.

Maximum water content of hydraulic oil: < 0.1 %

5.6.4.1

LIEBHERR hydraulic oil LIEBHERR recommends using the following hydraulic oils in its machines (depending on temperature range):

Fig. 5-7

Liebherr hydraulic oil, viscosity grade selection based on temperature

A Ambient temperature B Cold-start range with mandatory warm-up C Operating range Liebherr Hydraulic Plus and Liebherr Hydraulic Plus Arctic are suitable for both long-term use and use in environmentally sensitive areas.

If LIEBHERR oils are not available locally, use one of the engine oils listed in section "Engine oils for use as hydraulic oils" (before choosing an oil, contact the respective customer service department).

Use only LIEBHERR hydraulic oils. The use of other oils is not permitted.

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Maintenance

Operating manual

Specifications for fuels, lubricants and process chemicals

5.6.4.2

Engine oils for use as hydraulic oils When using engine oils (third-party products) as hydraulic oils, we advise customers to request a certificate from the oil manufacturer, confirming that the product meets the following specifications.

Engine oils that are to be used as hydraulic oils must meet the following specifications: Single grade engine oils (1):

API - CD / ACEA - E1 (MB 226.0 and 227.0)

Multigrade oils (2):

API - CD, CE, CF / ACEA - E2, E3, E4 (MB 227.5, 228.1, 228.3 and 228.5)

Tab. 5-7

Classification of products, engine oils for use as hydraulic oils

Fig. 5-8

Engine oil for use as hydraulic oil, viscosity grade selection based on temperature*

A Ambient temperature

1

Single grade engine oils

B Cold-start range with mandatory warm-up

2

Multigrade oils

C Operating range *

5.6.4.3

For oils with deviating viscosity grade, consult LIEBHERR customer service.

Warm-up instruction The black bar B indicates ambient temperatures that are up to 20 °C below the operating range C. For cold starting at an ambient temperature below range B, the following warm-up instruction for the hydraulic oil applies: 1. Start the diesel engine and set it to medium speed (not exceeding 50% of maximum speed).

2. Carefully actuate the working hydraulics. Operate the hydraulic cylinders and move them briefly to the stop.

3. After approx. 5 minutes, actuate the travel hydraulics. Total warm-up time: approx. 10 minutes.

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Operating manual

Maintenance Specifications for fuels, lubricants and process chemicals

For cold starting at lower ambient temperatures, follow the warm-up instruction below: Before starting the engine, warm up the hydraulic oil tank. Then proceed according to the warm-up instruction in 1.

5.6.4.4

Biodegradable hydraulic oils Caution!

Do not mix hydraulic oil products!

When mixing different ester-based biodegradable hydraulic oils or mixing such products with mineral oils, aggressive chemical reactions might occur, causing damage to the hydraulic system.

Therefore never mix biodegradable hydraulic oils from different producers, and never mix bio hydraulic oils with mineral oils!

LIEBHERR recommends using the following hydraulic oils in its machines (depending on the temperature range): Liebherr Hydraulic Plus or Liebherr Hydraulic Plus Arctic These products are polyalphaolefins (HEPR) conforming to CEC-L-33-A-93, and are biodegradable.

When using these hydraulic oils, bypass filtration might be omitted.

If these oils are not available locally, use a fully saturated hydraulic environmental ester synthetic oil (HEES fluid) (before choosing an oil, contact the respective customer service department).

Caution!

The use of synthetic ester-based oils without bypass filter causes damage to the hydraulic system!

If synthetic ester-based oils are to be used, bypass filtration is mandatory, as the water content in the oil must be kept below 1000 ppm (0.1%).

Always use a bypass filter (optional equipment).

For synthetic ester-based oils, we recommend replacing the hydraulic hoses every 4000 operating hours or at least every 4 years.

Do not use vegetable oils, as they do not possess the necessary thermal stability.

The use of polyglycols is not permissible, as they cause damage to paintwork.

When using third-party products, we advise customers to request a certificate from the oil manufacturer, confirming that the product meets the above specifications.

5.6.4.5

Oil change, oil analysis and filter change Oil change Note!

LIEBHERR recommends having the oil regularly checked by analysis (see chapter , "Oil analyses" on page 20).

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Maintenance

Operating manual

Specifications for fuels, lubricants and process chemicals

Oil change Not for use in environmentally sensitive areas without oil analysis

with oil analysis* (optional)

For use in environmentally sensitive areas (only permissible with oil analysis*)

LIEBHERR mineral oil Liebherr Hydraulic HVI Liebherr Hydraulic Basic 68 Liebherr Hydraulic Basic 100

every 3000 h

every 6000 h

- ***

Liebherr-PAO** Liebherr Hydraulic Plus Liebherr Hydraulic Plus Arctic

every 4000 h

every 8000 h

every 8000 h

Third-party product - mineral oil

every 2000 h

every 2000 h

- ***

Third-party product - fully saturated synthetic ester

- ***

- ***

every 2000 h

Oil type

Tab. 5-8

Oil change intervals

*

If the result of the oil analysis is satisfactory, you may continue using the oil for a longer period.

If the result of the oil analysis is negative, immediately change the oil. ** PAO = polyalphaolefin *** not allowed

Use in environmentally sensitive areas: Machines operated in such areas must be filled with biodegradable hydraulic oil.

If the machine is operated for less than 1000 hours per year, an oil sample must be taken at least once a year. If a hydraulic oil is used for a prolonged period of time, it must be changed at least every 4 years (mineral oils and fully saturated synthetic esters) or every 6 years (Liebherr-Plus oils).

If the machine is not in use for a period of more than 6 months, carry out an oil analysis before restarting it.

Oil analyses For regular oil analyses, LIEBHERR recommends contracting the specialist company OELCHECK and changing the oil when indicated by the test results in the lab report.

– Yellow kit for biodegradable hydraulic oils – Green kit for mineral oils See also customer service and product information.

Reasons for regular oil analyses: – Reduction of costs thanks to prolonged oil change intervals – Detailed information regarding the hydraulic system, its components and the medium – Better protection of resources and the environment

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Operating manual

Maintenance Specifications for fuels, lubricants and process chemicals

Oil sampling / operating conditions Oil sampling in machines operated under normal operating conditions

Oil sampling in machines operated under extremely dusty conditions

The oil sampling interval is determined by the actual operating conditions (for more information, see chapter "Dust-intensive applications, reduction of oil contamination").

Tab. 5-9

Symbols: Oil sampling depending on operating conditions

Oil sampling Not for use in environmentally sensitive areas (oil analysis optional)

For use in environmentally sensitive areas (oil analysis mandatory)

LIEBHERR mineral oil Liebherr Hydraulic HVI Liebherr Hydraulic Basic 68 Liebherr Hydraulic Basic 100

every 1000 h

every 250 h

- **

- **

Liebherr-PAO* Liebherr Hydraulic Plus Liebherr Hydraulic Plus Arctic

every 1000 h

every 250 h

first at 0 h, then every 1000 h

first at 0 h, then every 250 h

Third-party product - mineral oil

first at 1000 h, then every 500 h

every 250 h

- **

- **

Third-party product - fully saturated synthetic ester

- **

- **

first at 0 h, then every 500 h

first at 0 h, then every 250 h

Oil type

Tab. 5-10 Oil sampling depending on operating conditions * PAO = polyalphaolefin ** not allowed

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Maintenance

Operating manual

Specifications for fuels, lubricants and process chemicals

Filter change Filter change / operating conditions Filter change in machines operated under normal operating conditions

Filter change in machines operated under extremely dusty conditions

The filter change interval is determined by the actual operating conditions (for more information, see chapter "Dust-intensive applications, reduction of oil contamination").

Tab. 5-11 Symbols: Filter change depending on operating conditions

Change of return filter (use only LIEBHERR filters)

every 1000 h

every 500 h

Tab. 5-12 Filter change depending on operating conditions

Change of bypass oil filter LIEBHERR filter

Filters from other manufacturers

every 2000 h or as indicated

every 500 h

every 250 h

Tab. 5-13 Filter change depending on operating conditions

5.6.4.6

Dust-intensive applications, reduction of oil contamination If the machine is normally operated with a hydraulic hammer or under similar conditions (considerable dust generation), the hydraulic oil might become more contaminated than under normal working conditions.

To prevent premature wear of the hydraulic components, the oil change and sampling intervals must be shortened.

Observe the following: – The filter cartridge(s) in the return filter must be replaced every 500 operating hours and after every hydraulic oil change.

– Use 10-µm filter cartridges instead of the standard 20 / 5-µm cartridges.

– The 2-µm breather filter must be replaced every 500 operating hours and at every hydraulic oil change.

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Operating manual

Maintenance Specifications for fuels, lubricants and process chemicals

Machines delivered with hydraulic hammer attachment and retrofitted hydraulic hammer kits are already fitted with 10-µm filter cartridges in the return filter. Please take this into account when ordering spare parts.

5.6.5 5.6.5.1

Lubricants for axles and gearboxes Quality Recommended lubricant

Specification

Liebherr Gear Basic 90 LS

API: GL-5 MIL-L: 2105 D ZF: TE-ML 05C, 12C, 16E, 21C

Liebherr Gear Plus 20W-40

API: Niveau von GL4 ZF: TE-ML 05F, 06K, 17E

Liebherr Gear Hypoid 90 EP

API: GL 5 MIL-L: 2105 B, C, D ZF: TE-ML 05A, 12A, 16C, 17B, 19B

Liebherr Hypoid 85W-140 EP

API: GL-5 MIL-L: 2105 D, PRF-2105 E ZF: TE-ML 05A, 07A, 16D, 21A

Liebherr Hydraulic-Gear ATF

GM: Dexron II D ZF: TE-ML 03D, 04D, 11A, 14A, 17C

Liebherr Syntogear Plus 75W-90

API: GL-4, GL-5, MT-1 MIL-L: 2105 D, PRF-2105 E ZF: TE-ML 02B, 05B, 07A, 12B, 16F, 17B, 19C, 21B

Tab. 5-14 Lubricating oil specifications If LIEBHERR oils are not available locally, use an oil that conforms to the specifications (before choosing an oil, contact our customer service department).

