Liebherr R 964 C Litronic 448 1008 1009 1126 1145 1278 Hydraulic Excavator Operating Manual SN 22612

en

Operating instructions

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

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

Address

MJFCIFSS

Machine data

Vehicle ident. number:

Construction year:

First start-up date:

MJFCIFSS

Preface

machine operator maintenance personnel

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

Operation

Maintenance Transportation

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

MJFCIFSS

Modifications, conditions, copyright

MJFCIFSS

1

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

2

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

3

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

MJFCIFSS

4

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

MJFCIFSS

5

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

MJFCIFSS

MJFCIFSS

1 Product description 1.1 Assembly - overview

1.1.1

Machine with backhoe attachment

Fig. 1-1

Machine with backhoe attachment

100 310

200 320

340

330

MJFCIFSS

300 330

1-1

1.1.2

Machine with shovel attachment

Fig. 1-2

1.1.3

100

200

400

410

420

430

440

450

460

Uppercarriage

Fig. 1-3

1-2

Machine with shovel attachment

Uppercarriage

MJFCIFSS

500 535

530 540

565

566

700

800

1000

1400

6000 6230

6220 7100

7600 9050

8700 9300

9500

1.1.4

Undercarriage

Fig. 1-4

Undercarriage

205

206

207 209

208 1000

4500 8020

8010

1.2 Technical data

MJFCIFSS

1-3

1.3 Vibration emissions

Hand-arm vibration

Whole-body vibration

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

Typical working cycles

x-axis 1

2

y-axis 3

Tab. 1-1

1-4

MJFCIFSS

1

2

z-axis 3

1

2

3

Ý®¿©´»® Û¨½¿ª¿¬±®

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2 Safety instructions

2.1 Meaning of the symbols in this manual

Danger Caution

Note

Danger!

Caution!

Note!

MJFCIFSS

2-1

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

2.2 Use in accordance with the regulations

2.3 Safety Instructions General safety instructions

2-2

MJFCIFSS

MJFCIFSS

2-3

Avoidance of crushing and burns

Avoidance of fire and explosions

2-4

MJFCIFSS

2.4 Bringing the machine safely into service

Safely getting up

NOTE

MJFCIFSS

2-5

Adjusting the operator’s standing position

Protection from vibration - seat adjusting

Utilisation in confined spaces

Starting the machine safely

Stopping the machine safely

2-6

MJFCIFSS

Safely getting down

Working safely with the machine

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

MJFCIFSS

2-7

2-8

MJFCIFSS

Safe use with a hydraulic hammer

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

MJFCIFSS

2-9

Safe use of machines with tower elevation

2 - 10

MJFCIFSS

(Caution! swinging grab)

Protection from vibration

MJFCIFSS

2 - 11

Attaching and removing equipment parts safely

Removing and installing equipment bolts safely

2 - 12

MJFCIFSS

Transporting the machine safely

2.5 Servicing the machine safely General safety instructions

MJFCIFSS

2 - 13

Cleaning

2 - 14

MJFCIFSS

Crack testing

MJFCIFSS

2 - 15

Welding, drilling, firing and grinding work

Process materials

Repair work

2 - 16

MJFCIFSS

Electrical system

MJFCIFSS

2 - 17

Hydraulic accumulator

Hydraulic hoses and sheathed cables.

2 - 18

MJFCIFSS

2.6 Signs on the machine 2.6.1

Introduction the safety plates

MJFCIFSS

2 - 19

the information plates the nameplates

Danger! safety plates

2.6.2

Arrangement of signage

Fig. 2-1

2 - 20

Arrangement of signage on the machine

4

15

20 30

22 35

40

45

47

50

MJFCIFSS

52

54

55

56

60

65

71

73

74

75

76 80

77 90

91 101

103

Note !

2.6.3

Explanation of signage Serially installed signage

"mociw"

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

MJFCIFSS

2 - 21

"mociw"

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

Plate 4: Machine nameplate LAM (Liebherr America)

Plate 15: Lubrication chart

Plate 20: Prohibiting sign

Plate 22: Operating symbols

2 - 22

MJFCIFSS

"mociw"

"NA" Plate 30: Lubrication chart, engine

Plate 35: Loading and anchoring points

Plate 40: Lashing point

Plate 45: Stop-lift point

Plate 47: External starting

MJFCIFSS

2 - 23

"mociw"

"NA" Plate 50: Obstruction

Plate 52: Engine-off

Plate 54: Accident prevention

Plate 55: Safety lever

Plate 56: Equipment

2 - 24

MJFCIFSS

"mociw"

"NA" Plate 60: Sound/power level [truck]

*XX

Plate 65: Load chart

Plate 71: Explosion hazard

Plate 73: High voltage hazard

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

Plate 75: Hazard of an impact by moving attachment parts

MJFCIFSS

2 - 25

"mociw"

"NA" Plate 76: Burning hazard due to hot machine parts

Plate 77: Risk of burning due to hot fluids

Plate 80: Safety belt

Plate 90: Prohibition sign - no lifting point

Plate 91: Removal of counter-weight

Signage relating to optional equipments "mociw"

"NA" Plate 101: Crushing hazard

Plate 103: Hazard of thrown out objects

2 - 26

MJFCIFSS

2.6.4

Nameplates on the machine

Fig. 2-2

Important nameplates on the machine

1 2

4 5

3

6

MJFCIFSS

2 - 27

2 - 28

MJFCIFSS

3 Control and operation 3.1 Operating and control elements 3.1.1

Controls in the operator’s cab

A3

E8

H1

H10

P5 S1

S2

S5L

S5R or unlocking of cylinder cut-off (NA

S5M

or travel alarm on/off (NA) S6L or rotating device left (NA)

S6M

S6R or rotating device right (A)

S7

S42

S55

S57 or lifting magnet (NA)

S71

S72

S73 S84-1

S84-2

S99 S218

S248

U20

U21

U22

U23

U24

U26

U27

U38

*

MJFCIFSS

3-1

(NA)

This location only for North America

Fig. 3-1

3-2

Controls in the cab

MJFCIFSS

3.1.2

The joysticks Control of the working movements

Fig. 3-2

Joystick right (3) and left (4)

Standard control system according to ISO 4 4 4

a c

b d

3

e

f

3

g

h

3

Special control systems Note !

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

S 247 H 292

MJFCIFSS

3-3

Push buttons and switches in the joysticks

Fig. 3-3

Arrangement of push buttons and switches in the control levers

Button -Switch

Function

Push button S5L

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

Push button S5M

Horn

Push button S5R

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

Push button S6L

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

Push button S6M

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

Push button S6R

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

Push switch S55

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

Rocker switch S57

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

Tab. 3-1

Functions of push buttons and switches in standard execution

Caution!

3-4

MJFCIFSS

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

Button -Switch

Function

Push button S5L

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

Push button S5M

Horn

Push button S5R

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

Push button S6L

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

Push button S6M

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

Push button S6R

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

Push switch S55

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

Rocker switch S57

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

Tab. 3-2

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

MJFCIFSS

3-5

3.1.3

Control unit

Fig. 3-4 M

3-6

Excavator control unit

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

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

MJFCIFSS

S10

Working floodlights

S11

Windshield washer

S14

Windshield wiper

S17

Preselection of swing brake operating mode

MJFCIFSS

3-7

S18

Overload warning device (optional equipment)

S19

Rotating device (optional equipment)

S20

Engine low idle automatic

Adjustment of the time lag for low idle automatic

3-8

MJFCIFSS

S21

Travel speed increase

S22

Auxiliary floodlights (optional equipment)

S36

No function

S41

Rotating beacon (optional equipment)

S56

Working pressure increase (optional equipment)

S85

No function

MJFCIFSS

3-9

S86

Operating mode preselection

L F E P

P4

3 - 10

Engine RPM indicator

S228

Engine RPM increase

S229

Engine RPM decrease

S354

No function

MJFCIFSS

3.1.4

Monitoring display

Fig. 3-5

Monitoring display

A B

H24 P2

C D

P2.1 P3

H2

P3.1

H12

S349

H19

S350

H20 H23

S351 S352

MJFCIFSS

3 - 11

Area A : Display of analog-values P2

Diesel engine coolant temperature gauge

P2.1

P2 E 503

E 523

P3 – Fuel level display

P3.1

3 - 12

MJFCIFSS

Area B :Indicator lights H2 – Indicator light, low engine oil pressure

E 501

E 522

H12

Indicator light, battery charge

H19 – No function

H20 – No function

H23 – No function

H24 – No function

MJFCIFSS

3 - 13

Area D : Menu control keys

Fig. 3-6

Menu control keys

S349 Back S350 Down S351 Up S352 Menu

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

Up

Down

To change the brightness of the LCD screen: Back

Up

Down

Note

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

Up

3.1.5

Down

Main screen Menu

3 - 14

MJFCIFSS

Fig. 3-7

Main screen - Division into four fields

EC

SY

INF

TI

Constitution of the main screen SY field

EC field

Up

Down

INF field

MJFCIFSS

3 - 15

TI field

"

Control of the screen at error recognition

Danger!

Back

Warning symbols in the SY field A) Warning symbols for operating faults

3 - 16

MJFCIFSS

E 502 – Low coolant level

Caution!

E 503

Coolant overheat - Warning stage

E 504

Low hydraulic oil level

E 505

Hydraulic oil overheat

E 506

Splitterbox oil overheat

E 511

High voltage of batteries

MJFCIFSS

3 - 17

E 512 – Under voltage for the Diesel control system

E 513 – Over voltage for the Diesel control system

E 516

Safety shut off for EDC default

E 517 – Safety shut off for injector default

E 518 – Safety shut off for starting synchronisation default starting synchronisation

E 519 – Overspeed of Diesel engine - Warning stage

E 520 – Overspeed of Diesel engine - Safety stage

E 521 – Beide Drehzahlgeber des Dieselmotors defekt both engine RPM sensors are simultaneously defective

E 522 – Low engine oil pressure - Safety stage

E 523 – Coolant overheat - Safety stage

E 524 – Boost air overheat - Safety stage

3 - 18

MJFCIFSS

E 525 – Engine in safety mode

E 526 – Fuel overheat - Warning stage

E 527 – Fuel overheat - Safety stage

E 528 – High water level in the fuel filter

E 530 – Centralized symbol - safety limit exceeded

E 532 – Low fuel pressure - Warning stage

E 533 – Low fuel pressure - Safety stage safety

E 534 – High fuel pressure - Warning stage

E 535 – High fuel pressure - Safety stage safety

E 536 – Low fuel pressure in Rail 1 - Warning stage warning E 537 – Low fuel pressure in Rail 1 - Safety stage safety

MJFCIFSS

3 - 19

E 538 – Low fuel pressure in Rail 2 - Warning stage warning E 539 – Low fuel pressure in Rail 2 - Safety stage safety E 597 – Boost air overheat - Warning stage

Tab. 3-3

Warning symbols for operating faults with corresponding error codes

B) Warning symbols for special operating states und system errors

Quick change adapter (optional equipment)

One or several solenoid valves are off in the servo control circuit

Servo control pressure too low

Internal default in Master module (U47)

Internal default in one Slave module

CAN communication default

3 - 20

MJFCIFSS

Tab. 3-4

Warning symbols for special operating sequences and system errors

Information symbols in the INF field Preheating

End of preheating End of preheating Manual Diesel speed adjustment

Service due

Acknowledge error E5xx type error code

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

Servo control operation changed S73

MJFCIFSS

3 - 21

Overload warning device (optional equipment)

No overload warning device recognized S18

Warm up procedure

Working pumps swivelled back to minimum delivery

Diesel engine stop

Current air bleeding procedure

Air bleeding procedure achieved

Pontoon operation

Hydraulic system failure

3 - 22

MJFCIFSS

3.1.6

Information provided in the menus (Software Version V6.0) Menu selection from main screen:

Fig. 3-8

Main screen

Menu

Fig. 3-9

List of menus

To select a menu: Down

Up

Reset daily operating hours Menu Back

Symbol of menu

Denomination of menu

MJFCIFSS

Role of the menu

3 - 23

Symbol of menu

Tab. 3-5

Denomination of menu

Role of the menu

Overview of the possible menus

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

Fig. 3-10

Resetting the daily operating hours counter Up Menu Up

To exit the menu: Back

3 - 24

MJFCIFSS

Down

Menu

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

Fig. 3-11

Menu "Set Service"

Up Menu

Back

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

Caution!

