Liebherr R 984 C Litronic 1224 Machine for Industrial Operating Manual SN 57000 - PDF DOWNLOAD

Machine for Industrial Applications R 984 C Litronic from serial number 57000

ORIGINAL OPERATING MANUAL 11140260 / 2014 R 984 C Litronic from serial number 57000 LHB - Technical documentation department

LIEBHERR Hydraulikbagger GmbH R 984 C Litronic 1224 CE

Liebherr Hydraulikbagger GmbH Liebherr-Straße 12 D - 88457 Kirchdorf / Iller

Operating manual

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

This will also be helpful when ordering spare parts.

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MJFCIFSS

R 984 C Litronic / 11140260

This operating manual has been specifically devised for and . 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.

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: including tooling, troubleshooting during work, general care and cleaning, disposal of fuels and lubricants. including inspection, servicing and repair. 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.

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.

copyright by R 984 C Litronic / 11140260

MJFCIFSS

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.

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.

copyright by

MJFCIFSS

R 984 C Litronic / 11140260

Operating manual

1.1 1.2 1.3

Design and overview ............................................................................................................................. 1-1 Vibration emissions................................................................................................................................ 1-2 Technical data ....................................................................................................................................... 1-3

2.1 2.2 2.3

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........................................................................................................................................ 2-8

2.4

3.1

3.2

3.3

3.4

3.5

Operating and control elements............................................................................................................. 3-1 3.1.1 Overview of operator's platform................................................................................................ 3-1 3.1.2 Keyboard .................................................................................................................................. 3-3 3.1.3 Monitoring display .................................................................................................................... 3-6 3.1.4 Main screen and operator's menu ............................................................................................ 3-8 Control ................................................................................................................................................. 3-20 3.2.1 Entering and exiting machine ................................................................................................. 3-20 3.2.2 Adjusting vertical position of the operator's cab (optional equipment) ................................... 3-22 3.2.3 Emergency lowering of the operator's cab ............................................................................. 3-23 3.2.4 Safety lever ............................................................................................................................ 3-23 3.2.5 Operator seat ......................................................................................................................... 3-24 3.2.6 Sun blind ................................................................................................................................ 3-28 3.2.7 Emergency exit through rear window ..................................................................................... 3-29 3.2.8 Inside lighting ......................................................................................................................... 3-29 3.2.9 Fire extinguisher (optional equipment)*.................................................................................. 3-30 3.2.10 Windscreen wiper ................................................................................................................... 3-30 3.2.11 Lighting................................................................................................................................... 3-32 3.2.12 Heating and air-conditioning system ...................................................................................... 3-33 Operation ............................................................................................................................................. 3-39 3.3.1 Safety instructions .................................................................................................................. 3-39 3.3.2 Starting machine .................................................................................................................... 3-40 3.3.3 Switching off diesel engine..................................................................................................... 3-46 3.3.4 Jump start procedure ............................................................................................................. 3-46 3.3.5 Travel operation ..................................................................................................................... 3-47 3.3.6 Operating instructions for travel gear ..................................................................................... 3-50 3.3.7 Travel alarm system (optional equipment) ............................................................................. 3-51 Working with the machine.................................................................................................................... 3-51 3.4.1 Safety Instructions .................................................................................................................. 3-51 3.4.2 Sensor-controlled low idle automatic...................................................................................... 3-55 3.4.3 Working position ..................................................................................................................... 3-55 3.4.4 Operating working attachment ............................................................................................... 3-56 3.4.5 Swivelling the uppercarriage .................................................................................................. 3-58 3.4.6 Halting the uppercarriage ....................................................................................................... 3-58 3.4.7 Lowering the working attachment when engine is shut off ..................................................... 3-60 3.4.8 Turning, swivelling locking and releasing attachment ............................................................ 3-61 Installation and removal of attachment parts ....................................................................................... 3-62 3.5.1 Safety Instructions .................................................................................................................. 3-62