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Maintenance

Operating manual

Specifications for fuels, lubricants and process chemicals

5.6.5.2

Viscosity

Fig. 5-9

Temperature-based selection of the SAE class

A Ambient temperature 1 Use in gearboxes 2 3

Use in automatic transmissions Use in axles

4

Use in pump distributor gear systems

*

If the pump distributor gear is equipped with an oil cooler, the oil is not suitable for the marked temperature range (shaded area).

The choice of the lubricating oil viscosity is based on the SAE classification (Society of Automotive Engineers). The SAE classification does not provide any indication as regards the quality of a lubricating oil. The relevant factor for the correct choice of SAE class is the ambient temperature. Incorrect viscosity can impair the operation of axles and gearboxes.

The temperature ranges shown in the diagram are approximate ranges that might temporarily be exceeded.

5.6.6

Lubricating oil for transmission Recommended lubricant

Specification

Liebherr Motoroil 10W-40

API: CF

If LIEBHERR oils are not available locally, use an oil that conforms to the specifications (before choosing an oil, contact our customer service department).

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Operating manual

Maintenance Specifications for fuels, lubricants and process chemicals

5.6.7

Grease

5.6.7.1

Quality Recommended lubricant

Specification

Liebherr Universalfett 9900

Soap-base grease (lithium complex) KPF 2 N - 25 (DIN 51502) NLGI grade: 2 (DIN 51818) VKA welding force: > 6000 N (DIN 51350 / 4)

- Liebherr Universalfett Arctic (for lowtemperature operation)

Soap-base grease (lithium complex) KPFHC 1 N - 60 (DIN 51502) NLGI grade: 1 (DIN 51818) VKA welding force: > 5500 N (DIN 51350 / 4)

The grease is used for both automatic and manual machine lubrication. it is supplied by the central lubrication system or through lubrication nipples to the respective lube points.

Examples: – Slewing ring bearings – Crown gears, geared wheels – Bolts, axles and screws – Attachments

5.6.7.2

Operating temperature

Fig. 5-10

Operating temperature for Liebherr greases

A Grease temperature *

The grease is not suitable for the temperature range (shaded), if used in a central lubrication system.

** The grease may only be within the temperature range (shaded) for short periods of time. Peak temperatures of max. 200 °C (392 °F) are possible.

5.6.8

Lubricants and care products for electrical and mechanical components Medium, purpose

Product (manufacturer)

Contact spray for slip rings

Cramolin

Lubricant for pistons, piston nuts and for the mounting of piston rod bearings at hydraulic cylinders

Gleitmo 800

Special corrosion inhibitor for mounting recesses of sealing elements at hydraulic cylinders

Rostilo Tarp CFX

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Maintenance

Operating manual

Diesel engine

5.7 Diesel engine 5.7.1

Checking the oil level in the diesel engine Danger!

Risk of burning.

The engine oil is hot when it near its operating temperature.

Do not allow hot oil or oil-bearing parts to come into contact with the skin.

The machine must be standing level.

Shout down the engine.

Wait until the oil has collected in the oil pan.

Fig. 5-11

Oil level markings on the dipstick

Withdraw the dipstick and wipe with a clean lint-free cloth.

Fully insert the dipstick.

Withdraw the dipstick again and check the oil level.

The oil level must lie between the MIN and MAX marks.

5.7.2

Changing the diesel engine oil Note!

Only carry out the oil change when the engine is warm.

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Operating manual

Maintenance Diesel engine

Fig. 5-12

Drain valve on the oil pan, oil filter cartridges, oil filling nozzle

Drain the oil (A): Unscrew the cover cap on the oil pan drain valve.

Screw the supplied oil drain hose 1 onto the oil pan drain valve.

Collect the oil in a suitable container.

Unscrew the oil drainage hose and screw the cover cap onto the drain valve.

To change the oil filter cartridges (B): Danger!

Risk of burning.

Avoid skin contact with the hot oil when unscrewing the oil filter cartridges.

Note!

Protect the ribbed V-belt against any oil that leaks out when changing the filter cartridge!

Loosen the oil filter cartridge using a strap spanner and unscrew the filter.

Clean the sealing surface on the filter bracket.

Oil the rubber sealing ring on the new oil filter cartridges.

Screw on the new filter elements until the sealing ring fits against the filter head.

Use the oil filter key to tighten the oil filter cartridges 1/2 to 3/4 turn by hand.

Fill with oil (C): Add the oil through oil filler nozzle until the level reaches the upper marking on the dipstick.

Close off the oil filling nozzle.

Start the engine and check the oil pressure.

Shout down the engine after 2-3 minutes.

Check the oil level and add more oil if necessary.

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Maintenance

Operating manual

Diesel engine

5.7.3

Ribbed V-belt for A/C compressor and alternator installation The diesel engine is fitted with a tensioning device for the ribbed V-belt. This is selftensioning and therefore maintenance-free. The ribbed V-belt should be regularly checked for wear and replaced if necessary.

Fig. 5-13

Replacing the ribbed V-belt

To replace the ribbed V-belt: To replace the ribbed V-belt, you will need a ratchet compliant with DIN 3122 D12.5 (1/2").

Reset the tensioning device in a counter-clockwise direction against the spring force as far as the stop.

Remove the ribbed V-belt.

Place the new ribbed V-belt on the belt pulleys for the crankshaft, a/c compressor, alternator and deflection pulley with the tensioning device reset.

Move the tensioning device in a clockwise direction back to the tensioned position.

Note!

When replacing the ribbed V-belt, check the tensioning pulley and deflection pulley for ease of movement. Immediately replace defective tensioning pulleys and deflection pulleys.

5.7.4

Crankcase bleeding point

Fig. 5-14

Replace the filter element

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Operating manual

Maintenance Diesel engine

Replace the filter insert: Carefully clean the crankcase bleeding point and surrounding area.

Unscrew and remove the cover cap; if necessary, use a screwdriver.

Withdraw the filter cartridge insert and dispose of it in an environmentally acceptable manner.

Fit the new filter cartridge insert and push it to the stop position.

Fit the cover cap and turn it by hand until you reach the stop position.

5.7.5

Grease the starter tooth ring The maintenance cover is located behind the flywheel housing on the right side of the engine.

Fig. 5-15

Grease the starter tooth ring

1 2

Maintenance cover Starter tooth ring

3

Sensor tooth ring

4 5

Turning device Pinion

Note!

When greasing, ensure that sensor tooth ring 3 is kept free of grease.

Unscrew maintenance cover 1.

Fit turning device 4 to the flywheel housing.

Turn the flywheel with turning device 4 and use pinion 5 on the turning device to transfer grease onto starter tooth ring 2.

Remove turning device 4.

Screw on maintenance cover 1.

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Maintenance

Operating manual

Cooling system

5.8 Cooling system 5.8.1

Checking and cleaning the cooling system

Fig. 5-16

Cooling system

The machine has a combined water-charge air-fuel-hydraulic oil cooler.

Optimal cooling can only be achieved when the cooler is kept clean.

Check the engine, fan and cooler for damage and clean if necessary.

If required, clean the cooling fins with compressed air or a steam jet (from inside out).

In case of leaks, change the pressure relief valve (sealing cap of expansion tank).

Regularly check the condition and seals on the connecting hoses between the coolant cooler and engine as well as on the coolant hoses.

5.8.2

Checking the coolant level Danger!

Risk of burning due to hot coolant.

The engine cooling system is hot and pressurized when running at operating temperature.

Avoid touching coolant or coolant-bearing parts.

Only check the coolant level when the sealing cap on the filler neck has cooled sufficiently.

Open the sealing cap a half turn.

Relieve any pressure that may be present in this position. After the pressure has equalised, slowly turn it fully open.

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Operating manual

Maintenance Cooling system

Fig. 5-17

Checking the expansion tank, coolant level

The coolant level when cold must reach the lower end of the immersion tube under the filler neck.

Add more coolant if necessary.

Close the sealing cap.

After adding coolant, allow the engine to run for a short time with the heating switched on and check the coolant level once again.

5.8.3

Changing the coolant Danger!

Risk of burning due to hot coolant.

Only change the coolant when the engine is cold.

Fig. 5-18

Cooling circuit shutoff valves

The following points should be noted when changing the coolant: – Change the coolant in the entire coolant circuit at least every two years.

– The coolant should preferably be changed with the cooling circuit shutoff valves closed.

– Bleed the cooling circuit after it is refilled.

– Coolant can only flow through the cooling circuit when the ignition key is in the contact position.

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Maintenance

Operating manual

Cooling system

5.8.3.1

Draining the coolant

Fig. 5-19

Draining the coolant

To drain the coolant at the cooler: Unscrew the protective cap of drain valve 1 on the coolant radiator.

Screw the supplied drain hose to the drain valve.

Allow the coolant to drain into a suitable container.

To drain the coolant at the diesel engine: Unscrew the protective cap on drain valve 2 on the engine oil cooler plate.

Screw the supplied drain hose to the drain valve.

Allow the coolant to drain into a suitable container.

5.8.3.2

Refilling the coolant and bleeding the coolant circuit Close drain valve 1 on the coolant cooler.

Close drain valve 2 on the engine.

Fully open the regulating valve on the heating unit.

Fill with coolant through filler neck until it reaches the upper edge of the filler neck.

Re-close the sealing cap.

Allow the engine to run under load for approx. 20 minutes.

If necessary, partially cover the cooling system so that the opening temperature of the thermostats is exceeded.

The overheating indicator should not be triggered.

The water temperature indicator on the monitoring display must remain below the red area.

Remove any covers that may be on the cooling system.

Allow the engine to continue to run at a low idle for approx. one minute.

Re-check the coolant level in the expansion tank and refill with coolant if necessary.

Open the sealing cap.

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Operating manual

Maintenance Cooling system

Fill with coolant through the filler neck until it reaches the upper edge of the filler neck.

Re-close the sealing cap.

If the coolant level sensor is triggered, check the coolant level (refill if necessary).

Bleed as described above.

Caution!

The engine could be damaged.

Immediately bring the engine to a low idle if the temperature or coolant level indicator starts to flash.

Switch off the engine.

Check the coolant level and refill with coolant if necessary.

5.8.4 5.8.4.1

Checking coolant, adjusting mixing ratio Coolant with corrosion inhibitor/antifreeze agent The mixing ratio must at all times conform to a frost protection of -37 °C. Take a coolant sample and analyse it with a suitable method for the frost protection temperature.

Adjust mixing ratio, if the frost protection is not sufficient.