MJFCIFSS

3 - 25

Fig. 3-12

Menu "Set option"

EV1

EV2

EV6

Note!

Up

Down

to select another attachment

Menu

To exit the menu: Back

3 - 26

MJFCIFSS

Fig. 3-13

Main screen, the choosen option is displayed

1

2

Note!

Menu "Info-hours" - operating hours of components, duration of processes, ..

Fig. 3-14

Menu "Info Hours" operating hours of Diesel engine

Menu

MJFCIFSS

3 - 27

Fig. 3-15

Menu "Info Hours" duration of the various movements Menu

Menu

Fig. 3-16

3 - 28

Menu "Info Hours" general machine data

MJFCIFSS

Menu

Fig. 3-17

Menu "Info Hours" Data of the Master modul of the machine

Menu

To exit the menu: Back

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

Fig. 3-18

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

MJFCIFSS

3 - 29

Note!

Menu

Fig. 3-19

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

Menu

3 - 30

MJFCIFSS

Fig. 3-20

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

Fig. 3-21

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

MJFCIFSS

3 - 31

Menu

3 - 32

Fig. 3-22

Menu "Info In/outputs" Currents to the regulation valves on the spools

Fig. 3-23

Menu "Info In/outputs" Currents to the regulation solenoid valves for swing movements and pressureless lowering

MJFCIFSS

Fig. 3-24

Menu "Info In/outputs" Output signals of joysticks and pedals

Fig. 3-25

Menu "Info In/outputs" Presentation of actuated servo control units

To exit the menu: Back

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

Fig. 3-26

Menu "i-errors" Display of the memorized errors

MJFCIFSS

3 - 33

list Exxx list E-elec list S-Exxx Exxx

list

To select the desired error type: Down

Up

Menu Down

Up

"list Exxx": Operating faults

Fig. 3-27

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

Down

Up

Menu

Back Back

Down

Back

3 - 34

MJFCIFSS

Up

Notice!

E 5xx

list Exxx

Back Down

Up

Back

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

Fig. 3-28

List of the electrical errors list E-elec."

Menu

Back Down

Menu

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

Fig. 3-29

List of operating faults appeared in service mode

MJFCIFSS

3 - 35

list S-Exxx Exxx

Menu "set clock" - Time setting

Fig. 3-30

Setting of the clock

UP

DOWN

MENU

Enter

Fig. 3-31

3 - 36

Confirmation of the storage of the new time

MJFCIFSS

list

3.1.7

Controls on side control desks

Fig. 3-32

Switches and control lights on the side control desks

Note:

S41 – Selector switch / Emergency lowering movements

S42

Touch / Emergency lowering of working attachment

Note:

S84-1

Touch / Central lubrication of attachment and swing ring roller races

S84-2

Touch / Central lubrication of swing ring teeth

MJFCIFSS

3 - 37

S218 – Touch / Cab roof window wiper

S248 – Touch / Air bleeding of main control valves

3 - 38

MJFCIFSS

3.1.8

Controls and instrumentation for optional equipments

Fig. 3-33

H90

Controls for optional equipments

Control light / Rotation in opposite direction of reversible fan

MJFCIFSS

3 - 39

H292

Control light / Special control system

S26

Touch / Fuel preheater

S40

Touch / Frequency commutation for hydraulic hammer

S41 – Rotary switch / Emergency lowering of attachment parts

3 - 40

S42

Touch / Emergency lowering of working attachment

S45

Touch / Priority for special equipment

S46

Touch / Lifting magnet operation

S47

Push button / Quick change adapter

S53

Touch / Special control circuit supply

MJFCIFSS

S54

Rotary switch / Unlocking of cylinder end position

S74

Code key switch / Anti-theft protection system

S76

Touch / Travel parking brake

S77

Touch / Pressurized driver's cab

S78 - Push button / Height adjustable cab - emergency down

S79

Touch / Flow divider for special attachment

S84-1

Touch / Central lubrication of attachment and swing ring roller races

S84-2

Touch / Central lubrication of swing ring teeth

S90 Potentiometer / Intermittent mode of the cab roof window wiper

MJFCIFSS

3 - 41

S98

Touch / Low pressure protection for boom cylinders

S104

Touch / Hydraulic width adjustment of undercarriage

S114

Key switch / Control of a special attachments with the joysticks

S121

Touch / Float position of working attachment on pontoon excavator

S122

Touch / Operation of the air compressor

S123 – Rotary switch / Excavator operation - Pontoon operation

3 - 42

S125

Touch / Deactivation of the travel motions

S157

Touch / Flow reduction for special tools

MJFCIFSS

S160

Push button / Control of reversible fan in opposite direction

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

S200 – Rotary switch / Height adjustable cab - up or down

S218

Touch / Cab roof window wiper

S232

Control unit / Standstill cab heater

S247

Key switch / Commutation Normalized control system - Special

control system

S248 – Touch / Air bleeding of main control valves

S275

Touch / Additional floodlight on rear of cab roof

S276

Touch / Additional floodlight on counterweight

MJFCIFSS

3 - 43

S358

3.1.9

Push button / Washer for cab roof window

Display for LIEBHERR particle filter (optional).

A175

Fig. 3-34

Control unit A175

A

B

C

D

E

F

G

A175

Use / monitoring of the particle filter system

3 - 44

MJFCIFSS

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

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

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

Note:

3.2 The access to the cab Safely getting up

NOTE

MJFCIFSS

3 - 45

Safely getting down

3.2.1

Entering or leaving the cab Caution!

Fig. 3-35

3 - 46

Climb up and leave the cab using handrails and steps

MJFCIFSS

Getting in the cab

Fig. 3-36

Cab door outer side

1

2

11

11

1 2

4. .

Getting out the cab Caution!

Fig. 3-37

Cab door inner side

3

4

MJFCIFSS

3 - 47

3 2

4

3.3 The equipment of the cab 3.3.1

The safety lever

Fig. 3-38

Safety lever

Caution !

S17 S17

3 - 48

MJFCIFSS

3.3.2

Operator’s seat

Fig. 3-39

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

1

4b

7

2

5

8

3 4a

6

10

Setting the armrests

Fig. 3-40

Setting the armrests 3

a

3

b

MJFCIFSS

3 - 49

Setting the seat and backrest

Fig. 3-41

Setting the seat and backrest 4a 4b 10

Setting the horizontal seat position

Fig. 3-42

Setting the horizontal 1 2

3 - 50

MJFCIFSS

Setting the seat springs

Fig. 3-43

Setting the seat springs 5

Options setting (optional extras)

Fig. 3-44

Switch bar on the air-cushioned operator’s seat

To set the vibration damping: 5 +

-

To set the lumbar support: 6 +

-

7 +

-

To set the seat heating: 8

MJFCIFSS

3 - 51

Putting on / releasing the safety belt

Fig. 3-45

Safety belt

2

1 3

Danger!

4 1

3.3.3

Windscreen

Fig. 3-46

Locked positions of the windscreen

a b

3 - 52

MJFCIFSS

Caution!

To change the position of the windscreen 1 2 b

3.3.4

a

1

Sunshade

Fig. 3-47

Sunshades at windscreen and at cab roof

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

MJFCIFSS

3 - 53

3.3.5

Emergency exit – rear window

Fig. 3-48

Emergency exit – rear window 2 1

3.3.6

Interior lighting

Fig. 3-49

Dome light for cab interior lighting 1 1 1 1

3.3.7

3 - 54

Fire extinguisher*

MJFCIFSS

2 3

Fig. 3-50

Possible locations for fixing the fire extinguisher

Note!

Caution!

3.3.8

The heater and air conditioner

MJFCIFSS

3 - 55

Control unit of the heating and air conditioning system

Fig. 3-51

Control unit of the airco system

Control keys

Indications at the LCD display

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

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

Note!

F1-F5

3 - 56

MJFCIFSS

Turning the control unit on

Fig. 3-52

Turning the control unit on and setting the cab temperature 4

AUTO

(20)

Setting the desired cab temperature 25 2 3

Manual setting of the heating output

Fig. 3-53

Setting of the heating output and of the fan speed 7

2

3

7

Manual setting of the fan speed

MJFCIFSS

3 - 57

2

3

Air conditioning operation

Fig. 3-54

Air conditioning operation and Reheat-operation 1 15

15 Note!

Reheat-operation

6 14

6

3 - 58

MJFCIFSS

Note!

6

Recirculated air and fresh air operation

Fig. 3-55

Recirculated air and fresh air operation

8

13

13

Note!

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

Air repartition

8a 8b 8c 8d

MJFCIFSS

3 - 59

Fig. 3-56

Air repartition in the cab

heating 8c air conditioner operation 8d 8b 12 Note!

3 - 60

MJFCIFSS

8a 8b 10 11

12 9

Changing the temperature from °Celsius to °Fahrenheit

Fig. 3-57

Switching over °Celsius - °Fahrenheit 8

3.3.9

Additional standstill heater (Option)

Operating the standstill heater Notice!

SH

MJFCIFSS

3 - 61

Fig. 3-58

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

Notice!

The control unit of the standstill heater

3 - 62

MJFCIFSS

Functioning of the additional standstill heater

Operation of the heater using the mini-clock

Setting functions on the mini-Clock Notice!

Setting-up for the first time:

Setting the current time:

MJFCIFSS

3 - 63

Note!

Setting the heating time:

Setting the preset times:

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

Turning off the heater:

3 - 64

MJFCIFSS

Continuous operation:

Activating / deactivating the preset time:

3.4 Setting the machine into operation 3.4.1

Safety instructions for the starting of the machine Bringing the machine safely into service

Starting the machine safely

MJFCIFSS

3 - 65

Stopping the machine safely

3.4.2

Before starting the machine General information Note!

Activities before starting Caution!

Caution!

3 - 66

MJFCIFSS

3.4.3

Turning on the electrical system Positions of the ignition key

Fig. 3-59 0 1

Ignition switch 2 3

P

Switching on the electrical system

1 1

Note!

MJFCIFSS

3 - 67

S22

Display of the term of the next service work

Fig. 3-60

3.4.4

Display of the term of upcoming maintenance works

Starting the Diesel engine Note !