copyright by R 984 C Litronic / 11140260

Operating manual

3.6

3.7

4.1 4.2

4.3

4.4

4.5

5.1

5.2

5.3 5.4 5.5

5.6

3.5.2 Attachment of grapple to industrial stick ................................................................................. 3-63 3.5.3 Industrial stick with hydraulic quick-change adapter (optional equipment)............................. 3-64 General working methods .................................................................................................................... 3-70 3.6.1 Tips for the proper operation of the machine preventing damage and wear .......................... 3-70 3.6.2 Preparation ............................................................................................................................. 3-72 3.6.3 Working with grapples ............................................................................................................ 3-73 3.6.4 Loading operation ................................................................................................................... 3-73 3.6.5 Load lifting operation .............................................................................................................. 3-74 3.6.6 Overload warning system (optional equipment) ..................................................................... 3-75 3.6.7 Overload warning system (optional equipment) ..................................................................... 3-76 Transport and assembly ...................................................................................................................... 3-77 3.7.1 Procedure ............................................................................................................................... 3-77 3.7.2 Preparation ............................................................................................................................. 3-78 3.7.3 Loading with crane ................................................................................................................. 3-78 3.7.4 Securing the machine for transportation................................................................................. 3-79

Error code list......................................................................................................................................... 4-1 Engine diagnostic system ...................................................................................................................... 4-4 4.2.1 Engine monitoring..................................................................................................................... 4-4 4.2.2 Eliminating fault ........................................................................................................................ 4-5 4.2.3 Viewing error codes .................................................................................................................. 4-5 Troubleshooting ..................................................................................................................................... 4-6 4.3.1 Diesel engine and fuel system.................................................................................................. 4-6 4.3.2 Hydraulic system ...................................................................................................................... 4-7 4.3.3 Travelling .................................................................................................................................. 4-8 4.3.4 Electrical system....................................................................................................................... 4-8 4.3.5 Heating and air conditioning system......................................................................................... 4-9 4.3.6 Working attachment.................................................................................................................. 4-9 Fuses and relays.................................................................................................................................... 4-9 4.4.1 Fuse box E50 ......................................................................................................................... 4-10 4.4.2 A1010 printed circuit board..................................................................................................... 4-11 Emergency operation........................................................................................................................... 4-12 4.5.1 Emergency control.................................................................................................................. 4-12 4.5.2 Emergency operation of the hydraulic pump .......................................................................... 4-14 4.5.3 Towing the machine ............................................................................................................... 4-15

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 Access points for maintenance .............................................................................................................. 5-5 5.2.1 Uppercarriage ........................................................................................................................... 5-5 5.2.2 Bottom side of undercarriage ................................................................................................... 5-7 Cleaning machine .................................................................................................................................. 5-8 Care for rubber components .................................................................................................................. 5-9 Fuels, lubricants and process chemicals ............................................................................................... 5-9 5.5.1 General information .................................................................................................................. 5-9 5.5.2 Filling volumes, lubricating chart ............................................................................................ 5-10 Lubricants and fuels............................................................................................................................. 5-12