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Maintenance

Operating manual

Cooling system

Fig. 5-20

Determining refill volume - example for -15 °C:

1

Corrosion inhibitor/antifreeze agent (concentrate), refill volume in litres

3

Max. frost protection temperature of the cooling system -°C

2

Auxiliary line

4

Coolant volume in radiator in litres

Determining refill volume - example for -15 °C / 50 litres of coolant: Based on the measured frost protection temperature (-15 °C) follow the auxiliary line 2 from the left bottom corner to the vertical line 4 (coolant volume – 50 litres) and from there horizontally to the left scale. The refill volume 1 is 14.8 litres.

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Operating manual

Maintenance Cooling system

This corresponds to the refill volume of corrosion inhibitor/antifreeze agent (concentrate) to be added in order to again achieve a frost protection temperature of -37 °C. Correcting mixing ratio The necessary refill volume is known.

To correct the mixing ratio, at least the (previously determined) volume must be drained from the cooling system.

Add the determined volume of corrosion inhibitor/antifreeze agent (concentrate).

To achieve the required coolant level, add some of the previously drained coolant.

5.8.4.2

Coolant with corrosion inhibitor (without antifreeze agent) When using DCA 4: Take a coolant sample and analyse the concentration using a Fleetguard CC 2602 M testing kit.

If the concentration is incorrect, correct the mixing ratio (according to the values indicated by the test kit).

When using Caltex / Chevron / Havoline / Total: The mixing ratio must always show a Brix value of 2.8-0.9+0.9 % . This corresponds to 5 to 10 % of corrosion inhibitor and 90 to 95 % of water.

Take a coolant sample and analyse with a Gefo refractometer.

Fig. 5-21

Gefo refractometer 2710

Refractometer: – Adjusting screw for adjustment to 0-line (water line) – Adjustment of acuity by turning the eyepiece – Soft edge of eyepiece – Sturdy metal housing – Safe handling thanks to rubber jacket Measuring procedure: Carefully clean the lid and prism.

Apply 1 to 2 drops of sample liquid onto the prism.

Close the lid.

The liquid is distributed.

Hold the device against a light-coloured background and look through the eyepiece.

Adjust focus on scale and read the value at the blue separating line.

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Maintenance

Operating manual

Cooling system

Fig. 5-22

Determining refill volume - example for 1 % Brix.

1

Corrosion inhibitor, refill volume in litres

3

Refractometer value in % Brix

2

Auxiliary line

4

Coolant volume in radiator in litres

Determining refill volume - example for 1 % Brix / 50 litres of coolant: Based on the measured value (1 % Brix), follow the auxiliary line 2 from the left bottom corner to the vertical line 4 (coolant volume – 50 litres) and from there horizontally to the left scale. The refill volume 1 is 2.4 litres.

This corresponds to the refill volume of corrosion inhibitor (concentrate) to be added in order to again achieve a value of 2.8 % Brix.

Correcting mixing ratio The necessary refill volume is known.

To correct the mixing ratio, at least the (previously determined) volume must be drained from the cooling system.

Add the determined volume of corrosion inhibitor.

To achieve the required coolant level, add some of the previously drained coolant.

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Operating manual

Maintenance Fuel system

5.9 Fuel system Danger!

Danger of explosion!

Avoid open flames when working on the fuel system and when refuelling.

Do not smoke.

5.9.1

Refuelling Note!

If the fuel tank is emptied while the diesel engine is running, the fuel system must be bled, which is a complicated and time-consuming procedure.

Therefore avoid running the tank empty and refuel the machine on time.

Fig. 5-23

Tank lid

Remove the tank lid 1.

Refill fuel through the strainer.

5.9.1.1

Electric refuelling pump (optional equipment)

Fig. 5-24

Electric refuelling pump

The electric refuelling tank is used to refill fuel into the fuel tank of the machine.

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Maintenance

Operating manual

Fuel system

It is located below the flap on the front side of the hydraulic and fuel tanks. The control panel 3 is removable.

To refuel and then store away the hoses, proceed as follows: Remove the tank lid.

Insert the free end of the suction hose 1 into the fuel container.

Open the stop cock 2 (position B).

Switch on the refuelling pump with the switch S25 (green) to pump fuel into the tank of the machine.

The pump is automatically switched off when the maximum fill level is reached.

The refuelling pump can be switched off at any time with the switch S59 (red).

Caution!

Prevent the pump from running dry!

Ensure that the fuel level does not drop below the suction height of the suction hose.

Close the stop cock 2 (position A).

Before storing away the hose, ensure that no fuel is left in the suction hose 1.

Roll up the suction hose 1 and store it away it in the storage place.

Close the flap.

Replace the tank lid.

5.9.2

Dewatering fuel tank

Fig. 5-25

Dewatering fuel tank

The fuel tank must be dewatered daily: The tank base is equipped with a water drain valve 1.

Place a suitable container under the machine.

Open the drain valve 1 at the bottom of the fuel tank.

Drain off the water until fuel begins to escape.

Close the drain valve 1.

Depending on the fuel quality and the conditions under which the machine is operated, the interval may be prolonged to one week.

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Operating manual

Maintenance Fuel system

Note!

To minimise condensation in the tank, keep the fuel level as high as possible.

The indicator P3 indicates the fuel level in the tank.

When the red bars P3.1 are on, there is very little fuel left in the tank.

If the fuel level is low, refuel before starting work.

5.9.3

Emptying and cleaning fuel tank

Fig. 5-26

Fuel tank

Place a suitable container under the machine.

To drain off the water from the tank, open the drain screw out the drain valve 1 by two full revolutions and let the water flow out until fuel begins to escape.

Screw in the screw.

To empty the tank, remove the tank lid 3 and the drain valve 1 and collect the fuel in a suitable container.

Regularly check the fuel tank and the strainer 2 for dirt.

If required, replace the strainer 2 and/or rinse out the fuel tank.

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Maintenance

Operating manual

Fuel system

5.9.4

Maintenance of fuel filter

Fig. 5-27 1

5.9.4.1

Overview of fuel filter

Fuel pre-filter

2

Fuel fine filter

Dewatering fuel pre-filter:

Fig. 5-28

Fuel pre-filter

Place a suitable container under the filter.

Screw out the drain plug a.

Operate the hand pump b to drain off the water until fuel begins to escape.

Screw in the drain plug a.

5.9.4.2

Replacing filter cartridges Switch off the diesel engine.

Carefully clean the fuel filter and the adjacent area.

Place a suitable container under the tank.

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Operating manual

Maintenance Fuel system

Changing the fuel pre-filter:

Fig. 5-29

Fuel pre-filter

1 4

Filter head Bleeder screw

2 5

Filter cartridge Fuel pre-heating plug

3 6

Water separator tank Water level sensor plug

7 b

O-ring Hand pump

8

Seal ring

a

Drain plug

Disconnect the electrical connections 5 and 6.

Screw out the bleeder screw 4 and the drain plug a and drain off the fuel.

Remove the filter cartridge 2.

Screw the water separator tank 3 from the filter cartridge 2.

Clean the water separator water 3 with clean fuel.

Apply fuel to the O-ring 7.

Insert the new filter cartridge and tighten it by hand.

Screw in the drain plug a.

Apply clean fuel to the seal ring 8 of the new filter cartridge.

Fill the filter cartridge 2 with clean fuel.

Screw in the filter cartridge until the seal ring touches the filter head 1 and tighten it by hand.

Reconnect the electrical connections 5 and 6.

Close the bleeder valve 4.

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Maintenance

Operating manual

Fuel system

Changing the fuel fine filter:

Fig. 5-30

Fuel fine filter

Remove the filter cartridge.

Apply clean fuel to the seal ring of the new filter cartridge.

Fill the filter cartridge with clean fuel.

Screw in the filter cartridge until the seal ring touches the filter head and tighten it by hand.

5.9.5

Bleeding fuel system The fuel filter must be bled after: – Change of fuel filter The entire fuel system must be bled after: – Emptying fuel tank – Commissioning of the diesel engine after work on the fuel system Note!

To bleed the fuel system, do not open the fuel/injection line or screw connections.

Bleeding fuel filter:

Fig. 5-31

Bleeding fuel filter

Switch off the diesel engine.

Place a suitable container under the tank.

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Operating manual

Maintenance Fuel system

Loosen the bleeder screw 1 at the filter head of the fuel pre-filter 2 and turn it out by 3 thread turns.

Operate the hand pump 2 until the fuel escapes without bubbles.

Tighten the bleeder valve 1.

Operate the hand pump 2 until there is a discernable resistance.

Remove the bleeder screw 3 at the filter head of the fuel fine filter 2 and turn it out by 3 thread turns.

Operate the hand pump 2 until the fuel escapes without bubbles.

Tighten the bleeder valve 3.

Operate the hand pump 2 until there is a discernable resistance.

Bleeding crankcase:

Fig. 5-32

Bleeder screw at the crankcase

Loosen the bleeder screw 1 at the crankcase and turn it out by 2-3 thread turns.

Operate the hand pump 2 until the fuel escapes without bubbles at the bleeder screw.

Tighten the bleeder screw 1 at the crankcase.

Operate the hand pump 2 until there is a discernable resistance.

If required, start the diesel engine in purge mode (PURGE).

Starting diesel engine in PURGE mode: Note!

To start the machine in purge mode, the fuel tank must be driven empty.

First bleed the emptied fuel system by hand (see previous chapter). Some air remains however in the fuel high pressure system. This air can only escape when the diesel engine is started.

The purge mode (drive menu, PURGE option) assists this procedure. The fuel high pressure system is automatically bled, so that the diesel engine starts better.

The PURGE is only available if the diesel engine is not on.

Switch on the ignition.

In the operator's menu, select the PURGE option.

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Maintenance

Operating manual

Dry air filter

Fig. 5-33

PURGE menu

Press the Menu button.

The purge mode is activated (purge = ON) Start the diesel engine.

The injection unit uses the maximum possible quantity of fuel. This results in increased build-up of fumes.

When the diesel engine has started up and reached a certain speed (> 500 rpm), the purge mode is automatically deactivated (purge = OFF) and the menu disappears from the display.

The injection unit works again in normal mode.

Do not operate the starter for more than 20 seconds.

If the diesel engine fails to start, bleed the fuel system again and restart the engine in purge mode.

5.10 Dry air filter It is only possible to provide maximum engine protection against premature dust wear by ensuring that the air filter is serviced at regular intervals.