0

Starting procedure 3

Starting procedure for low temperatures

Preheating ON

3 - 68

MJFCIFSS

1

Preheating END

1 Preheating ON Preheating END 3

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

3.4.5

Speed adjustment and operating modes

Fig. 3-61

Speed adjustment and operating modes selection P4 S86

- orS228

S229

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

MJFCIFSS

3 - 69

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

Fig. 3-62

S229.

Engine speed adjustment via the arrow keys S228 and S229

S86

3 - 70

MJFCIFSS

Absenken der Drehzahl über die Funktion Leerlaufautomatik S20,

3.4.6

Notes after starting the engine Danger!

Caution!

3.4.7

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

P2 Note !

Hydraulic oil

MJFCIFSS

3 - 71

Note !

3.4.8

Switching the Diesel engine off Caution

S229 P4

Emergency stop of the Diesel engine (Option)

Caution!

S2-1

3 - 72

MJFCIFSS

S34

Fig. 3-63

Emergency off switches on keyboard and on uppercarriage structure

Danger!

Diesel engine stop with after running (Option)

S229 P4 0"

MJFCIFSS

3 - 73

Notice !

3.4.9

Starting aids Fuel preheating S26 (optional extra)

S26

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

Fig. 3-64

3 - 74

Coolant / motor oil / hydraulic oil preheating

1

5

2

6

MJFCIFSS

3

7

4

8

8 4 1 5 2 6 3 8

3.4.10

Jump start procedure Danger!

Connecting the batteries

Caution!

Disconnecting the batteries

MJFCIFSS

3 - 75

3.4.11

Anti-theft device with code key (option)

Fig. 3-65

Electronic anti-theft device 1

3.4.12

Immobilizer with electronic ignition key (option) System description

Activation of the immobilizer

3 - 76

S74

MJFCIFSS

Note!

Deactivation of the immobilizer

Note!

Master key and operation keys

Fig. 3-66

Ignition switch with immobilizer via electronic operation keys

5

6

Imprinting procedure of an operation key

MJFCIFSS

3 - 77

Note!

Deleting imprinted operating keys

Note!

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

Operation security

Function security

3.5 Working with the machine Working safely with the machine

3 - 78

MJFCIFSS

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

MJFCIFSS

3 - 79

Safe use with a hydraulic hammer

3 - 80

MJFCIFSS

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

MJFCIFSS

3 - 81

Safe use of machines with tower elevation

(Caution! swinging grab)

Protection from vibration

3 - 82

MJFCIFSS

3.5.1

The travel movements Straight travel

Fig. 3-67

Straight travel

MJFCIFSS

3 - 83

1 2

5 6

Caution!

1 2 Travelling forwards: 5a Travelling backwards: 5b Caution!

Turning over one track

Fig. 3-68

Turning over one track

Turning right: 5

5a

Turning left: 6 Notice!

3 - 84

MJFCIFSS

6a

6b

6a

Counter rotation

Fig. 3-69

Counter rotation

Turning right: 5

5a 6

6b

Turning left: 6

6a 5

5b

Danger!

Levers for manual control of travel movements

Fig. 3-70

Levers for manual travelling control

MJFCIFSS

3 - 85

Travel speed preselection travel in normal speed travel in increased speed S21

3.5.1.1

1

S21

1

S21

The travel brakes

The hydraulic operating brakes 6

Caution!

3 - 86

MJFCIFSS

Fig. 3-71

Arrangement of mechanical brakes 5 and hydraulic brake valves 6

The mechanical stop and parking brake 5

Limit of gradeability Danger!

Note!

MJFCIFSS

3 - 87

Travelling up

Fig. 3-72

Travelling up

Travelling down

Fig. 3-73

3.5.2

Travelling down

Drive warning device (optional extra)

Fig. 3-74

Drive warning device 5

3 - 88

6

MJFCIFSS

Deactivating the drive warning device: S6R

3

S5R

4

Caution!

S6R

Note!

3.5.3

The uppercarriage swing movements 4

Fig. 3-75

Rotating the uppercarriage

Caution! normal control, according to ISO-standards

4

c d

Braking the uppercarriage The hydraulic swing brake

MJFCIFSS

3 - 89

4

4 The mechanical swing brake

S17

S17

S57 S57

S57,

Note!

Caution!

Ermergency stop of the uppercarriage swing motion

Caution

To check the mechanical swing gear brake:

S17

3 - 90

MJFCIFSS

4

The positioning swing brake (option)

Fig. 3-76

Positioning swing brake pedal

Note!

10

3.5.4

Working position

Fig. 3-77

Working position of the machine

MJFCIFSS

3 - 91

Note!

3.5.5

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

Control of the stick cylinder 4

Fig. 3-78

Stick cylinder control 4

(a) 4

(b)

Control of the boom cylinders 3

3 - 92

MJFCIFSS

Fig. 3-79

Boom cylinders control 3

(g) 3

(h)

Float position of the boom with shovel attachment

3 S6M

Fig. 3-80

h.

3

Float position of the boom cylinders with a shovel attachment

Note!

3

MJFCIFSS

3 - 93

Control of the bucket or grapple cylinders 3

Fig. 3-81

Operation of the bucket or grapple cylinders 3 3

e f

Danger Never allow anybody to guide the grapple by hand!

Combined movements

3.5.6

Lowering the working attachment with the engine shut down

Note

3 - 94

MJFCIFSS

Fig. 3-82

Lowering the attachment with shut down engine 1

3.5.7

Control of a rotating device

Fig. 3-83

Rotating device activation (S19) and control (S5L/S5R)

S19

S5L

MJFCIFSS

3 - 95

Fig. 3-84

Movement of rotating devices S5R

S5L S5R Caution!

3 - 96

MJFCIFSS

3.5.8

Lifting magnet control system (optional equipment)

S46 S46

S228 S229

S86

S20

S6L

Fig. 3-85

Lifting magnet control system

Danger!

S6L S6L

S6L

Caution!

4

S55 S6L S55 S55

MJFCIFSS

3 - 97

3.5.9

3 - 98

Control of special equipments via the additional pedals

Fig. 3-86

Special equipments controlled by the additional pedals

Fig. 3-87

Disposition of the additional pedals

MJFCIFSS

Danger!

Caution!

Notice!

Control of the hydraulic hammer

m

Fig. 3-88

Control of a hydraulic hammer

MJFCIFSS

3 - 99

Note!

Control of a bottom dump shovel n p

Fig. 3-89

Control of the flap of a bottom dump shovel

Control of the other special equipments

m

k

3 - 100

MJFCIFSS

3.5.10

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

e

f

3.

Fig. 3-90

Commutation of the control for an AHS add on kit user

Danger!

Caution!

!

S114 S114

joystick

S114 S114

MJFCIFSS

foot pedal

3 - 101

S114

3.5.11

Special control system of the joysticks (Option)

S247

Fig. 3-91

Example for a special control system

Danger!

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

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

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

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

S247 H292

3 - 102

MJFCIFSS

Fig. 3-92

Instruction plate A and warning plate B

Caution!

3.5.12

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

MJFCIFSS

3 - 103

Danger!

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

Caution!

Danger!

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

Note!

Adjustment of the cut off point Prerequesite:

3 - 104

MJFCIFSS

Fig. 3-93

Cut off position of an industrial stick

Setting

Fig. 3-94

Setting of the proximity switch

MJFCIFSS

3 - 105

Note !

Unlocking of movements cut off

Fig. 3-95

Switch for the unlocking of attachment movements cut off S54

Danger!

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

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

Note!

3 - 106

MJFCIFSS

3.5.13

Use of the excavator for lifting loads overhead

Danger!

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

an overload warning device (optional extra)

a boom lowering control device

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

Danger!

MJFCIFSS

3 - 107

3.5.14

Overload warning device (Option) General

Note!

Using the overload warning device Danger!

Mode of operation

3 - 108

MJFCIFSS

Starting the overload warning device Danger!

S18

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

Caution!

Deactivation of the overload warning device Note!

S18

3.5.15

Height adjustable cab (Option)

MJFCIFSS

3 - 109

Fig. 3-96

Driver’s cab adjustable in height - in inclination

Danger!

Instruction for repair works and maintenance Danger!

Adjustment of the cab height / inclination Rotary switch / Height adjustable cab

S200

Raising the driver’s cab: S200 S200

3 - 110

MJFCIFSS

Lowering the driver’s cab: S200 S200

Emergency lowering of the height adjustable cab

Emergency lowering from inside the cab: S78 S78

Emergency lowering from outside:

Fig. 3-97

Shjutoff valve for emergency lowering

MJFCIFSS

3 - 111

Danger!

Notice!

3.6 Operating the excavator in safety modes 3.6.1

Board E52 for safety mode of Diesel engine & servo control

Fig. 3-98

Control board for safety operation E52

E52

S71

H11

S72

H60

S73

Starting the Diesel engine in safety mode

3 - 112

MJFCIFSS

H11 S71a

Safety operation of the Diesel engine

Notice !

Caution!

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

Diesel engine RPM adjustment in safety mode

MJFCIFSS

3 - 113

Fig. 3-99

Emergency control of the engine RPM S72 S72

Notice !

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

Safety operation of the servo control circuits

Fig. 3-100 Safety mode of servo circuits - Safety switch and symbols at the display

S73

3 - 114

MJFCIFSS

Danger!

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

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

Note !

3.6.2

Safety operation of the main working pumps

Fig. 3-101 Switching the main pumps in safety operation

1

Y50

2 3

MJFCIFSS

3 - 115

3.6.3

Emergency attachment lowering with defective servo circuit

Fig. 3-102 Emergency lowering of the attachment

Preselection of emergency lowering movements (Option)

Hinweis

Position of preselection switch S41

3 - 116

Induced movement for emergency lowering Demolition attachment

MJFCIFSS

Industrial attachment

3.6.4

Emergency supply of the boom cylinders (optional)

Caution!

MJFCIFSS

3 - 117

Fig. 3-103 Device for emergency supply of the boom cylinders To connect an external pressure source:

Note !

To raise the working attachment:

To lower the working attachment:

3 - 118

MJFCIFSS

After ending the attachment movement with the external pressure source:

3.6.5

Towing with the machine, emergency towing of the machine

Towing and lashing hooks and eyes on the undercarriage

MJFCIFSS

3 - 119

3 4 5

Caution!

Danger!

Emergency towing of the excavator

3

3 - 120

MJFCIFSS

2

Fig. 3-104 Fastening of the pulling device around the swing ring support Notice!

Fig. 3-105 Releasing the travel brakes 6

7

8

MJFCIFSS

3 - 121

Notice!

6

7 8

3.7 Removal and installation of attachment parts Attaching and removing equipment parts safely

Removing and installing equipment bolts safely

3 - 122

MJFCIFSS

3.7.1

Removal and installation of a bucket

Fig. 3-106 Removing and installing the bucket 1

222

2

232

3-4

25

5-6 7

25.1 25.2 25.3

MJFCIFSS

3 - 123

To remove a bucket

5 3

6 4

25 4

To reinstall a new bucket

A 4

25 25 25.1

4

6 7 B

3

25 25 25.1

3

5 3

4

Note!