copyright by R 984 C Litronic / 11140260

Operating manual

5.7

5.8

5.9

5.10

5.11

5.12

5.13

5.14

5.6.1 Diesel fuels............................................................................................................................. 5-12 5.6.2 Engine oils .............................................................................................................................. 5-13 5.6.3 Coolant ................................................................................................................................... 5-14 5.6.4 Hydraulic oils .......................................................................................................................... 5-15 5.6.5 Axle oil .................................................................................................................................... 5-17 5.6.6 Gear oils ................................................................................................................................. 5-18 5.6.7 Transmission oils.................................................................................................................... 5-19 5.6.8 Pump distributor gear oils....................................................................................................... 5-19 5.6.9 Energy recuperation cylinder oils ........................................................................................... 5-20 5.6.10 Greases.................................................................................................................................. 5-21 5.6.11 Windscreen washer fluid ........................................................................................................ 5-21 5.6.12 Lubricants and care products for electrical and mechanical systems .................................... 5-22 Diesel engine ....................................................................................................................................... 5-22 5.7.1 Checking the oil level ............................................................................................................. 5-22 5.7.2 Changing engine oil................................................................................................................ 5-23 Cooling system .................................................................................................................................... 5-24 5.8.1 Checking and cleaning the cooling system ............................................................................ 5-25 5.8.2 Checking coolant level ........................................................................................................... 5-25 5.8.3 Changing coolant ................................................................................................................... 5-25 5.8.4 Coolant ................................................................................................................................... 5-26 5.8.5 Changing water filter .............................................................................................................. 5-27 Fuel system ......................................................................................................................................... 5-27 5.9.1 Refuelling ............................................................................................................................... 5-27 5.9.2 Fuel tank maintenance ........................................................................................................... 5-28 5.9.3 Fuel filter................................................................................................................................. 5-29 Dry air filter .......................................................................................................................................... 5-30 5.10.1 Checking suction vacuum ...................................................................................................... 5-30 5.10.2 Cleaning pre-filter ................................................................................................................... 5-31 5.10.3 Replacing filter cartridges....................................................................................................... 5-31 5.10.4 Checking the clean air lines ................................................................................................... 5-33 Hydraulic system ................................................................................................................................. 5-34 5.11.1 Check position........................................................................................................................ 5-34 5.11.2 Checking the oil level in the hydraulic tank ............................................................................ 5-35 5.11.3 Depressurising the hydraulic system...................................................................................... 5-35 5.11.4 Changing the breather filter.................................................................................................... 5-36 5.11.5 Emptying and refilling the hydraulic tank ................................................................................ 5-36 5.11.6 Return filter ............................................................................................................................. 5-37 5.11.7 Control oil unit, control circuit ................................................................................................. 5-38 5.11.8 Bleeding the hydraulic pumps ................................................................................................ 5-39 5.11.9 Removing the suction hose .................................................................................................... 5-41 5.11.10 Replacing the feed line filter ................................................................................................... 5-41 5.11.11 High-pressure filter ................................................................................................................. 5-42 5.11.12 Bypass oil filter (optional equipment) ..................................................................................... 5-43 5.11.13 Maintenance of hydraulic cylinders ........................................................................................ 5-45 5.11.14 Replacing hydraulic hoses ..................................................................................................... 5-45 Oil change in components ................................................................................................................... 5-46 5.12.1 General instructions ............................................................................................................... 5-46 5.12.2 Slewing gear mechanism ....................................................................................................... 5-47 5.12.3 Pump distributor gear ............................................................................................................. 5-48 5.12.4 Travel gear ............................................................................................................................. 5-49 Travel gear........................................................................................................................................... 5-49 5.13.1 Cleaning drive gear ................................................................................................................ 5-49 5.13.2 Checking fixtures of components ........................................................................................... 5-50 5.13.3 Checking chain tension .......................................................................................................... 5-51 5.13.4 Tensioning chain .................................................................................................................... 5-51 5.13.5 Releasing chain...................................................................................................................... 5-52 5.13.6 Changing lubrication nipple .................................................................................................... 5-52 Electrical system.................................................................................................................................. 5-53

copyright by R 984 C Litronic / 11140260

Operating manual

5.15

5.16

5.17

5.18

5.19

5.20 5.21

5.22

5.14.1 Notes regarding the electrical system .................................................................................... 5-53 5.14.2 Battery main switch ................................................................................................................ 5-53 5.14.3 Battery care ............................................................................................................................ 5-54 5.14.4 Slip ring body .......................................................................................................................... 5-55 Heating and air-conditioning system.................................................................................................... 5-55 5.15.1 Recirculated and ambient air filter .......................................................................................... 5-55 5.15.2 Heating system ....................................................................................................................... 5-56 5.15.3 air-conditioning system ........................................................................................................... 5-57 Compressed-air system ....................................................................................................................... 5-58 5.16.1 Compressed air accumulator and antifreeze pump ................................................................ 5-58 5.16.2 Compressed air unit of central lubrication system .................................................................. 5-59 Automatic lubrication of the machine ................................................................................................... 5-59 5.17.1 Semi-automatic lubrication system of slewing gear................................................................ 5-59 5.17.2 Automatic central lubrication system ...................................................................................... 5-60 Manual lubrication of the machine ....................................................................................................... 5-63 5.18.1 Attachments (optional equipment) .......................................................................................... 5-64 5.18.2 Industrial stick with hydraulic quick-change adapter............................................................... 5-65 5.18.3 LIKUFIX MH 110 quick-coupling system ................................................................................ 5-65 Couplings of the quick-change adapter systems (optional equipment) ............................................... 5-66 5.19.1 Hydraulic coupling .................................................................................................................. 5-66 5.19.2 LIKUFIX electric coupling ....................................................................................................... 5-67 Travel and swing brakes ...................................................................................................................... 5-68 General maintenance issues ............................................................................................................... 5-68 5.21.1 Replacing working parts ......................................................................................................... 5-68 5.21.2 Welding work on the machine ................................................................................................ 5-68 Inspection and maintenance schedule................................................................................................. 5-69