The dry air filter is designed to provide maximum protection over long maintenance intervals.

Washing the filter cartridges is not recommended for safety reasons.

Fig. 5-34

Low pressure indicator

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Operating manual

Maintenance Dry air filter

Low pressure indicator 1 stores the maximum attained suction underpressure reached at the filter outlet when the diesel engine is running.

The appearance of the red display strip in alarm window 3 indicates that the maximum permissible underpressure of 50 mbar has been reached.

Replace the main element.

Press reset button 2 to clear the stored underpressure reading.

Fig. 5-35

Dust discharge valve extractor slot

The dust discharge valve on the dry-air filter is accessible via an opening on the underside of the engine compartment.

Push up by hand the extractor slot on the dust discharge valve once a week to ensure that it does not stick due to humidity and dust.

5.10.1

Changing the main element Caution!

Only replace the main element when the maximum permissible suction underpressure has been reached, or at least once a year.

Installing and removing the main element too often could damage the seals between the filter element and filter housing.

Only replace the safety element after every third change of the main element, or at least once a year.

Before installing a new insert, carefully clean the seal and seal contact surface in the housing.

Fig. 5-36

Changing the filter cartridges

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Maintenance

Operating manual

Dry air filter

1 2

Filter housing cover Filter housing

3 4

Main element Safety element

Remove the cover 1 with the engine switched off.

Remove the contaminated main element 3.

Clean the interior of the air filter housing and the sealing surface in the housing using a damp cloth.

Caution!

Dirt could enter the engine intake!

Do not clean the housing by blasting it out with compressed air.

Insert the new main element and ensure that it is sealed and positioned correctly.

Close filter housing 2 using cover 1.

5.10.2

Changing the safety element Note!

Replace the safety element after replacing the main filter cartridge three times or at least once a year.

Immediately replace the safety element if a visual check has shown that the safety element is heavily contaminated.

Remove main element 3.

Remove safety element 4.

Clean the interior of the air filter housing carefully using a damp cloth.

Clean sealing surfaces in the housing and inspect for any damage.

Insert the new safety element 4 carefully.

Insert the main filter cartridge 3 and ensure that it is sealed and positioned correctly.

Close filter housing 2 using cover 1.

5.10.3

Checking the filtered air line

Fig. 5-37

Checking the filtered air line

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Operating manual

Maintenance Hydraulic system

Check the filtered air line between the filter outlet and the engine suction pipe 8 for damage and leaks each time the filter element is replaced.

If necessary, retighten the tension clamp screws 7.

5.11 Hydraulic system Maintenance work on the hydraulic system is generally limited to the hydraulic tank.

All other components of the system do not require any special maintenance or servicing.

The network of pipes and hoses must however be inspected regularly for leaks.

Note!

Cleanliness is of particular importance for the proper working of the hydraulic system.

For this reason, the prescribed intervals for – changing of the return filter – cleaning of the oil cooler – oil change must be strictly adhered to.

5.11.1

Preparation

Fig. 5-38

Machine position for the oil level check of the hydraulic system

Before checking the oil level or adding oil: – ensure that the machine is standing on level and firm ground, – the working attachment is placed on the ground and the stick and the bucket cylinders are fully extended (i.e. bucket and stick fully tilted in), – the supports (bade support / outriggers) are fully extended.

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Maintenance

Operating manual

Hydraulic system

5.11.2

Check the oil level in the hydraulic tank

Fig. 5-39

Oil level in hydraulic tank

When the machine is in inspection position, the level may not drop below the centre mark in the sight glass.

If required, add oil through the return filter until the level reaches the centre mark.

The upper mark MAXI indicates the maximum oil level when all cylinders are fully retracted.

The lower mark MINI indicates the minimum oil level when all cylinders are fully extended.

If the oil level drops below the lower mark MINI, the minimum level is reached and the respective warning symbol is shown on the display.

5.11.3

Depressurising the hydraulic system Danger!

Fine jets of fluid escaping under high pressure can penetrate the skin and result in serious injury.

Before carrying out any work on the hydraulic system, you must fully depressurise it.

In machines with an energy recovery cylinder, close the block ball valves on the boom.

Do not use your bare hands to check the system for leaks.

Observe the following: The machine must be in the position described above.

Turn the switch S75 to position 0 The oscillating axle is released.

Shut down the engine.

In machines with an energy recovery cylinder, close the block ball valves on the boom.

Depressurise the hydraulic system: Start the ignition and carefully move the pilot control units (joysticks and pedals) in all directions.

Risk of accident and injury from uncontrolled extension of the energy recovery cylinder and resulting movement of the boom. Please note that the energy

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Operating manual

Maintenance Hydraulic system

recovery cylinder remains pressurised even when the hydraulic system is depressurised.

Danger!

When at operating temperature, the hydraulic oil is hot and might be under pressure.

Avoid skin contact with hot hydraulic oil or parts containing oil.

Fig. 5-40

Hydraulic system pressure, breather filter

Turn out the breather filter 1 by maximum one full turn.

The hydraulic system is gradually being depressurised.

The breather filter 1 can be rotated by hand when the safety pin 2 is inserted. If necessary, use an open end spanner to turn the filter.

5.11.4

Changing the breather filter The hydraulic system must be depressurised.

Replace the filter 1 with the safety pin 2 (see Fig. 5-40) at each hydraulic oil change.

Note!

In areas with excessive dust, observe the special instructions for filter change.

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Maintenance

Operating manual

Hydraulic system

5.11.5

Emptying and refilling the hydraulic tank

Fig. 5-41 1

Draining and adding hydraulic oil

Breather filter

2

Return filter

3

Drain valve

If possible, empty and refill the hydraulic system using a filler unit.

Draining oil: The hydraulic system is depressurised.

Turn out the breather filter 1 by maximum one full turn.

The hydraulic system is gradually being depressurised.

Remove the lid from the return filter 2.

Screw the drain hose onto the drain valve 3 at the bottom of the tank and let the oil drain into a suitable container.

Adding hydraulic oil: Turn out the breather filter 1 by maximum one full turn.

The hydraulic system is gradually being depressurised.

Remove the lid from the return filter 2.

Add oil through the filter cartridge until the oil level reaches the centre mark in the sight glass.

Tighten the breather filter 1.

Replace the lid of the return filter 2.

Caution!

Hydraulic components can be damaged, if the system is not bled!

Bleed the hydraulic pumps after each hydraulic oil change.

Draining off condensate (only for mineral oil): Regularly drain the condensate from the system.

Place a suitable container under the machine.

Connect the drain hose to the drain valves 3 (see Fig. 5-41) until the oil flowing into the container does not contain any water.

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Operating manual

Maintenance Hydraulic system

5.11.6

Return filter

Fig. 5-42

Return filter

1

Cover

4

Flat gasket

2 3

Hex head screw Magnetic rod

5 6

Filter cartridge Protective cylinder

The magnetic rod 5 of the return filter must be cleaned at regular intervals (see maintenance schedule) and must be replaced together with the filter cartridge 6.

Note!

In areas with excessive dust, observe the special instructions for filter change.

Cleaning the magnetic rod, replacing the filter cartridge: The hydraulic system is depressurised.

Loosen the screws at the filter cover and lift off the cover 1 together with the magnetic rod 5.

Carefully clean the magnetic rod 5, removing any persistent dirt.

Remove the spent filter cartridge 6 holding it by the bracket.

Insert the new filter cartridge vertically into the tank, holding it by the bracket, and push it slightly down. Place the bracket along the side of the tank ring.

Caution!

Ensure that the filter cartridge is inserted vertically into the tank.

Centre and place the lid 1 with the bypass cage 4 carefully on the filter cartridge 6. Ensure that the sealing ring 3 is not damaged.

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Maintenance

Operating manual

Hydraulic system

Note!

The filling opening of the hydraulic tank is equipped with a protective cylinder 7. It prevents foreign particles entering the hydraulic tank. If required, the protective cylinder can be removed from the filling opening.

Note!

After each replacement of the filter cartridge 6, also replace the pressure filter cartridge integrated into the control oil unit.

5.11.7

Control oil filter

Fig. 5-43

Control oil unit

1 2

Control oil unit Pressure filter

5 6

Filter cartridge sealing ring Filter pot

3 4

Mounting stud Filter cartridge

7 8

Filter pot sealing ring Accumulator

The pressure filter 2 is an integral part of the control oil unit 1 located at the rear of the hydraulic tank.

Note!

Cleaning and re-using the filter cartridge is prohibited!

Replace the cartridge each time you open the filter pot.

Replacing filter cartridge: The hydraulic system is depressurised.

Screw off the filter pot 6 of the pressure filter 2 and pull out the filter cartridge 4.

Clean the filter pot.

Apply a little hydraulic oil to the threads and sealing faces of the filter pot 6 and the control oil unit 1 as well as to the sealing rings 5 and 7.

Carefully place the new filter cartridge 4 onto the mounting stud 2.

Screw in the filter pot 6 to the stop and tighten it by hand.

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Maintenance Hydraulic system

5.11.8

Control circuit The transmitter units do not require any special maintenance or servicing.

Regularly inspect the pipelines and the connections of all units (pumps, pressure accumulators, pressure-relief valve, pressure filter, etc.) for leakage.

Danger!

The pressure accumulator 8 (see Fig. 5-43) ensures that the control circuit remains pressurised after the diesel engine has been shut down so that a number of movements remain possible.

Prior to interfering with the control pressure circuit, it must be depressurised: To do this, place the working attachment on the ground.

Shut down the engine.

Operate both joysticks (while the ignition key is in start position).

5.11.9

Bleeding the hydraulic pumps Prior to commissioning the pumps, after repairs and after a replacement of a pump, fill the pump housing through the leak oil connection with hydraulic oil.

After the system has been filled, and after an oil change in the hydraulic system, bleed the hydraulic pumps.

Caution!

Risk of damage to machine or limited functionality!

Hydraulic pumps that were not bled might be damaged during operation, or might result in a limited functioning of the fan drive.

Always bleed the hydraulic pumps, if air has been trapped in the system as a result of work carried out on the hydraulic system.

The system must be bled at two points of the hydraulic system in the following sequence: – Hydraulic pumps (see Fig. 5-44) – Hydraulic pump of the fan drive (see Fig. 5-45)

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Maintenance

Operating manual

Hydraulic system

Bleeding the hydraulic pumps:

Fig. 5-44

Double hydraulic pump

Place a suitable container to collect the hydraulic oil under the machine.