222

3.7.2

3 - 124

232

Attaching and dismounting the bucket with improved sea-

MJFCIFSS

ling

Fig. 3-107 Attaching and dismounting the bucket 1 2

7 8

1.1

9

2.1

222

3-4 5-6

232

MJFCIFSS

3 - 125

Dismounting a bucket

5

6 8

9

1.1 3

4 4 9

Attaching a new bucket 1 9

1.1 7

A 4

6 7 B

3 2.1

5 9 D

1.1 8 3

4

Note!

222

3 - 126

MJFCIFSS

232

3.7.3

Attaching and dismounting the grab on stick

Fig. 3-108 Attaching and dismounting the grab on the stick 1

11

4

12

6

13

7

14

8

15

9

25

10

MJFCIFSS

3 - 127

Danger!

Attaching the grab

7

9

8

10

1 4 4

25 6 11

12 13

14

Operating the grab

15 A B 15

B

Note

15 4

3 - 128

MJFCIFSS

B

Dismounting the grab

15

A

11

12

A

13

14

6

3.7.4

4

25 4

Attaching and dismounting the grab on the industrial stan-

MJFCIFSS

3 - 129

chion

Fig. 3-109 Attaching and dismounting the grab on the industrial stanchion

Danger!

Attaching the grab

1 4

6 11

3 - 130

MJFCIFSS

12

13

14

Operating the grab

Dismounting the grab

11

12

13

14

6

4

MJFCIFSS

3 - 131

3.7.5

Attaching and dismounting the stick to the boom

Fig. 3-110 Attaching and dismounting the stick to the boom 7 16

20 21

17 18

222

Dismounting the stick Figure A

7

3 - 132

MJFCIFSS

16 17 16

17

Figure B then

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

18 20

20

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

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

20 20 and

20

17 21

18

Figure A 16

17

MJFCIFSS

3 - 133

Note 222

3.7.6

Mechanical quick-change adapter (optional extra) Safety information

Overview

Fig. 3-111 1

3 - 134

3

MJFCIFSS

5

2

4

6

Attaching the work tool To move the equipment into position:

Fig. 3-112 Positioning the equipment

To unlock the quick-change adapter: Danger!

2

3 3

1 1

1 Taking up the work tool:

Fig. 3-113 Taking up the work tool

MJFCIFSS

3 - 135

To lock the quick-change adapter:

Fig. 3-114 Locking the quick-change adapter Danger!

3

1

1 2 Danger!

4 2 2

Caution!

3 - 136

MJFCIFSS

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

To unlock the quick-change adapter:

Fig. 3-115 Unlocking the quick-change adapter Danger!

2

3 3

1 1

1 To put down the work tool:

Fig. 3-116 Putting down the work tool

MJFCIFSS

3 - 137

Using the quick-change adapter for hoisting work

Fig. 3-117 Mechanical quick-change adapter

Danger!

6

3.7.7

Hydraulic quick-change adapter (optional extra) Safety information

3 - 138

MJFCIFSS

Overview

Fig. 3-118 Hydraulic quick-change adapter 1

5

MJFCIFSS

6

3 - 139

Operating elements

Fig. 3-119 Operating elements for the hydraulic quick-change adapter

Switch S19 S19

Key switch S47

Pushbuttons L and R L R

Fig. 3-120 Pushbutton on the joystick E

3 - 140

F

MJFCIFSS

Symbol "Quick change adapter"

Two-hand operation S47

L

R

L

R

S47 S47

L

R

Caution !

S47

Attaching the work tool To move the equipment into position:

Fig. 3-121 Positioning the equipment

To unlock the quick-change adapter: S19

S47 R

MJFCIFSS

3 - 141

Taking up the work tool:

Fig. 3-122 Taking up the work tool

To lock the quick-change adapter: S19

S47 L

S47 S19

Caution!

3 - 142

MJFCIFSS

Danger!

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

To unlock the quick-change adapter: Danger!

S19

S47 R

MJFCIFSS

3 - 143

To put down the work tool:

Fig. 3-123 Putting down the work tool

Using the quick-change adapter for lifting work

Fig. 3-124 Hydraulic quick-change adapter

Danger!

6

S19 S47

3 - 144

MJFCIFSS

To cancel the buzzer (warning tone)

S349

3.7.8

LIKUFIX – hydraulic coupling system (optional extra)

Overview

Fig. 3-125 LIKUFIX 1

4

2

5

3

MJFCIFSS

3 - 145

Attaching and dismounting work tools

Fig. 3-126 Connecting LIKUFIX

1 2 3

1

4

2

Attaching LIKUFIX work tools to a quick-change adapter wi-

3 - 146

MJFCIFSS

thout LIKUFIX

Fig. 3-127 LIKUFIX work tool on quick-change adapter without LIKUFIX Caution!

6

4 5

3.8 General working methods 3.8.1

Minimum impact working methods for your machine

MJFCIFSS

3 - 147

3.8.2

Preparatory activities Danger!

Fig. 3-128 Working position – machine

Danger! not

Fig. 3-129 Safe working

3 - 148

MJFCIFSS

Danger! r

Caution!

3.8.3

Using a backhoe bucket Danger!

Fig. 3-130 Aligning the stick and backhoe bucket

Fig. 3-131 Taking up grab material

MJFCIFSS

3 - 149

Fig. 3-132 Raising grab material

3.8.4

Loading a transport vehicle Danger!

Fig. 3-133 Emptying grab material

3 - 150

MJFCIFSS

3.8.5

Skimming

Fig. 3-134 Skimming

Danger!

Caution!

MJFCIFSS

3 - 151

3.8.6

Using a clamshell bucket (earthmoving attachment) Danger!

Fig. 3-135 Straightening the stick

Fig. 3-136 Closing the grab shells

3 - 152

MJFCIFSS

Danger!

Fig. 3-137 Raising grab material

Fig. 3-138 Emptying grab material

MJFCIFSS

3 - 153

3.8.7

Using a multiple tine grapple (industrial attachment)

Fig. 3-139 Taking up the load

Fig. 3-140 Transporting a load

Caution!

3 - 154

MJFCIFSS

3.8.8

Using an hydraulic hammer

Danger!

Fig. 3-141 Hydraulic hammer

MJFCIFSS

3 - 155

Fig. 3-142 Permissible A and not permissible B work areas of the machine with hydraulic hammer Danger!

A

3.9 Installing & removing the serial counterweight Safety recommandations for installation and removal of the counterweight Danger!

Suspension of the counterweight

3 - 156

MJFCIFSS

Fig. 3-143 Lifting points of the counterweight - Lifting forces 2

3

4

6

Caution!

Machine modell - counterweight

MJFCIFSS

Force F [kN]

Force T [kN]

3 - 157

Machine modell - counterweight

Force F [kN]

Removal of the counterweight

3

Installation of the counterweight

Danger!

3

Caution!

3.10 Transport Transporting the machine safely

3 - 158

MJFCIFSS

Force T [kN]

3.10.1

Transporting the excavator on flatbed trailers Caution

MJFCIFSS

3 - 159

Loading the machine onto the trailer Bringing the machine onto the trailer:

Fig. 3-144 Entering the flatbed trailer under the machine

Note

Danger!

To secure the machine on the flatbed trailer:

Danger!

3 - 160

MJFCIFSS

Fig. 3-145 To secure the machine using the stowage ears of the undercarriage

Note

Transport route Danger!

3.10.2

Loading the machine with a crane

MJFCIFSS

3 - 161

Danger!

Loading the complete basic machine

Fig. 3-146 Loading the machine with removed attachment and counterweight Removing the machine components:

3 - 162

MJFCIFSS

Caution!

6

Fig. 3-147 disconnection of quick couplings

Caution!

MJFCIFSS

3 - 163

Caution!

Attaching the liftling tools:

On machines R964 and R974

On machines R954

Fig. 3-148 Installing the lifting tools Hooking the machine to the lifting crane:

3 - 164

MJFCIFSS

Note

Machine modell

Fr (kN)

Ff (kN)

L (mm)

Lifting tool Order Nb

Note

Danger!

Loading the machine

Danger!

MJFCIFSS

3 - 165

Securing the machine on the transport vehicle:

Fig. 3-149 Securing the machine (without sideframes) on the trailer Danger!

Unloading and reassembling the machine after transport:

3 - 166

MJFCIFSS

Note

MJFCIFSS

3 - 167

3 - 168

MJFCIFSS

4 Malfunctions Warning messages and fault messages:

Identifying and rectifying faults and errors:

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

Fig. 4-1

LIEBHERR service

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

MJFCIFSS

4-1

4.1 Error code charts Danger!

4.1.1 Error code

Effect

Electrical errors in the engine control system (PLD-CR) Cause

Measure / remedy

S71

S72

S71

S72

Y50

Y50

4-2

MJFCIFSS

Error code

Effect

Cause

Measure / remedy S71

S72

S71

S72

S71

S72

Y50

Y50

Y50

MJFCIFSS

4-3

Error code

4-4

Effect

Cause

MJFCIFSS

Measure / remedy

Error code

Effect

Cause

Measure / remedy

Possible starting difficulties at low ambient temperatures

Left heater flange R51-1 is defective

Check, if necessary replace the heater flange R51-1 .

Possible starting difficulties at low ambient temperatures

Right heater flange R52-1 is defective

Check, if necessary replace the heater flange R52-1 .

4.1.2 Error code

System errors in the electrical servo control circuit

Effect

Cause

Measure / remedy

Possibly incorrect function of the travel pedals U22/U23

The sensors B40/B45 are active, even though the pedals U22/U23 are not actuated .

Travel pedals U22/U23 wrong adjusted or defective

Check the pedals U22/U23 for proper function, if necessary readjust or replace pedals.

Possibly incorrect function of the pressureless lowering

Short circuit to ground or to +24V in the load circuit of Y401

Check, if necessary repair the commutation solenoid valve Y401 and its connecting circuit

Possibly incorrect function of the servo control for additional movement

Short circuit to ground or to +24V in the load circuit of the commutation solenoid valve

Check, if necessary repair the commutation solenoid valve for additional movement and its connecting circuit

Possibly incorrect function of the servo control for additional movement

Short circuit to ground or to +24V in the load circuit

Check, if necessary repair the load circuit

Possibly incorrect function of the servo control circuit

Short circuit to ground or to +24V in the load circuit of the commutation solenoid valve Y 369A

Check, if necessary repair the commutation solenoid valve Y369A and its connecting circuit

Possibly incorrect function of the servo control circuit

Short circuit to ground or to +24V in the load circuit of the commutation solenoid valve Y 370B

Check, if necessary repair the commutation solenoid valve Y370B and its connecting circuit

Possibly incorrect function of the servo control for additional movement

Short circuit to ground or to +24V in the load circuit

Check, if necessary repair the load circuit

Possibly incorrect function of the pressureless lowering

Short circuit to ground or to +24V in the load circuit Y109

Check, if necessary repair the commutation solenoid valve Y109 and its connecting circuit

Possibly incorrect function of the servo control for swing left

Short circuit to ground or to +24V in the load circuit Y150

Check, if necessary repair the commutation solenoid valve Y150 and its connecting circuit

Possibly incorrect function of the servo control for swing right

Short circuit to ground or to +24V in the load circuit Y151

Check, if necessary repair the commutation solenoid valve Y151 and its connecting circuit

MJFCIFSS

4-5

Error code

Effect

Cause

Measure / remedy

No or incorrect function of the servo control

Missing 24V supply of the servo control plate U46/D

Check 24V supply circuit, r(epair as necessary (Fuse F153, connectors X830-1 & X830-3, .)

Possibly incorrect function of the servo control for lowering boom.

Possibly incorrect function of the servo control for lifting boom.

Possibly incorrect function of the servo control for bucket tilting out.

Possibly incorrect function of the servo control for bucket tilting in.

Possibly incorrect function of the servo control for travelling left backwards.

Possibly incorrect function of the servo control for travelling left foreward.

Possibly incorrect function of the servo control for retracting or extending stick.

Possibly incorrect function of the servo control for extending or retracting stick.

No or incorrect function of the servo control

Possibly incorrect function of the servo control for travelling foreward.

Possibly incorrect function of the servo control for lifting boom.

4-6

Short circuit to ground or to +24V in the load circuit Yr1-A1 Broken wire in the load circuit to regulation solenoid valve Yr1-A1 Short circuit to ground or to +24V in the load circuit Yr1-B1 Broken wire in the load circuit to regulation solenoid valve Yr1-B1 Short circuit to ground or to +24V in the load circuit Yr1-A2 Broken wire in the load circuit to regulation solenoid valve Yr1-A2 Short circuit to ground or to +24V in the load circuit Yr1-B2 Broken wire in the load circuit to regulation solenoid valve Yr1-B2 Short circuit to ground or to +24V in the load circuit Yr1-A3 Broken wire in the load circuit to regulation solenoid valve Yr1-A3 Short circuit to ground or to +24V in the load circuit Yr1-B3 Broken wire in the load circuit to regulation solenoid valve Yr1-B3 Short circuit to ground or to +24V in the load circuit Yr1-A4 Broken wire in the load circuit to regulation solenoid valve Yr1-A4 Short circuit to ground or to +24V in the load circuit Yr1-B4

Check, if necessary repair the regulation solenoid valve Yr1-A1 and its connecting circuit Check, if necessary repair the regulation solenoid valve Yr1-B1 and its connecting circuit Check, if necessary repair the regulation solenoid valve Yr1-A2 and its connecting circuit Check, if necessary repair the regulation solenoid valve Yr1-B2 and its connecting circuit Check, if necessary repair the regulation solenoid valve Yr1-A3 and its connecting circuit Check, if necessary repair the regulation solenoid valve Yr1-B3 and its connecting circuit Check, if necessary repair the regulation solenoid valve Yr1-A4 and its connecting circuit

Broken wire in the load circuit to regulation solenoid valve Yr1-B4

Check, if necessary repair the regulation solenoid valve Yr1-B4 and its connecting circuit

Missing 24V supply of the servo control plate U48-1/A , connector X840-3

Check 24V supply circuit, r(epair as necessary (Fuse F151, connector X840-3, .)

Short circuit to ground or to +24V in the load circuit Yr1-A5 Broken wire in the load circuit to regulation solenoid valve Yr1-A5 Short circuit to ground or to +24V in the load circuit Yr1-B5 Broken wire in the load circuit to regulation solenoid valve Yr1-B5

MJFCIFSS

Check, if necessary repair the regulation solenoid valve Yr1-A5 and its connecting circuit Check, if necessary repair the regulation solenoid valve Yr1-B5 and its connecting circuit

Error code

Effect

Cause

Possibly incorrect function of the servo control for travelling right backw. (R964 C) or bucket tilting out (R974 C).

Short circuit to ground or to +24V in the load circuit Yr1-A6

Possibly incorrect function of the servo control for travelling right foreward (R964 C) or bucket tilting in (R974 C).

Short circuit to ground or to +24V in the load circuit Yr1-B6

Possibly incorrect function of the servo control for travelling right backw. (R974 C) or bucket tilting out (R964 C).

Short circuit to ground or to +24V in the load circuit Yr1-A7

Possibly incorrect function of the servo control for travelling right foreward (R974 C) or bucket tilting in (R964 C).

Short circuit to ground or to +24V in the load circuit Yr1-B7

Possibly incorrect function of the servo control for retracting stick (only R974C)

Broken wire in the load circuit to regulation solenoid valve Yr1-A6

Broken wire in load circuit to regulation solenoid valve Yr1-B6

Broken wire in load circuit to regulation solenoid valve Yr1-A7

Broken wire in load circuit to regulation solenoid valve Yr1-B7 Short circuit to ground or to +24V in the load circuit Yr1-A8 Broken wire in load circuit to regulation solenoid valve Yr1-A8 Short circuit to ground or to +24V in the load circuit Yr1-B8

Possibly incorrect function of the servo control for extending stick (only R974C) No or incorrect function of the servo control

Possibly incorrect function of the servo control for shovel flap opening. (only R964C) Possibly incorrect function of the servo control for shovel flap closing (only R964C)

Check, if necessary repair the regulation solenoid valve Yr1-A6 and its connecting circuit Check, if necessary repair the regulation solenoid valve Yr1-B6 and its connecting circuit Check, if necessary repair the regulation solenoid valve Yr1-A7 and its connecting circuit Check, if necessary repair the regulation solenoid valve Yr1-B7 and its connecting circuit Check, if necessary repair the regulation solenoid valve Yr1-A8 and its connecting circuit

Broken wire in load circuit to regulation solenoid valve Yr1-B8

Check, if necessary repair the regulation solenoid valve Yr1-B8 and its connecting circuit

Missing 24V supply of the servo control plate U48-1/A , connector X840-1

Check 24V supply circuit, r(epair as necessary (Fuse F151, connector X840-1, .)

Short circuit to ground or to +24V in the load circuit Yr2-A2 Broken wire in load circuit to regulation solenoid valve Yr2-A2 Short circuit to ground or to +24V in the load circuit Yr2-B2 Broken wire in load circuit to regulation solenoid valve Yr2-B2

Possibly incorrect function of the servo control for shovel stick retraction (R964C) or shovel flap opening (R974C)

Short circuit to ground or to +24V in the load circuit Yr2-A1

Possibly incorrect function of the servo control for shovel stick extension (R964C) or shovel flap closing (R974C)

Short circuit to ground or to +24V in the load circuit Yr2-B1

Possibly incorrect function of the servo control for extension of additional cylinder

Measure / remedy

Broken wire in load circuit to regulation solenoid valve Yr2-A1

Broken wire in load circuit to regulation solenoid valve Yr2-B1 Short circuit to ground or to +24V in the load circuit Yr3-B1 Broken wire in load circuit to regulation solenoid valve Yr3-B1

MJFCIFSS

Check, if necessary repair the regulation solenoid valve Yr2-A2 and its connecting circuit Check, if necessary repair the regulation solenoid valve Yr2-B2 and its connecting circuit Check, if necessary repair the regulation solenoid valve Yr2-A1 and its connecting circuit Check, if necessary repair the regulation solenoid valve Yr2-B1 and its connecting circuit Check, if necessary repair the regulation solenoid valve Yr3-B1 and its connecting circuit

4-7

Error code

Effect

Cause

Possibly incorrect function of the servo control for retraction of additional cylinder Possibly incorrect function of the servo control for swing left

Possibly incorrect function of the servo control for swing right No or incorrect function of the servo control

Possibly incorrect function of the servo control for pressureless lowering Possibly incorrect function of the servo control for additional movement No or incorrect function of the servo control

4.1.3 Error code

Effect

Short circuit to ground or to +24V in the load circuit Yr3-A1 Broken wire in load circuit to regulation solenoid valve Yr3-A1 Short circuit to ground or to +24V in the load circuit Yr150 Broken wire in load circuit to regulation solenoid valve Yr150 Short circuit to ground or to +24V in the load circuit Yr151

Measure / remedy Check, if necessary repair the regulation solenoid valve Yr3-A1 and its connecting circuit Check, if necessary repair the regulation solenoid valve Yr150 and its connecting circuit

Broken wire in load circuit to regulation solenoid valve Yr151

Check, if necessary repair the regulation solenoid valve Yr151 and its connecting circuit

Missing 24V supply of the servo control plate U48-2/A , connector X850-3

Check 24V supply circuit, r(epair as necessary (Fuse F152, connector X850-3, .)

Short circuit to ground or to +24V in the load circuit Yr401 Broken wire in load circuit to regulation solenoid valve Yr401 Short circuit to ground or to +24V in the load circuit Broken wire in load circuit to regulation solenoid valve Missing 24V supply of the servo control plate U48-2/A , connector X850-1

Check, if necessary repair the regulation solenoid valve Yr401 and its connecting circuit Check, if necessary repair the regulation solenoid valve for additional movement and its connecting circuit Check 24V supply circuit, r(epair as necessary (Fuse F152, connector X850-1, .)

Communication and coding errors Cause

Measure / remedy

S71 S72 Y50

S73

S71 S72 Y50

4-8

MJFCIFSS

Error code

Effect

Cause

Measure / remedy

S71 S72 Y50

Possibly incorrect function of the servo control circuit

Internal default of servo control plate U47

Consult LIEBHERR customer service.

Possibly incorrect function of the servo control circuit

Internal default of servo control plate U48-1

Consult LIEBHERR customer service.

Possibly incorrect function of the servo control circuit

Internal default of servo control plate U48-2

Consult LIEBHERR customer service.

Possibly incorrect function of the servo control circuit

Internal default of servo control plate U46

Consult LIEBHERR customer service.

Possibly incorrect function of the travel pedals U22/U23

Pedals U22/U23 actuated, even though B40/B45 not active Travel pedals U22/U23 wrong adjusted or defective

Check the pedals U22/U23 for proper function, if necessary readjust or replace pedals.

E 328

No or incorrect function of the electrical servo control system

No communication with the U101 coding unit

Consult LIEBHERR customer service.

E 329

No or incorrect function of the electrical servo control system

Incorrect CAN-Bus connection (Timeout) between control unit and servo control plate U47

Consult LIEBHERR customer service.

E 330

No or incorrect function of the electrical servo control system

Incorrect CAN-Bus connection between CAN 3-1 and CAN 3-2

Consult LIEBHERR customer service.

E 331

No or incorrect function of the electrical servo control system

Incorrect CAN-Bus connection between CAN 4-1 and CAN 4-2

Consult LIEBHERR customer service.

E 332

No or incorrect function of the electrical servo control system

Incorrect CAN-Bus connection between CAN 5-1 and CAN 5-2

Consult LIEBHERR customer service.

E 333

No or incorrect function of the electrical servo control system

Defective Bus CAN 3

Consult LIEBHERR customer service.

E 334

No or incorrect function of the electrical servo control system

Defective Bus CAN 4

Consult LIEBHERR customer service.

E 335

No or incorrect function of the electrical servo control system

Defective Bus CAN 5

Consult LIEBHERR customer service.

E 337

No or incorrect function of the electrical servo control system

Incorrect CAN-Bus connection between servo control plate U47 and left joystick

Consult LIEBHERR customer service.

E 340

No or incorrect function of the electrical servo control system

Incorrect CAN-Bus connection between servo control plate U47 and right joystick

Consult LIEBHERR customer service.