Slightly loosen the leak oil hose 1 and let the air escape.

The working pumps are being bled.

As soon as the hydraulic oil escapes without bubbles, tighten the leak oil hose 1.

Slightly loosen the leak oil hose 2 and let the air escape.

The slewing gear pump is being bled.

As soon as the hydraulic oil escapes without bubbles, tighten the leak oil hose 2.

Bleeding the hydraulic pump of the fan drive:

Fig. 5-45

Hydraulic pump of the fan drive

Place a suitable container to collect the hydraulic oil under the machine.

Turn the screw plug by one full rotation (see arrow) and let the air escape.

As soon as the hydraulic oil escapes without bubbles, tighten the screw plug.

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Operating manual

Maintenance Hydraulic system

5.11.10

Removing the suction hose

Fig. 5-46

Suction hose, shut-off valve

The shut-off valve of the suction hose has two positions: – a open – b closed If the suction hose is to be disconnected at the pump or at the hydraulic tank, close the stop cock b.

Place a suitable container to collect the hydraulic oil under the machine.

Depressurise the hydraulic system.

Drain the hydraulic oil from the pump and suction hose.

After completion of the repair, turn the stopcock to its initial position a and engage it.

Tighten the breather filter on the hydraulic tank.

5.11.11

Feed line filter of the slewing gear circuit

Fig. 5-47

Feed line filter of the slewing gear circuit

The cartridge of the feed line filter attached to the slewing gear pump must be replaced at prescribed intervals.

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Maintenance

Operating manual

Hydraulic system

The hydraulic system is depressurised.

Open the filter pot.

Remove the filter cartridge and insert a new one.

Mount the filter pot.

5.11.12

Leak oil filter

Fig. 5-48

Leak oil filter

The leak oil filter is located in the engine compartment. It is mounted on the hydraulic tank. The filter cartridge must be inspected at prescribed intervals and each time a hydraulic system is replaced. If necessary, the cartridge must be cleaned.

Cleaning filter cartridge: The hydraulic system must be depressurised.

Unscrew the filter pot 1.

Remove the filter cartridge.

Wash the filter cartridge with petrol or replace it.

Clean the filter pot 1 and the filter head.

Reinstall the filter pot 1 with the filter cartridge.

Caution!

After cleaning or replacing the cartridge, check the system for leakage: Start the engine and operate the machine for a short period of time.

Check the filter pot and the filter head for leakage.

5.11.13

Bypass oil filter (optional extra) The bypass oil filter has the task of filtering fine dirt and water out of the hydraulic system.

Replace the filter element whenever the return-line filter is changed. The filter should always be changed every six months.

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Operating manual

Maintenance Hydraulic system

Note!

LIEBHERR strictly requires the use of bypass oil filters when environmentallyfriendly hydraulic oils are used.

Fig. 5-49

Bypass oil filter

1 2

Screw Washer

4 5

O-ring Filter element

3

Cover

6

Filter housing

Replace filter element: Switch off the engine.

Depressurize the hydraulic system.

Remove screw 1 and remove cover 3.

Slightly turn the old filter element 5 in a clockwise direction using the support straps and lift at the same time.

Wait until the oil has drained and then remove filter element 5. Catch any dripping oil using a suitable container.

Check the inlet and outlet of filter housing 6 for dirt residues and clean if necessary.

Take the new filter element 5 out of the packaging without removing the cardboard shroud around the filter element.

Note!

Damaged packaging may have resulted in the ingress of humidity which can limit the life of the filter element.

Ensure that the packaging of the new filter element has not been damaged.

Insert the new filter element 5.

Fill filter housing 6 with the same hydraulic oil as the machine.

Clean cover 3 and fit a new O-ring 4.

Attach the cover 3 and fasten with screw 1. Tighten to a torque of 50 Nm. Start the engine and check whether the bypass oil filter is tight.

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Maintenance

Operating manual

Hydraulic system

5.11.14 5.11.14.1

Maintenance of hydraulic cylinders Checking piston rod bearing

Fig. 5-50

Piston rod bearing

Note If there is a leak at the piston rod bearing of a hydraulic cylinder (arrow), we recommend having the seal kit replaced by a LIEBHERR technician.

5.11.14.2

Preservation of piston rods Prior to standstills of more than 4 weeks, and in particular prior to any sea transport of the machine, carry out the following tasks: If possible, position and transport the machine in such a way that the piston rods are fully retracted into the cylinders.

Exposed piston rods must be protected with a thick layer of acid-free corrosion protection grease.

Before loading the machine, check the piston rods again for proper preservation.

Also apply corrosion protection grease to the piston rods, if the respective cylinder is rarely operated during work. Piston rods that are not frequently retracted and extended are not properly lubricated with hydraulic oil.

Regularly check the preservation of rarely operated hydraulic cylinders.

5.11.15

Replacing hydraulic hoses

Fig. 5-51

High pressure hose with SAE fitting

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Operating manual

Maintenance Changing the oil on components

Danger!

A defective hydraulic hose can cause accidents and injuries.

Replace defective hydraulic hoses (bubbles, moisture, damaged top edge etc.) immediately.

Install new hydraulic hoses without torsion.

Ensure that the hydraulic hose is not twisted when mounting.

Installed high pressure hoses with SAE connections have a nominal diameter of 16, 20 or 25.

Tighten the mounting screws of SAE fittings with the following tightening torques. :

Screw

Grade

Torque

M10

10.9

68 Nm

M12

10.9

117 Nm

M14

10.9

185 Nm

Tab. 5-15 Tightening torques for SAE fittings

5.12 Changing the oil on components 5.12.1

General notes The machine must be in level position.

Shut down the engine.

Wait for a short time until the oil has collected in the oil pan.

If possible, drain the oil when it is at operating temperature.

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Maintenance

Operating manual

Changing the oil on components

5.12.2

Swin gear - oil change

Fig. 5-52

Changing the oil on the swing gear

1

Drain valve

3

Oil container

2

Drain hose

4

Cap

To drain the oil: Remove the cap 4.

Unscrew the cover of the drain valve 1 via the opening on the base plate of the swing platform.

Screw the provided drain hose 2 on the drain valve and allow the oil to flow into a suitable container.

Remove the hose 2.

Reinstall the cover of the drain valve 1.

To add the oil: Add the oil via the tank 3 until the level reaches the MAX mark.

Reinstall cover 4.

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Operating manual

Maintenance Changing the oil on components

5.12.3

Pump distributor gear - oil change

Fig. 5-53

Oil change in the pump distributor gear

1

Oil filler neck / dipstick

2

Drain valve

3

Drain hose

Draining oil: Remove the dipstick 1.

Remove the screw cap at the drain valve 2.

Connect the drain hose 3 to the drain valve 2 and let the oil drain into a suitable container.

Disconnect the drain hose 3.

Replace the screw cap at the drain valve 2.

Filling oil: Add oil through the filler neck 1 until it reaches the upper mark (max) on the dipstick.

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Maintenance

Operating manual

Drive

5.12.4

Travel gear - oil change

Fig. 5-54

Travel gear - changing oil

Before the oil change, ensure that the machine is at operating temperature: Draining oil: To drain off oil or to add oil, position the chassis in such a way that the screw plugs 1, 2 and 3 are in the positions indicated in the drawing.

Place a suitable collecting vessel (approx. 5 litres) under the screw plug 3.

Remove the screw plug 3.

Remove the screw plug 1 or 2.

Collect the escaping oil in the vessel.

Adding oil: Close the screw plug 3.

Add oil through the opening 1 until the oil level reaches the opening.

Insert and tighten the screw plugs 1 and 2.

5.13 Drive The running gear is maintenance-free, unless the running surfaces or the flanges requires regeneration or until all drive parts are completely worn.

The lifetime design of the support rollers, running rollers and idlers prolongs the service life of the drive, while the metal seals protect it against dirt.

5.13.1

Cleaning drive Do not start the machine, if stones, pieces or timber, metal, wire or cable sections are jammed in the drive.

Dry or frozen mud, stones and other extraneous material inside the drive components can cause serious damage to the machine, if it is started. Do not attempt to free the machine by means of engine power.

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Maintenance Drive

If the ambient temperature is below zero, place the machine on planks to prevent the chains from becoming frozen to the ground.

Caution!

To prevent serious damage, do not attempt to free a machine frozen to the ground with force.

Frozen chains can be freed by carefully heating the base plates.

Fig. 5-55

Lifting machine

Caution!

Risk of the machine becoming dislodged.

When propping up the machine, secure it with timber beams.

Before placing the machine on the ground, remove the dirt from heavily contaminated drive components.

Remove sand and dirt from the sliding surfaces at the tensioning units and lubricate them.

To clean the drive, lift one side of the chassis from the ground, propping the machine up with the working attachment, (see Fig. 5-55).

5.13.2

Checking fixtures of drive components

Fig. 5-56

Fixtures of drive components

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Maintenance

Operating manual

Drive

Carry out regular visual inspections of the securing screws of the base plates and the drives in order to find any loose bolts.

Check tightening torques.

• Mounting bolts 7 of the base plates: 520 Nm • Mounting bolts 8 of the drive: 620 Nm • Mounting bolts 9 of the tumbler wheel: 560 Nm • Mounting bolts 10 of the hydraulic motor: 280 Nm

5.13.3

Checking chain tension

Fig. 5-57

Check chain tension.

Release the chain by moving forward and back.

Place the measuring rod 1 onto the section between the idler and the support roller.

Measure the distance A between the measuring rod lower edge and the base plate.

Under normal operating conditions, the dip between the support roller and the idler should be between 20 to 40 mm.

If necessary, tension the chain.

5.13.4

Tensioning chain

Fig. 5-58

Chain tension insufficient (A) and correct (B)

As the chassis is exposed to normal wear, the chain tension must be regularly checked and retensioned, if necessary.

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Maintenance Drive

Fig. 5-59

Tensioning chain

Remove the lid 3 from the longitudinal member of the undercarriage.

Screw the high pressure hose 1 to the hand grease gun.

Open the high pressure hose 1 to connect it with the lubrication nipple 2 of the grease tensioner.

Add grease until the chain is sufficiently tensioned.

Check chain tension.