MJFCIFSS

4-9

Error code

E 355

Effect

Cause

Measure / remedy

No or incorrect function of the electrical servo control system

Incorrect CAN-Bus connection between servo control plate U47 and left travel pedal U22

Consult LIEBHERR customer service.

No or incorrect function of the electrical servo control system

Incorrect CAN-Bus connection between servo control plate U47 and right travel pedal U23

Consult LIEBHERR customer service.

No or incorrect function of the electrical servo control system

Incorrect CAN-Bus connection between servo control plate U47 and pedal for special attachments U24

Consult LIEBHERR customer service.

No or incorrect function of the electrical servo control system

Unknown excavator coding in coding unit U101

Consult LIEBHERR customer service.

No or incorrect function of the electrical servo control system

Incorrect CAN-Bus communication between control plate U47 and U481

Consult LIEBHERR customer service.

No or incorrect function of the electrical servo control system

Incorrect CAN-Bus communication between control plate U47 and U482

Consult LIEBHERR customer service.

No or incorrect function of the electrical servo control system

Incorrect CAN-Bus communication between control plate U47 and U46

Consult LIEBHERR customer service.

4.1.4

Error code

Effect

Other electrical errors (general switches and transmitter circuits, ...)

Cause

Measure / remedy

S71 S72 Y50

S71 S72 Y50

4 - 10

MJFCIFSS

Error code

Effect

Cause

Possibly incorrect function of the left joystick U20 in X-axis.

Possibly incorrect function of the left joystick U20 in Y-axis.

Possibly incorrect function of the right joystick U21 in X-axis.

Possibly incorrect function of the right joystick U21 in Y-axis.

Incorrect neutral position of left joystick U20 (in X-axis) is recognized Broken wire or short circuit in circuit to U20 (X-axis) Incorrect neutral position of left joystick U20 (in Y-axis) is recognized Broken wire or short circuit in circuit to U20 (X-axis) Incorrect neutral position of right joystick U21 (in X-axis) is recognized Broken wire or short circuit in circuit to U20 (X-axis) Incorrect neutral position of right joystick U21 (in Y-axis) is recognized Broken wire or short circuit in circuit to U20 (X-axis) Incorrect neutral position of the left travel pedal U22 is recognized

Possibly incorrect function of the servo control for travel left.

Defective wire - connection to the left travel pedal U22 Incorrect neutral position of the right travel pedal U23 is recognized

Possibly incorrect function of the servo control for travel right.

Defective wire - connection to the right travel pedal U23

Possibly incorrect function of the servo control for additional movement (AHS 11) .

Incorrect neutral position of the pedal 1 in the double pedal U24 is recognized Defective wire - connection to the pedal 1 in the double pedal U24

MJFCIFSS

Measure / remedy

Check, if necessary repair the left joystick U20 and its connecting circuit Check, if necessary repair the left joystick U20 and its connecting circuit Check, if necessary repair the right joystick U21 and its connecting circuit Check, if necessary repair the right joystick U21 and its connecting circuit Check, if necessary repair the left travel pedal U22 and its connecting circuit Check, if necessary repair the right travel pedal U23 and its connecting circuit Check, if necessary repair the left double pedal U24 and its connecting circuit

4 - 11

Error code

Effect

Cause

Possibly incorrect function of the servo control for additional movement (AHS 11) .

Possibly incorrect function of the servo control for additional movement (AHS 12) .

Possibly incorrect function of the servo control for additional movement (AHS 12) .

Incorrect neutral position of the pedal 2 in the double pedal U24 is recognized Defective wire - connection to the pedal 2 in the double pedal U24 Incorrect neutral position of the pedal 1 in the double pedal U27 is recognized Defective wire - connection to the pedal 1 in the double pedal U27 Incorrect neutral position of the pedal 2 in the double pedal U27 is recognized Defective wire - connection to the pedal 2 in the double pedal U27

Check, if necessary repair the left double pedal U24 and its connecting circuit

Check, if necessary repair the right double pedal U27 and its connecting circuit

Check, if necessary repair the right double pedal U27 and its connecting circuit

Automatic idling on left joystick does not function, i.e. the engine remains at low speed.

Short circuit + 24 V

Possibly incorrect function of the servo control for swing brake

Defective wire - connection to the pedal for swing brake U26

Check, if necessary repair the swing brake pedal U26 and its connecting circuit

Automatic idling on right joystick does not function, i.e. the engine remains at low speed.

Short circuit + 24 V Short circuit to earth or cable break

Deactivate automatic idling S20, consult LIEBHERR customer service.

Possibly incorrect commutation for the variable flow travel motors

Defective wire - connection to the pressure transmitter B 144

Check, if necessary repair the connecting wire to the press. switch

Possibly incorrect function of the servo control for swing brake.

Incorrect neutral position of the pedal for swing brake U26 is recognized

Check, if necessary repair the swing brake pedal U26 and its connecting circuit

Possibly incorrect commutation for the pressureless lowering function

Defective wire - connection to the pressure transmitter B 145

Check, if necessary repair the connecting wire to the press. switch

Possibly incorrect commutation for the pressureless lowering of crowd cylinder on shovel attachment

Defective wire - connection to the pressure transmitter B 167

Check, if necessary repair the connecting wire to the press. switch

Defective wire - connection to the pressure transmitter B 141

No action required - B141 is actually only a reserve

Defective wire - connection to the pressure transmitter B 149

No action required - B149 is actually only a reserve

Swing motor RPM no longer recorded

Short circuit + 24 V

Consult LIEBHERR customer service.

Incorrect fuel gauge.

Short circuit + 24 V

Short circuit to earth or cable break

Short circuit to earth or cable break Short circuit to earth or cable break Connection default for plate ESP01

4.1.5

4 - 12

Measure / remedy

Deactivate automatic idling S20, consult LIEBHERR customer service.

Check fuel level visually, consult LIEBHERR customer service.

Consult LIEBHERR customer service.

Operation errors (also displayed as warning symbols in field SY)

MJFCIFSS

Error code

Effect

Cause

Measure / remedy

-

MJFCIFSS

4 - 13

Error code

Effect

Cause

Measure / remedy

4.2 Faults and remedies 4.2.1 Fault / error

4 - 14

Diesel engine and fuel system Cause

MJFCIFSS

Solution

Fault / error

Cause

Solution

Note!

4.2.2 Fault / error

Hydraulic system Cause

Solution

Note!

MJFCIFSS

4 - 15

Fault / error

Cause

4.2.3 Fault / error

Fault / error

4 - 16

Transmission Cause

4.2.4

Solution

Solution

Electrical system Cause

MJFCIFSS

Solution

Fault / error

Cause

4.2.5 Fault / error

Solution

Work equipment Cause

MJFCIFSS

Solution

4 - 17

4.2.6 Fault / error

Heating/air-conditioning system Cause

Solution

Error code “F0“ faulty room temperature gauge:

Cause of gauge error:

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

Cause of gauge error:

Error code “F2“ faulty reserve temperature gauge:

Cause of gauge error:

4 - 18

MJFCIFSS

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

Cause of flap fault:

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

Cause of flap fault:

Error code “F5“ faulty data transmission operating feature / control unit: Cause of the fault:

4.3 LIEBHERR particles filter system

LCD display message

LED

Cause

Remedy

"Themo element 1 (or 2) is defective"

E

"ERROR idling / Temp. ignition block active"

E

"Error interrupt. Terminal W"

E

"Pre-loading pressure achieved"

MJFCIFSS

4 - 19

LCD display message

LED

Cause

Remedy

"Main load pressure achieved."

E

"Filter breakage or pressure line clogged"

E

"Call service"

E

4 - 20

MJFCIFSS

4.4 Fuses and relays 4.4.1

Electrical power box E50 with main fuses

Fig. 4-2

Electrical power box E50

MJFCIFSS

4 - 21

F19 F19-2 F20 F31 F37 F50 F109 F110 F115 F116 F117 F122 F123 F130 F131 F132 F150 F151 F152 F153 K56 K127 K128 K222 K288 K302 K302-2

4.4.2

Control plate A1010 with fuses

Danger

4 - 22

MJFCIFSS

Fig. 4-3

Control plate A1010 with fuses and Relays Fuses on terminal 15 (Kl15)

F1 F2 F3 F4

F5 F6 F7 F8

F9

MJFCIFSS

4 - 23

Fuses on terminal 30 (Kl30) F10 F11 F12 F13 F14 F15 Relays on printplate A1010 K5 K6 K7 K8

4 - 24

MJFCIFSS

5 Maintenance 5.1 Servicing the machine safely General safety instructions

MJFCIFSS

5-1

Cleaning

Crack testing

5-2

MJFCIFSS

Welding, drilling, firing and grinding work

Process materials

Repair work

MJFCIFSS

5-3

Electrical system

5-4

MJFCIFSS

Hydraulic accumulator

Hydraulic hoses and sheathed cables.

MJFCIFSS

5-5

5-6

MJFCIFSS

5.2 Maintenance access doors 5.2.1

Overview of access doors

Fig. 5-1

Pos.

Access doors for maintenance on the machine

Denomination / location of the door

Locking device in opened position

Locking device in closed position

Side door right rear

Retaining rod 3

Lock up handle 4

Side door right front

Retaining rod 3

Lock up handle 4

Air filter door

Gas pressure spring 5

Door fixed by screws

Side door left

Retaining rod 3

Door fixed by screws

Engine hood

Mechanical retainer 2 + two gas pressure springs 5

Locking device 6. Access after opening hood 25

Cooler cover

Gas pressure spring 5

Cover fixed by screws

Cover front right

Retaining rod 3

Lock up handle

Cover tool box

Gas pressure spring 5

Lock up handle 4

Tab. 5-1

MJFCIFSS

5-7

Pos.

Denomination / location of the door

Locking device in opened position

Locking device in closed position

Hood left rear

Gas pressure spring 5

Locking device 6. Access after opening door 13

Tab. 5-1

4 32

5.2.2

Door retaining rods

Caution!

Fig. 5-2

5-8

Door retaining rod

MJFCIFSS

33

5.2.3

Opening, closing, locking the engine hood 21

Fig. 5-3

Locking of engine hood in opened and closed position 1

21

13

7

25

25 6

21

Caution!

5

5 21 2

21

2

To close the engine hood 21: 21 21

2 6

1

MJFCIFSS

5-9

5.3 Lubricants and operating fluids 5.3.1

General information on changing lubricants and operating fluids Note

Note!

Note!

Danger!

0

5 - 10

MJFCIFSS

5.3.2

Lubrication chart

Fig. 5-4

Lubrication chart - R 964 C-Litronic

MJFCIFSS

5 - 11

Symbols on the lubrication chart Symbol

5.3.3 Designation

Medium

Meaning

Symbol

Meaning

Lubricants chart Symbol

Classification

Viscosity

ISO VG 46 (32-68) ISO VG 46 (32-68)

Quantities* Liter / (USgal)

In whole hydraulic circuit

For oil change Mercedes Benz specificat. 226.0 & 227.0

Mercedes Benz specifications 227.5, 228.1 & 228.3

Tab. 5-2

5 - 12

MJFCIFSS

Designation

Medium

Symbol

Classification

Viscosity

Quantities* Liter / (USgal)

Tab. 5-2 Tab. 5-3

5.3.4 Designation

Lubricants chart

Operating material chart Medium

Symbol

MJFCIFSS

Quantities* Liter / (USgal)

5 - 13

Designation

Medium

Tab. 5-4

Symbol

Quantities* Liter / (USgal)

Operating material chart

5.4 Lubricants and operating fluids specification 5.4.1

Diesel fuel Specifications

Sulphur content of diesel fuel

5 - 14

MJFCIFSS

Note!

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

Diesel fuels for operation at low temperatures (winter)

Caution!

5.4.2

Diesel fuels with the LIEBHERR Particles filter Caution!

5.4.3

Lubricating oil for the Diesel engine

Classification

Tab. 5-5

Specification

Lubricating oil for the Diesel engine - specifications

MJFCIFSS

5 - 15

Caution !

Viscosity

Fig. 5-5

Temperature-based selection of the SAE class

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

Liebherr Motoroil 5W-30

Lubricating oil change intervals

adverse factors

5 - 16

MJFCIFSS

Operating conditions

Tab. 5-6

5.4.4

Oil change interval dependent on oil quality:

Oil change intervals for the Diesel engine

Coolant for the diesel engine

General recommandations

Note!

Water quality

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

MJFCIFSS

5 - 17

Contents

Tab. 5-7

Quantity

Fresh water quality

Fresh water quality when using coolant with DCA 4 Contents

Tab. 5-8

Quantity

Fresh water quality with use of DCA 4

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

Mixing ratio

°C

Water %

°F

Tab. 5-9

Mixture ratio (for all seasons)

Fig. 5-6

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

A

5 - 18

A%

MJFCIFSS

Permitted corrosion inhibitors / antifreeze agent Note!

Product description

MJFCIFSS

Manufacturer

Country

5 - 19

Permitted premixed coolants Note!

Product description

Manufacturer

Country

Permitted corrosion inhibitors without antifreeze agent exceptional circumstances above freezing points

ambient temperatures that are always

DCA 4 Caltex / Chevron / Havoline / Total

Note!

Product description

5 - 20

MJFCIFSS

Manufacturer

Country

Product description

5.4.5

Manufacturer

Country

Hydraulic liquids

Hydraulic oil

Fig. 5-7

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

A B C

Engine oil

MJFCIFSS

5 - 21

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

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

Fig. 5-8

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

A B

1 2

C

Warm-up instruction B C B 1.

2.

1

5 - 22

MJFCIFSS

Biodegradable hydraulic oils Note!

Liebherr Hydraulic Plus

Liebherr Hydraulic Plus Arctic

Fully saturated synthetic ester-based oils, HEES

Monitoring, filter change and oil change Note!

Biodegradable hydraulic oils

mineral oils .

Symbol

Signification

MJFCIFSS

5 - 23

Tab. 5-11 Key to figures

Hydraulic oil in normal use

Fig. 5-9

Oil sampling and filters change in normal use

Hydraulic oil used in dust intensive applications

Fig. 5-10

5 - 24

Taking oil samples and changing return filters in heavy dust environments

MJFCIFSS

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

Note!

5.4.6

Lubricating grease and other lubricants Lubricant

Description / manufacturer KP2k

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

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

MJFCIFSS

5 - 25

Lubricant

Description / manufacturer

Tab. 5-12 Lubricating grease and other lubricants

5.5 Diesel engine

Danger !

5.5.1

Checking the oil level in the Diesel engine Danger!

5 - 26

MJFCIFSS

Fig. 5-11

Oil dipstick 1 and oil filler neck 2 1

min

5.5.2

max

1

Replacing the engine oil and the engine oil filter elements Note!

To drain the oil:

Fig. 5-12

Arrangement of the oil filter units

MJFCIFSS

5 - 27

11

Fig. 5-13

12

Drain valve on the engine oil

Replacing the oil filter elements: Danger!

14

11 14

Fig. 5-14

Replacing the oil filter elements 14 15

5 - 28

MJFCIFSS

11

15

14

11

14 12

13 14

11

11

14

Refilling the Diesel engine with oil: 2

min

max

1 2

11

5.5.3

Polyvee belt for the airco compressor and alternator drive

MJFCIFSS

5 - 29

Fig. 5-15

Replacing the belt

To replace the belt:

5.5.4

5 - 30

Lubricating the starter ring gear

MJFCIFSS

Fig. 5-16

Starter ring gear

1

2

3

1

2

1 2

Note!

2

3

1

MJFCIFSS

5 - 31

5.5.5

Checking mounting bolts

Fig. 5-17

Pos.

Mounting bolts

Mounting screw

2 3 7

5 - 32

MJFCIFSS

tightening torque in N.m (ft.lbs)

5.5.6

Oil separator

Fig. 5-18

Replacing the oil separator

To replace the oil separator:

1

2 3 4 6 5

3 1

5.5.7

2

1

Heater flanges

MJFCIFSS

5 - 33

Fig. 5-19

5.5.8

Heater flanges

Checking and adjustment of valve clearance Preparation

Note !

Fig. 5-20

5 - 34

Arrangement of cylinders, intake and exhaust valves

MJFCIFSS

Sequence of valve clearance adjustments - 8 cylinders V-engine D9508

Tab. 5-13 Correpondence between overlapping valves and valves to be adjusted

Checking and adjusting the valve clearance

Fig. 5-21

Checking and adjusting intake valve clearance

Fig. 5-22

Checking and adjusting exhaust valve clearance

MJFCIFSS

5 - 35

5.6 Cooling system 5.6.1

Checking and cleaning the cooling system

Fig. 5-23

Filler cap and pressure relief valve of the cooling system

7

5.6.2

Checking the coolant level Danger!

6

7

5

6 6

5 - 36

MJFCIFSS

6

6

Fig. 5-24

Coolant filler cap 6 and pressure relief valve 7

5.6.3

Coolant antifreeze and anti-corrosion fluid

5.6.4

Changing the coolant Danger!

MJFCIFSS

5 - 37

Fig. 5-25

Shutoff valves for cab heating circuit

Note!

Draining the coolant

To drain the coolant at the Diesel engine: 1 1

5 - 38

Fig. 5-26

Coolant draining valve and screw on engine front side

Fig. 5-27

Coolant draining valves on engine rear side

MJFCIFSS

2 2 4 1 3 1 2

4

To drain the coolant at the cooler:

Fig. 5-28

Coolant draining valve on watercooler 5 5

5.

Refilling the coolant and bleeding the coolant circuit 6 6

It is not possible to overfill the coolant system when the pressure relief valve 7 is installed!

6

Caution!

MJFCIFSS

5 - 39

5.7 Fuel system Danger!

5.7.1

Refuelling Fuel filler cap

Fig. 5-29

Fuel filler cap 15 20

5 - 40

MJFCIFSS

Electrical refuelling pump (optional extra)

Fig. 5-30

Electrical refuelling pump

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

B

S25

S59 Caution!

2

A 1 1

Filling a tank fitted with quick refuelling coupling (option)

MJFCIFSS

5 - 41

Fig. 5-31

Fuel tank equiped with quick refuelling coupling

Caution!

2 2 3 2 2

5 - 42

MJFCIFSS

5.7.2

Draining the fuel tank

Fig. 5-32

Fuel tank

To daily drain the fuel tank and the fuel system:

36

36

Note!

P3 P3.1

5.7.3

Emptying and cleaning the fuel tank 36

MJFCIFSS

5 - 43

36 36 15 36 20 20

5.7.4

Draining the fuel prefilter

Fig. 5-33

Drain valve at fuel prefilter

The water separator of the fuel pre-filter must be drained on a daily basis and, if necessary, each time the symbol E528 appears at the display of the machine:

1

3

1

5.7.5

Replacing the fuel filter elements Danger !

5 - 44

MJFCIFSS

Replacing the fuel prefilter element

Fig. 5-34

Replacing the fuel prefilter element

Replacing the fuel fine filter elements

Fig. 5-35

Running plate at the top of Diesel engine

MJFCIFSS

5 - 45

Fig. 5-36

Fuel draining pipe - fine filter assembly

Fig. 5-37

Fuel fine filter - Replacement of filter elements 1

1

3 3

1 3

2 Caution!

5 - 46

MJFCIFSS

1

3 3

1

1

5.7.6

Bleeding the fuel system

Note !

Bleeding the fuel prefilter:

Fig. 5-38

Bleeding the fuel prefilter

1

2 1 2 1 2

MJFCIFSS

5 - 47

Bleeding the low pressure fuel system:

Fig. 5-39

Fuel return pipe

2

2

Note !

5.8 Dry air filter

3

5 - 48

MJFCIFSS

4

Fig. 5-40

Dry air filter 12 19 20 21

9 10 11

22

9 10 3 11

MJFCIFSS

9

5 - 49

5.8.1

Changing the main element Caution!

3

3 2

Fig. 5-41

Changing the filter elements

1 2

6 7

3

8

4

9 1

3 2 3

1

5 - 50

MJFCIFSS

5.8.2

Changing the safety element Note!

4

3

4

3 4 2 2 Caution!

4 3 2

5.8.3

1

Checking the intake air lines

20) 21

MJFCIFSS

22

5 - 51

5.9 LIEBHERR particles filter (In option)

Fig. 5-42

5.9.1

Water separator

Drain the condensation water: 203 203

5.9.2

Water separator maintenance: 201 105 Notice!

103

5 - 52

MJFCIFSS

101 to 104 130 101 to 104 105 201

202

5.10 Hydraulic system

Note!

5.10.1

Depressurizing the hydraulic system

Danger!

To relieve pressure in the high pressure circuits

To relieve pressure the servo oil circuits

To depressurize the hydraulic tank 1

maximum

MJFCIFSS

5 - 53

1

Fig. 5-43

2

Depressurizing the hydraulic tank

Note!

2 1 Danger!

5.10.2

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

Fig. 5-44

5 - 54

Machine position for checking the oil level in the hydraulic tank

MJFCIFSS

Checking the oil level in the hydraulic tank

Fig. 5-45

Hydraulic tank oil level

MAXI MINI MINI

MJFCIFSS

5 - 55

Emptying and refilling the hydraulic tank

Fig. 5-46

Draining and refilling the hydraulic oil

1

2

3

4

5 7

6 8

9 R

10 Rl

To drain the oil:

1 2

9 5

6 R

8

Rl

To refill the hydraulic oil: 1 2

5 - 56

MJFCIFSS

9

1 2 7 2 Caution!

To drain off condensation water

5 Note!

5.10.3

Checking and cleaning the oil cooler system

Fig. 5-47

Oil cooler

11 13

12 14

15

16

MJFCIFSS

5 - 57

5.10.4

Return filter

Fig. 5-48

Return filter

1 2

5 6

3 4

9 10 4 5

Note

To clean a magnetic rod and replace a filter element:

6

2 4 5

5 - 58

MJFCIFSS

4

Caution!

5 3 6 1

5.10.5

Servofilter 11

Fig. 5-49

1

Control oil unit with servo-filter

1

12

2 10

13 14

11

15

Note!

12 14 To replace the filter element:

14

11

12

14 14 13

1

15 12

MJFCIFSS

2

5 - 59

14

5.10.6

1/4

Replenishing oil filter in swing circuit

Fig. 5-50

Replenishing oil filter of swing circuit

2

7

3

10 2

3

10

2 2 7 2

5.10.7

Servo control circuit

Danger!