5.13.5

Releasing chain

Fig. 5-60

Releasing chain

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Maintenance

Operating manual

Electrical system

Danger!

Risk of injury from slacking chain or expelled grease.

When tensioning the chain, always wear protective goggles and gloves.

The lubrication nipple 1 may not be loosened.

When releasing the chain, keep your head away from the running roller frame.

When loosening the lubrication nipple extension 2 keep your hands away from the lubricating nipple. To loosen the lubrication nipple extension, always use suitable tools.

Clean the chain and remove any jammed objects.

Place machine on level ground.

Turn lubrication nipple extension 2 by a few revolutions until grease escapes from the longitudinal groove 3 of the lubrication nipple extension.

As soon as the desired chain tension is reached, tighten the lubrication nipple extension 2.

After adjustment, move the machine forward and back and then check the chain tension again.

5.13.6

Changing lubrication nipple Release the chain as described in section "Releasing chain".

As soon as no grease escapes from the longitudinal groove 3 of the lubrication nipple extension 2,(see Fig. 5-60): Fully unscrew the lubrication nipple extension.

Fully screw in and tighten the preassembled unit (lubrication nipple extension 2 and lubrication nipple 1).

Tension the chain as described in section "Tensioning chain".

5.14 Electrical system 5.14.1

Notes regarding the electrical system Regularly inspect the electrical system of the machine for defects.

Defects such as loose connections, chaffed cables or poorly fixed clamps must be eliminated without delay.

Identify the cause of blown fuses and broken incandescent lamps, eliminate it and replace the fuse or the lamp.

Before carrying out any work on the electrical system or carrying out electric arc welding work on the machine, disconnect the batteries.

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Maintenance Electrical system

5.14.2

Battery main switch Caution!

Do not interrupt the saving process of the engine control unit.

After switching off the diesel engine, the engine control unit remains activated for approx. 40 seconds in order to save system data. Switching off the battery main switch during saving might result in the loss of data so that the diesel engine cannot be restarted.

After switching off the diesel engine, wait for approx. 1 minute before switching off the battery main switch to ensure that the saving process is properly completed.

Caution!

The auxiliary heater (optional equipment) remains on for a little while after the ignition has been switched off. It might be damaged, if it is suddenly switched off with the battery main switch during this afterrun time.

Only switch off the battery main switch after the afterrun time of the auxiliary heater has lapsed.

Fig. 5-61

Battery main switch

Before carrying out any work on the electrical system or performing welding work on the machine, set the battery main switch to position 0 (off).

Note!

The battery might discharge itself during prolonged standstills.

Prior to prolonged standstills, switch the battery main switch to position 0 (off).

5.14.3

Battery care Danger!

Battery acid is highly corrosive.

When working on the battery, always wear protective goggles and gloves.

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Maintenance

Operating manual

Electrical system

Danger Risk of explosion from hydrogen gas and sparks.

Check the vent hoses for damage, especially after installation of the battery.

The negative pole (-) must be disconnected first and reconnected last.

Avoid sparks and naked flames when charging batteries or working on them.

Charge the batteries only in well ventilated rooms.

Fig. 5-62

Battery care

For proper functioning, the battery must always bee kept clean.

The liquid level in the cells should be about 10 to 15 mm above the upper edge of the plate. To refill the battery, only use demineralised water.

The hydrogen gas produced in the batteries must escape through rubber hoses B to the outside of the building. Ensure that the rubber hoses are not kinked or damaged, as this could lead to hydrogen gas collecting in the battery box.

Lay the vent hoses B in such a way that there are not kinks or blocked sections in the hoses.

Always replace damaged vent hoses.

Regularly clean the pole heads and cable terminals A and apply a thick layer of acid-proof grease.

From time to time, check the acid density using a battery tester C. If the battery is fully charged, the density is 1.28 kg/l (31.5° Bé).

If the battery tester shows a lower value, the battery is discharged to some degree and might need to be recharged.

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Operating manual

Maintenance Electrical system

5.14.4

Slip ring body (optional equipment)

Fig. 5-63

Slip ring body

The slip ring body connects the electrical components in the uppercarriage with the electrical consumers in the undercarriage. The slip ring body can be accessed from the uppercarriage and is located at the centre of the slewing gear.

Slip ring bodies are easily damaged by humidity, and insufficient care can lead to the formation of oxide layers on the conductive surfaces. This can impair the electric conductivity and result in malfunctions.

In order to prevent this, we recommend carrying out the following tasks every 500 operating hours: Loosen the lock nuts 2.

Remove the housing 1.

Remove any oxidation from the slip ring body (use a cleaning spray, if necessary).

Replace damaged (corroded) fork terminals.

Apply Cramolin contact spray to all slip ring elements.

Mount the housing 1.

Tighten the lock nuts 2 with a uniform torque.

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Maintenance

Operating manual

Heating and air-conditioning system

5.15 Heating and air-conditioning system 5.15.1

Recirculated and ambient air filter

Fig. 5-64

Recirculated air filter

Fig. 5-65

Ambient air filter

If the ambient air filters are dirty, the air flow is reduced. This in turn affects its performance and can result in frequent icing or shut-down of the a/c system.

Never operate the machine without filters, even for short periods, as this might result in blockage of the heat exchanger.

The filters must be cleaned or replaced every 500 operating hours (shorten interval, if the machine is operated in a particularly dusty environment).

Cleaning or replacing the recirculated and ambient air filters: To remove the recirculated air filter 1, tilt the backrest of the operator seat forward.

Open the quick fasteners 2 by turning them by 90 degrees.

Remove the recirculated air filter 1.

Remove the deflector 4.

Remove the ambient air filter 3.

Note!

Incorrect cleaning of the filters might damage them.

Never clean the filters with hot water or steam!

If the ambient air filter is damaged or in poor state, replace it.

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Operating manual

Maintenance Heating and air-conditioning system

To clean the filter elements 1 / 3, blow them out with compressed air or wash them in cold or lukewarm water.

5.15.2

Heating system Every year at the start of the heating period, have the following maintenance routine completed by a qualified specialist.

Check the entire coolant circuit for leakage.

Retighten the connections in the coolant circuit, the hose connections at the heat exchanger, the seals of the stop valves and the hose clamps.

If necessary, bleed the heating system.

Clean the solenoid valve.

Check the heat exchanger and clean it, if necessary.

The system may only be operated with coolant containing a suitable corrosion inhibitor and antifreeze agent.

5.15.3

air-conditioning system Switch on the a/c system every two to three weeks for about 10 minutes, irrespective of the season.

Inspection of the condenser:

Fig. 5-66 1

A/c condensers

A/c condenser

2

Cooler

During the operating period, check the condenser every 500 operating hours: Inspect the condenser 1 for dirt.

If necessary, clean the condenser: 1: loosen the securing screws and tilt the upper part slightly out. Clean it with compressed air, blowing it from the inside (blower side) out.

Ensure that the condenser fins are clean.

Dirt on the condenser might lead to excessive pressure in the coolant circuit, so that the air-conditioning system is automatically switched off.

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Maintenance

Operating manual

Automatic lubrication of the machine

Maintenance of a/c system: During the operating period, the following maintenance tasks must be carried out by a technician specialising in a/c systems: every 500 operating hours: – Testing of thermostat, blower and pressure switch – Inspection of the electrical lines – Testing of the condenser (if necessary: cleaning) – Testing of a/c compressor – If necessary, replace the dryer-collector unit. every 1000 operating hours: – Inspection of evaporator unit – Inspection of the electrical lines – Complete functional test of excess pressure switch – Check cooling performance Annually: – replace the dryer-collector unit.

For this purpose, the a/c system must be drained, inspected for leakage and refilled. Check the hose lines for chaffing and replace them, if necessary. If required, retighten the hose connections.

– Functional test of the air flaps and the defrost thermostat.

5.16 Automatic lubrication of the machine 5.16.1

Semi-automatic central greasing system The machine is equipped with a central greasing system.

The superstructure and the equipment do not need manual greasing. The bearing points connected to the greasing system can be greased during operations by starting the greasing process.

The chassis is not connected to the automatic greasing system and must be manually greased.

Fig. 5-67

Central greasing pump, semi-automatic

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Operating manual

Maintenance Automatic lubrication of the machine

1

Grease container

4

Lubricating nipple for manual intermediate greasing

2

Adapter (refilling the grease container with a filler pump 6)

5

Safety valve

3

Lubricating nipple – refill grease container

6

filler pump

Starting the greasing process: Greasing is done using switch S84. While the switch is pressed, the electric pump pumps grease to the connected bearing points.

The greasing process should be started once per work shift.

Press switch S84.

Indicator light in the switch flashes.

Grease is delivered to the connected bearing points.

Allow the switch to go on flashing until grease emerges from the bottom end of the hydraulic jacks.

Note!

The time needed for greasing depends on the temperature of the grease and of the components connected to the greasing system. In extremely low outside temperatures: up to 30 minutes.

Press switch S84 again.

Indicator light in the switch goes out.

The greasing process is completed.

Fig. 5-68

Monitoring pin on the main distributor

The main distributor for the lubrication lines is built into the uppercarriage. A functional check can be carried out using the monitoring pin (see arrow).

The continual backwards and forwards movement of the monitoring pin indicates whether the greasing process is functioning correctly (grease delivery). If the monitoring pin does not move, the error diagnosis is as follows: – Blockage or pinching of a supply line (grease flows out of safety valve 5).

– In low outside temperatures, the use of a grease which is too viscous.

– Lack of lubricant in the grease container.

– Breakdown in drive motor's supply circuit.

Find and rectify the cause of the problem immediately.

If the greasing pump is defective, the attached oiling points can be greased centrally with a greasing pump via lubricating nipple 4.

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Maintenance

Operating manual

Automatic lubrication of the machine

To refill the grease container: The grease container must be checked once a week and refilled if necessary.

Note!

In order to avoid contamination and damage, the grease container should remain closed.

Do not remove the cover of the grease container when refilling.

Refilling the grease container is normally done via adapter 2.

Insert a grease cartridge in the filler pump 6 supplied, connect the pump to the adapter 2 and squeeze the contents of the grease cartridge into the container.

If the filler pump 6 or grease cartridge are not available, the grease container can be refilled using a greasing pump or a grease gun via lubricating nipple 3.

After the grease container has been refilled, an intermediate greasing must be carried out.

Intermediate greasing: Automatic: Start the greasing process with switch S84. or Manually: Lubricate the lubricating points via lubricating nipple 4.

Carry out intermediate greasing until grease emerges from the bottom end of the hydraulic jacks.

5.16.2

Fully automatic central greasing system (optional extra) The machine may be fitted with a fully automatic central greasing system on request.

The upper carriage and equipment do not require manual greasing. The bearing points connected to the greasing system are greased at regular intervals during operation.

The undercarriage is not connected to the automatic greasing system and must be manually greased.

Fig. 5-69

Central greasing pump, fully automatic

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Operating manual

Maintenance Automatic lubrication of the machine

1

Grease container

4

Lubricating nipple for manual intermediate greasing

2

Adapter (refilling the grease container using filler pump 6)

5

Safety valve

3

Lubricating nipple – refilling of grease container

6

Filler pump

The indicator light in button S84 illuminates when the machine is switched on.

The greasing process begins automatically after a pause and stops when all bearing points h;ave been greased without the operator having to become involved.

Button S84 remains permanently lit during the greasing process.

Button S84 will flash if a fault occurs In addition, symbol E514 is displayed on-screen (error in central greasing system). The following defects may be responsible for the fault: – Blockage or pinching of a supply line (grease flows out of safety valve 5).

– Defective proximity switch or defect in its supply lead.

– The use of a grease which is too viscous at low outdoor temperatures.

– Lack of lubricant in the grease container.

– Failure of drive motor supply circuit.

Find and rectify the cause of the problem immediately.

The screen symbol E514 will disappear after the next successful greasing process.

If the greasing system is functioning correctly, it is possible to initiate an additional greasing pump cycle by pressing button S84 on the right control panel.

If the greasing pump is defective, the attached lubrication points can be greased centrally using a greasing pump via lubricating nipple 4.

To refill the grease container: The grease container must be checked once a week and refilled if necessary.

Note!

In order to avoid contamination and damage, the grease container should remain closed.

Do not remove the cover of the grease container when refilling.

The grease container is normally refilled via adapter 2.

Insert a grease cartridge in the supplied filler pump 6, connect the pump to adapter 2 and squeeze in the contents of the grease cartridge.

If the filler pump 6 or grease cartridge are not available, the grease container can be refilled using a greasing pump or a grease gun via lubricating nipple 3.

An intermediate greasing must be carried out after the grease container has been refilled.

Intermediate greasing: Automatic: Press button S84. or Manually: Lubricate the lubricating points via lubricating nipple 4.

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Maintenance

Operating manual

Manual lubrication of the machine

Continue intermediate greasing until grease emerges from the bottom end of the hydraulic jacks.

Adjusting grease quantity: Depending on the actual use of the machine, the lubricant quantities that are applied by the automatic lubrication system can be adjusted on the screen: see operator's menu option "Automatic central lubrication system".

5.17 Manual lubrication of the machine Certain parts of the working tools, attachments and the undercarriage are lubricated manually. The affected lubricating points are equipped with lubricating nipples.

Note!

We recommend using a grease gun, as it reduces the force required and ensures that the grease is squeezed in slowly.

5.17.1

Attachments (optional equipment)

Fig. 5-70

Lubricating attachment (example of grapple)

The attachments (e.g. grapple, quick-change adapter systems) must be lubricated manually. In grapples, the respective lubricating points are labelled.

For normal operation, the grapple must be lubricated daily or once per shift. Other working tools must be lubricated at weekly intervals.

Machines operated under adverse conditions (e.g. in contact with water or corrosive substances) should be lubricated more frequently.

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Operating manual

Maintenance Manual lubrication of the machine

Examine the attachment to detect all lubricating nipples.

Lubricate the attachment, using a grease gun. Press in grease until clean grease escapes at the respective bearing point (unless instructed otherwise).

If the attachment is equipped with a rotator, the moving parts must also be lubricated.

Lubricate the rotator (bearing, crown gear, pinion) using a grease gun, until clean grease escapes at the respective bearing point (approx. 2 lubricating strokes).

If the rotator is not equipped with a separate lubricating nipple, apply grease to the crown gear and the pinion.

5.17.2

Industrial stick with mechanical quick-change adapter

Fig. 5-71

Lubricating the mechanical quick-change adapter

Lubricate the quick-change adapter through the lubrication nipples with a grease gun (approx. 2 lubricating strokes).

Note!

If the mechanical quick-change adapter is lubricated while the bolts are extended, the cavity between the locking bolts is filled with grease, so that they cannot be retracted.

Therefore lubricate the system only, if the locking bolts are retracted.

5.17.3

Industrial stick with hydraulic quick-change adapter

Fig. 5-72

Lubricating the hydraulic quick-change adapter

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Maintenance

Operating manual

Manual lubrication of the machine

Lubricate the quick-change adapter through the lubrication nipples with a grease gun (approx. 2 lubricating strokes).

Note!

If the quick-change adapter is lubricated while the bolts are extended, the cavity between the locking bolts is filled with grease, so that they cannot be retracted.

Therefore lubricate the system only, if the locking bolts are retracted.

5.17.4

LIKUFIX MH 40 quick-coupling system

Fig. 5-73

Lubricating MH 40 (with removable protective cover)

Fig. 5-74

Lubricating MH 40 (with housing)

The lubrication nipple of the locking bolts are accessible through the recesses in the housing, (see Fig. 5-74), or when the protective cover is removed, (see Fig. 5-73).

If necessary, remove the protective cover 2.

Lubricate the locking bolts 1 through the lubricating nipple, using a grease gun (approx. 2 lubricating strokes).

Note!

If the quick-change adapter is lubricated while released, the cavity between the locking bolts is filled with grease, so that they cannot be extended.

Therefore do not lubricate the quick-change adapter when it is released.

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Operating manual

Maintenance Manual lubrication of the machine

5.17.5

Hydraulic quick change adapter The hydraulic quick change adapter is not greased via the central lubrication system.

The bearing points must be greased using the grease gun.

Fig. 5-75

Lubricating the quick change adapter

Grease the locking pins via the grease fitting with a grease gun.

Note!

The hydraulic quick change adapter cannot be sufficiently greased if the locking pins are extended.

Make sure that the locking pins are retracted during the lubrication procedure.

5.17.6

Mechanical quick-change adapter The mechanical quick-change adapter is not lubricated by the central lubrication system. The respective bearing points must therefore be manually lubricated with a grease gun.

Fig. 5-76

Lubricating quick-change adapter

Lubricate the lube points through the lubrication nipple, using a grease gun.

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Maintenance

Operating manual

Couplings of the quick-change adapter systems (optional equipment)

Note!

If the mechanical quick-change adapter is lubricated while the bolt is extended, the cavity between the locking bolts is filled with grease, so that they cannot be retracted.

Therefore lubricate the system only, if the locking bolts are retracted.

5.18 Couplings of the quick-change adapter systems (optional equipment) 5.18.1

Hydraulic coupling

Fig. 5-77

Hydraulic coupling plug

The LIKUFIX hydraulic coupling system and the multi-coupling system are equipped with hydraulic coupling plugs (see arrows).

The coupling plugs are maintenance-free. We recommend cleaning the system regularly. This prevents caking of dirt and icing up in winter. With regular cleaning, the seals of the system have a long service life.

Cleaning: Remove dirt and clean all coupling parts and sealing surfaces with a clean cloth and oil.

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Operating manual

Maintenance Couplings of the quick-change adapter systems (optional equipment)

Changing seal ring:

Fig. 5-78

Changing seal ring

Caution!

The hydraulic lines are under pressure.

Before changing the seal ring, depressurise the system using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick).

In the event of leakage at the coupling plugs (A), change the seal rings.

Hold down the seal washer of the coupling plug with a screwdriver and lever out the defective seal ring using a pointed tool (B).

Squeeze the new seal ring and place it with its open side facing downwards onto the seal washer (C).

Push the washer into the groove, place the screwdriver onto the centre of the seal ring and remove your hand (D).

Let the seal ring expand into the groove (E).

Remove the screwdriver (F).

The seal washer must move upwards.

If this is not the case, push the seal ring into the groove until the seal washer can move.

5.18.2

LIKUFIX electric coupling The LIKUFIX hydraulic coupling system is equipped with an additional electric coupling (e.g. for the operation of a magnet system). This coupling must be regularly inspected and cleaned.

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Maintenance

Operating manual

General maintenance tasks

Fig. 5-79 1

Electric couplings

Electric coupling top section

2

Electric coupling bottom section

Switch off the magnet system (if installed).

Remove the working tool, if required.

Switch off the diesel engine.

Check the contacts for corrosion and wear (e.g. burn marks).

Clean the contacts of the electric couplings 1 and 2 with a dry cloth and apply contact spray (Cramolin), if necessary.

Check the electric couplings and the screwed connections for proper fixture.

Check the contacts of the top section 1 for play: it must be possible to push in the contacts against the spring force.

Check whether the seals at the contacts of the electric couplings (see arrows) are properly installed and undamaged.

Repair any damage and replace defective parts.

5.19 General maintenance tasks 5.19.1

Replacing wear parts Apart from maintenance and care tasks that must be carried out at prescribed intervals, the following minor repairs can be made by the machine operator or a maintenance technician: – Replacement of worn teeth on digging tool.

– Replacement of defective seals on pipe and hose lines and at connections of the hydraulic units (with the exception of the pressure-relief valves, which are factorysealed).

– Replacement of high-pressure hoses, hydraulic lines and screw connections of the hydraulic unit.

Only use original LIEBHERR spare parts. This applies in particular to hoses and hydraulic lines that must be factory-mounted.

All other repairs, and in particular the removal of the counter weight, must be carried out by authorised specialist technicians.

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Operating manual

Maintenance General maintenance tasks

5.19.2

Replacing teeth on digging tool If the teeth are heavily worn, excess force is required to move the digging tool into the material to be excavated. This can lead to damage to the tooth adapters.

Therefore replace worn teeth in due course.

Do not work with the machine, if there are teeth missing on the digging tool or if they are heavily worn.

U system:

Fig. 5-80

U system – replacing teeth on digging tool

Drive out the roll pin 2 using a hammer and mandrel 1 (A).

Remove the old tooth.

Place the new tooth on the adapter (B).

Drive in the roll pin 2 using a hammer (C).