10

5 - 60

MJFCIFSS

3

10

5.10.8

Air bleeding of the servo control chambers

Notice!

Fig. 5-51

5.10.9

Air bleeding of servo control chambers

Bleeding the hydraulic pumps

MJFCIFSS

5 - 61

Note!

Fig. 5-52

Hydraulic pumps)

1 3

2 4

5

6

3

1 1

4

2 2 6

5 5

5.10.10

5 - 62

Bleeding the hydraulic cylinders

MJFCIFSS

Fig. 5-53

Hydraulic cylinder bleeding

2

3 2

Procedure 1 2 on 3

3 2

Procedure 2

The incorrect bleeding can cause the appearance of gas bubbles (mixture of air and hydrocarbon) which could explode due to the high pressure in the cylinder (Diesel effect).

MJFCIFSS

5 - 63

5.10.11

Removing the suction hose to the pumps

Fig. 5-54

Shut off valves and suction hoses to the hydraulic pumps

1

2

3

4

a b

b 1

a

5 - 64

MJFCIFSS

5.10.12

Breather filter on the hydraulic tank

Fig. 5-55

Hydraulic tank breather filter

1

2

Note!

2 1

5.10.13

High pressure filters in working circuit

Fig. 5-56

High pressure filters

MJFCIFSS

5 - 65

To clean a filter element :

1 4, 2 1

3, 4

4

5

6

Note!

1

5.10.14

3

Bypass oil filter for hydraulic system (Special equipment)

Note!

Fig. 5-57

Bypass oil filter for hydraulic system

1

5 - 66

2

MJFCIFSS

3

4

1

Checking filter contamination:

Replacing filter element:

2 4

4 3,

5.10.15

2

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

Fig. 5-58

Piston rod mount

Note

MJFCIFSS

5 - 67

Protecting the piston rods

Fig. 5-59

5.10.16

Replacing hydraulic hoses

Fig. 5-60

5 - 68

Machine with piston rods drawn in

High pressure hose with SAE fitting

MJFCIFSS

Danger!

Size of screw 4

Torque value in Nm - Quality 10.9 Half flanges 5a

Flat flange 5b

Conical flange 5c

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

Torque value in Nm - Quality 8.8 Half flanges 5a

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

5.11 Oil changes on components 5.11.1

General information

MJFCIFSS

5 - 69

5.11.2

Swing gear - Oil level check and oil change

Fig. 5-61

Checking oil level and changing oil in swing gear

1 2

3 4

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

3

4 3 To add the oil: Max. 2

5 - 70

MJFCIFSS

5.11.3

Travel gear oil change

Fig. 5-62

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

To drain the oil:

1 2

To add the oil: 2 1 1 Note!

MJFCIFSS

5 - 71

5.11.4

Splitterbox - Oil change

Fig. 5-63

Changing the oil in the splitterbox

4

5

6

7

To check the oil level: 5

To drain the oil: 4 6

7

6 7 To add the oil: 4 5 4

5.12 The track components

5 - 72

MJFCIFSS

5.12.1

Checking the mounting screws of the track components

Fig. 5-64

Track components mounting screws

7 1560 Nm (1150 ft.lbs) 2100 Nm (1550 ft.lbs) 8 960 Nm (710 ft.lbs) 1120 Nm (830 ft.lbs) 9 960 Nm (710 ft.lbs) 1120 Nm (830 ft.lbs) 10 960 Nm (710 ft.lbs)

5.12.2

Checking the track chains tension

MJFCIFSS

5 - 73

Fig. 5-65

Track unsufficiently (A) and properly (B) tightened

Fig. 5-66

Monitoring the track tension

1 A

20 to 30 mm 15 to 20 mm Note!

5 - 74

MJFCIFSS

5.12.3

Retensioning the track

Fig. 5-67

Retensioning the track 6 2

1 2

3

4

1

5.12.4

2

6

Releasing the track chain tension Danger!

5

3

MJFCIFSS

5 - 75

Danger!

3

3 27 mm 3.2 3

5.12.5

Cleaning the track components Before working

Caution!

At the end of a workday

5 - 76

3.1 3.2

MJFCIFSS

Fig. 5-68

Raising the machine on one side

Danger!

5.13 Electrical system 5.13.1

Notes on the electrical system Danger!

Danger!

MJFCIFSS

5 - 77

5.13.2

Main battery switch Caution!

Fig. 5-69

Main battery switch 0

Note!

0

5.13.3

Battery care A

5 - 78

MJFCIFSS

Danger!

B

Fig. 5-70

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

5.13.4

Slip ring assembly (optional extra)

Fig. 5-71

Slip ring assembly

MJFCIFSS

5 - 79

1 2

1 1

2

5.14 Heating/air-conditioning system

5.14.1

Recirculated and fresh air filters

Fig. 5-72

Recirculated air filter

Fig. 5-73

Fresh air filter

1

3

6 To clean and change the recirculated and fresh air filters:

5 - 80

MJFCIFSS

1 2 1 4 3 Note!

1

5.14.2

3

Heating system

Fig. 5-74

Heating unit with solenoid valve

To vent the heating system: A

To clean solenoid valve 5: 5

To check the heat exchanger: 6

MJFCIFSS

5 - 81

5.14.3

Air-conditioning system

Fig. 5-75 2

A/C compressor and condensor 7

To check the condensor: 2 2

To check the A/C compressor: 7

5 - 82

MJFCIFSS

Fig. 5-76

Dryer-accumulator unit

To check the dryer-accumulator unit: 10

9

Note!

11

9 12

9 9 9 9

9

Fig. 5-77

Fan motor on the heating/air-conditioning device

Additional maintenance work:

MJFCIFSS

5 - 83

13

14 B44

9

5.15 Greasing the machine 5.15.1

The centralized lubrication system

Construction and operation of the centralized lubrication system.

Fig. 5-78

Lubrication plants of the centralized lube system

U4-1 U4-2 U4 13

14

16

15

U4-1 2

5 - 84

MJFCIFSS

3 4 5

U4-2

Fig. 5-79

Centralized lubrication system

2

3

4

5

9 14

13 15

16

26

B51-1

B52-1

U4-1

U4-2

LP

Lube points connected to the lubrication plant U4-1:

Lube points connected to the lubrication plant U4-2:

MJFCIFSS

5 - 85

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

Notice!

5.15.2

Operation of the full automatic system Function of the automatic lubrication plants S84-1 17

B51

5 - 86

MJFCIFSS

16

16

S84-2

Fig. 5-80

Full automatic lubrication system

4 13

14

16 18

17 19

26 CD

B51 NS

S84

U4

Starting an additional lubrication procedure U4-1 S84-1

U4-2

S84-2

19

Monitoring of the automatic lubrication system U4-1 S84-1

S84-2

B51 18

U4-2 17

17 S84

26 B51 13 14

MJFCIFSS

5 - 87

Adjustments at the lubrication plants and grease consumption CD NS Lubrication plant U4-1

Lubrication plant U4-2

5.15.3

Emergency lubrication with defective lubrication system 15 25 U4-1 25 U4-2 25

5 - 88

MJFCIFSS

Fig. 5-81

Emergency lubrication

15

25

Caution!

5.15.4

To refill a grease container 13

Caution!

21 Note!

13

23 15

MJFCIFSS

5 - 89

Fig. 5-82

Refilling the grease container

13

15

21 23

22 31 31

Note!

31

U4-2

21 13

31 13

5.15.5

5 - 90

Changes in the lubrication circuit

MJFCIFSS

22

Fig. 5-83

5.15.6

Main and secondary distributor

Greasing the grab (optional extra)

Fig. 5-84

Greasing the grab

MJFCIFSS

5 - 91

5.16 Quick-change systems 5.16.1

Greasing the mechanical quick-change adapter (optional extra)

Fig. 5-85

Greasing the mechanical quick-change adapter

Note!

5.16.2

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

Fig. 5-86

5 - 92

Greasing the quick-change adapter

MJFCIFSS

1 Note!

Cleaning the sieve filter

Fig. 5-87

Cleaning the sieve filter 12

20

21 10 13 12

12 13

20

5.16.3

11

21

LIKUFIX (optional extra) Cleaning LIKUFIX

MJFCIFSS

5 - 93

Replacing the sealing ring

Fig. 5-88

Replacing the sealing ring A

B C D E F

5.17 Check mounting bolts for tightness

5 - 94

MJFCIFSS

Caution!

Notice :

5.17.1

Mounting bolts of the counterweight

Fig. 5-89

Counterweight mounting bolts 1

5.17.2

Mounting screws of the swing ring

Fig. 5-90

Swing ring mounting bolts

MJFCIFSS

5 - 95

5.17.3

Mounting screws of the hydraulic oil and fuel tank

Fig. 5-91

Hydraulic oil tank and fuel tank mounting bolts 5

5.17.4

Mounting bolts of the swing gear and motor

Fig. 5-92

Swing gear and swing motor mounting bolts 6 7 7

5.17.5

5 - 96

Mounting bolts central piece to side frames (option "removable side frames")

MJFCIFSS

Fig. 5-93

Side frame mounting bolts

5.18 Drive unit brakes and swing gear brakes

5.19 General maintenance points 5.19.1

Replacing working parts

MJFCIFSS

5 - 97

5.19.2

Checking or replacing the teeth on the bucket Note!

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

Fig. 5-94

Replacing the teeth 1

2 A

3

B

2 C

5 - 98

MJFCIFSS

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

1 3

2 4

5

10 5 3 10

3 A

3 2

1

4

To install a new tooth

Note!

3

4

4

1 2

1

3

MJFCIFSS

5 - 99

10 3 3a

4a 5 3

5.19.3

Welding work on the machine

Caution!

Caution!

5 - 100

MJFCIFSS

Note !

MJFCIFSS

5 - 101

5.20 Maintenance chart Caution!

Note

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 964 C By maintenance personnel (machine owner)

By authorized specialist personnel

DIESEL ENGINE AND SPLITTERBOX

Tab. 5-16

5 - 102

MJFCIFSS

Note

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 964 C By maintenance personnel (machine owner)

By authorized specialist personnel

Note

HYDRAULIC SYSTEM

Tab. 5-16

MJFCIFSS

5 - 103

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 964 C By maintenance personnel (machine owner)

By authorized specialist personnel

ELECTRICAL SYSTEM

Tab. 5-16

5 - 104

MJFCIFSS

Note

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 964 C By maintenance personnel (machine owner)

By authorized specialist personnel

Note

SWING GEAR

SWING RING

TRAVEL GEARS

FAHRWERK

CAB AND HEATER

Tab. 5-16

MJFCIFSS

5 - 105

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 964 C By maintenance personnel (machine owner)

By authorized specialist personnel

AIR-CONDITIONING SYSTEM

Tab. 5-16

5 - 106

MJFCIFSS

Note

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 964 C By maintenance personnel (machine owner)

By authorized specialist personnel

Note

HYDRAULIC QUICK-CHANGE ADAPTER

MECHANICAL QUICK-CHANGE ADAPTER

Tab. 5-16 Tab. 5-17 Maintenance chart 1 2 3 4

MJFCIFSS

5 - 107

5 - 108

MJFCIFSS