Z system:

Fig. 5-81

Removing teeth from digging tool - Z system

1

Plug

2

Locking bolt

3 5

Square spanner Tooth adapter

4 6

Tooth Locking piece

Remove the plug 1 from the square recess of the locking bolt 2 (A).

Turn the locking bolt with the square spanner 3 counter-clockwise (a - turn by approx. 30°).

Drive out the locking bolt from the opposite side (B).

Take off the tooth 4 from the tooth adapter 5 and remove the locking piece 6 (C).

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Maintenance

Operating manual

General maintenance tasks

Note!

Before mounting a new tooth, check the state of the locking bolt and locking piece.

Replace any deformed or corroded parts.

Fig. 5-82

Mounting teeth on digging tool - Z system

Insert the locking piece 6 into the recess of the tooth adapter 5 so that the flat locking piece side touches the tooth adapter (D).

Insert the new tooth into the tooth adapter.

Insert the locking bolt to the stop (E).

Turn the locking bolt with the square spanner -clockwise (b - turn by approx. 30°) (F).

The nose 2a of the locking bolt slides across the protruding part 6a of the locking piece and engages.

Insert the plug into the square recess of the locking bolt.

5.19.3

Welded parts on the machine All welding work on all main power-transmitting components (e.g. undercarriage frame, revolving deck, attachment parts, etc.) must be executed by the manufacturer or an authorised specialist workshop.

Before carrying out any arc welding work, disconnect the machine from the battery.

The negative pole (-) must be disconnected first and reconnected last.

Also switch off the battery main switch!

Caution!

Bearings or sealing elements might be damaged (scorched) by high electric currents!

When carrying out welding work, connect the earth cable as close as possible to the welding point so that the welding current does not travel through machine parts such as the slewing ring, joints, bearings, bushes, rubber elements or seals.

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Operating manual

Maintenance Inspection and maintenance schedule

5.20 Inspection and maintenance schedule Note!

Careful and proper maintenance is only possible, if the machine is clean. Important visual inspections, e.g. for cracks can only be performed properly on a clean machine.

Before carrying out any maintenance work, clean the machine (see also chapter "Cleaning").

Note!

The daily maintenance tasks of the machine operator include a functional test of the brakes (slewing gear brake, working brake, parking brake), the steering, the electrical and the hydraulic systems.

Also to be carried out is a daily visual inspection of the engine, hydraulic system, gearbox and axles for leakage.

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT R 934 C Litronic, type 1440 by maintenance personnel (machine owner) Initial interval Repeat interval Annually, at the start of the cold season As required

together with authorised specialist technicians Initial interval Repeat interval

DIESEL ENGINE Check oil level.

Perform visual inspection (leakage, dirt, damage).

Check oil level in pump distributor gear.

Change gear oil in pump distributor gear.

1)

Change diesel engine oil (at least once a year).

Change oil filter cartridge (at least once a year).

Check batteries and cable connections.

Belt drive: Check for damage and wear; replace, if necessary / ribbed V-belt: Check tension; adjust, if necessary.

Check intake and exhaust systems for damage, wear, leakage and proper fixture.

Grease flywheel starter ring gear.

Change filter cartridge at crankcase ventilation.

Check oil pan, engine bearings and diesel engine brackets for proper fixture.

Check / readjust valve play.

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Maintenance

Operating manual

Inspection and maintenance schedule

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT R 934 C Litronic, type 1440 by maintenance personnel (machine owner)

together with authorised specialist technicians

Initial interval Repeat interval Annually, at the start of the cold season As required

Initial interval Repeat interval

Check heater flange.

3000

Check vibration dampers for deformation.

COOLING SYSTEM Check coolant level.

Check cooling and heating system for damage and leakage.

Check corrosion inhibitor and antifreeze agent concentration in coolant.

3000

Change coolant (Liebherr Antifreeze, at least every 2 years).

6000

Change coolant (Liebherr Antifreeze OS, at least every 4 years).

FUEL SYSTEM Check water separator at the fuel pre-filter and drain off water, if necessary.

Remove water and deposits from fuel tank.

4)

Check fuel system for leakage, wear and damage.

4)

Change fuel pre-filter.

4)

Change fuel fine filter.

Bleed fuel system.

AIR FILTER Check underpressure indicator of air filter.

Clean dust removal valve of air filter.

Change main element of dry air filter (according to maintenance indicator / annually).

Change safety element of dry air filter (at every third main element change / annually) - do not clean or re-use!

ELECTRICAL SYSTEM OF DIESEL ENGINE Check control device bearing for general condition.

Check sensor devices and cable connections.

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Operating manual

Maintenance Inspection and maintenance schedule

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT R 934 C Litronic, type 1440 by maintenance personnel (machine owner)

together with authorised specialist technicians

Initial interval Repeat interval Annually, at the start of the cold season As required

Initial interval Repeat interval

HYDRAULIC SYSTEM Check oil level in hydraulic tank.

Clean magnetic rod in return filter (daily during first 300 operating hours).

2)

Change filter element in bypass filter (special equipment) (in machines used for dust intensive applications: every 250 operating hours).

2)

Change filter cartridge in return filter.

Change filter cartridge in control oil unit.

Change feed oil filter at slewing gear pump.

Check components and units for proper fixture.

Check hydraulic oil cooler for dirt; clean, if necessary.

Dewater hydraulic tank (max. permissible water content for environmentally friendly fluids: 0.1 %; use bypass filter, take oil sample).

Check hydraulic system for leakage; perform function test.

Check / readjust servo, primary and secondary pressures.

2), 3) 2)

Change hydraulic oil in tank (optimise interval by carrying out oil analyses).

Change breather filter on hydraulic tank.

Replace filter cartridge in leak oil filter.

ELECTRICAL SYSTEM Check indicator lights and indicating devices upon start-up.

Check lighting system.

Check acid density and level, wire terminals and terminal ports of the batteries.

Spray slip rings of slewing gear connection with Cramolin contact spray.

Perform function tests of the entire system and all components.

SLEWING GEAR MECHANISM Check oil level; check system for leakage.

Perform function test of slewing gear brake.

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Maintenance

Operating manual

Inspection and maintenance schedule

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT R 934 C Litronic, type 1440 by maintenance personnel (machine owner) Initial interval Repeat interval Annually, at the start of the cold season As required

together with authorised specialist technicians Initial interval Repeat interval

Check gearbox and oil motor for proper fixture.

Change gear oil.

SLEWING RING Check mounting bolts for proper fixture; check slewing gear pinion meshing.

DRIVE GEAR Check chain tension; adjust, if necessary.

Change oil in travel gear mechanisms (minimum every 2 years). In dusty environments or where travel operation amounts to more than 12% of total operation, change oil every 1000 hours.

Check travel gear mechanisms (oil level, leakage).

Clean and lubricate slide faces of tensioning mechanism.

Check fixture of track pads and sprocket wheels.

Check chains, guide rollers, carrier rollers and track rollers for wear.

Check chain guides for damage.

Check fixture of travel gear mechanism and hydraulic motors.

Perform function test of travel brake.

OPERATOR'S CAB + HEATING Check / add detergent solution to windscreen washer system tank.

Treat rubber seals of operator's cab with silicone or talcum powder.

Treat rubber seals of the access doors in uppercarriage with silicone or talcum powder.

Perform function test of heating.

Check heating system for leakage.

Check door hinges, window hinges and locks.

Check water inlet valve for dirt, and clean it, if necessary; perform function test of valve.

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Operating manual

Maintenance Inspection and maintenance schedule

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT R 934 C Litronic, type 1440 by maintenance personnel (machine owner)

together with authorised specialist technicians

Initial interval Repeat interval Annually, at the start of the cold season As required

Initial interval Repeat interval

AIR-CONDITIONING SYSTEM Regularly switch on air-conditioning system (at least once every 14 days).

Check condenser for dirt; blow it clean, if necessary.

Clean recirculated air filter and fresh air filter; replace, if necessary; shorten interval if there is excessive generation of dust.

Check compressor mounting bolts and drive belts.

Check dryer-collector unit (humidity, fill level); replace, if necessary.

Check evaporator unit; clean it, if necessary.

Check electrical lines for chafe marks; check plug connections for proper fixture.

Perform function test of overpressure switch.

Check cooling performance.

Change dryer-collector unit every 12 months; also check cooling circuit for leakage and change coolant and refrigeration oil.

Every 12 months, employ a refrigeration technician to perform a function test of the ventilation flaps and the defrost thermostat.

UNDERCARRIAGE + UPPERCARRIAGE + ATTACHMENT Lubricate bearings, using the central lubrication system. Exception: machines with fully automatic central lubrication system (special equipment) Lubricate bearing points (undercarriage and attachments) (lubricate daily when required, based on type of work and/or shift operation).

Inspect teeth for visible wear.

250

Check parts for cracks.

250

Check counterweight and tank for proper fixture.

Check lines and fittings for proper fixture.

Check panelling hinges, quick fasteners and gas pressure springs of hoods.

Instruct all operators in the proper use of the machine.

Instruct the operator on how the machine must be lubricated according to the lubrication chart and make him/her aware of potential operator errors and their consequences.

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Maintenance

Operating manual

Inspection and maintenance schedule

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT R 934 C Litronic, type 1440 by maintenance personnel (machine owner) Initial interval Repeat interval Annually, at the start of the cold season As required

together with authorised specialist technicians Initial interval Repeat interval

HYDRAULIC QUICK-CHANGE ADAPTER Perform function test of visual and acoustic warning devices.

Perform visual inspection of the extended lock bolts.

Check hydraulic hoses and wire harness for damage.

Lubricate lock bolts.

Clean screen filter.

MECHANICAL QUICK-CHANGE ADAPTER Perform visual inspection of the extended lock bolts.

Lubricate lock bolts.

GENERAL Check entire machine to ensure that it is properly maintained and in safe working order.

Explain the machine documentation (in particular the operating manual and safety instructions) to the operating personnel.

1 2 3 4

Replace motor oil more often, if temperatures and the quality of fuels and oils make this seem advisable.

In the case of application under conditions with excessive dust generation, shorten the maintenance intervals.

For environmentally friendly hydraulic fluids, adjust the maintenance interval on the basis of regular analyses.

The maintenance intervals might have to be shortened, depending on the operating conditions (e.g. generation of dust, barrel fuelling).

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R 934 C Litronic / 11692682