copyright by R 984 C Litronic / 11140260

Fig. 1-1

Overview

Access ladder

Operator's cab

Left drive gear

Undercarriage

Right drive gear

Grapple

Industrial stick

Stick cylinder

Industrial boom

Boom cylinder

Uppercarriage

copyright by R 984 C Litronic / 11140260

Product description

Operating manual

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.

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.

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 exposure to whole-body vibration of ri measured by international institutes, organizations and manufacturers". The method 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".

Crawler excavator

Mobile excavator

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.

copyright by R 984 C Litronic / 11140260

Operating manual

Product description Technical data

Power according to ISO 9249

504 kW (685 HP) at 1800 rpm

Engine type

Cummins-QSK-19 C 750

Design

6 cylinders, series

Cylinder capacity

159/159 mm

Displacement

18.9 l

Operating method

Low-emission 4-stroke diesel engine with direct injection, exhaust gas turbocharger

Cooling system

Water cooling

Air filter

Dry air cleaner with preliminary cleaner, main and safety element, automatic dust removal

Fuel tank capacity

1585 l

Standard equipment

Sensor-controlled idle automatic

Electrical system

Operating voltage: 24 V Battery: 2 x 144 Ah/12 V Starter: 24 V/9.0 kW Generator: 24 V/100 A three-phase current

Hydraulic pumps for attachment 3 and travel gear

3 Liebherr swash-plate type variable-displacement pumps Max. flow rate: 3 x 472 l/min Max. operating pressure: 320 bar

Pump actuation

Electro-hydraulic, with electronic horsepower control, pressure limitation and on-demand flow control

Hydraulic pump for slewing gear

Reversible swash plate variable-displacement pump, closed circuit Max. flow rate: 403 l/min Max. operating pressure: 340 bar

Hydraulic tank capacity

800 l

Hydraulic system capacity

1970 l

Filtration

2 filters in return line with integrated ultrafine filter (5 µm), 1 high-pressure filter each per working pump

Cooling

Compact cooler, consisting of a cooling unit for water, hydraulic oil and intercooling air, hydrostatically driven fan

MODE switching

Adjustment of engine power and hydraulic through a MODE preselection switch to suit the actual operating conditions LIFT - for load-lifting work FINE - for precision work with fine-controlled movements ECO - for particularly economical and environmentally friendly operation POWER - for maximum power and heavy-duty tasks

Speed adjustment

Stepless adjustment of the engine power through speed adjustment in the preselected mode

Auxiliary function menu

4 permanently adjustable flow rates for optional attachments

copyright by R 984 C Litronic / 11140260

Product description

Operating manual

Technical data

Power distribution

Through control valve block with integrated safety valves, flow summation for boom and stick, closed circuits for uppercarriage slewing gear

Actuation of attachment, slewing gear and travel gear

Proportionally acting joystick and pedals

Auxiliary functions

Through rocker switches or proportionally acting pedals

Drive

Swash plate oil motor

Gearbox

Liebherr compact planetary gear

Slewing ring

Liebherr internally toothed sealed single-row slewing ring.

Slewing speed

0-5.2 rpm, continuous

Slewing torque

390 kNm

Parking brake

Wet multi-disc brake (negative acting)

Optional equipment

Pedal-operated positioning brake

Cab

With flexible bearing, sound insulation, tinted windows, windscreen and roof glass panel in shatter-proof glass, door with sliding window

Operator seat

Vibration-damped, adjustable to weight of operator, 6 seat positions with detachable headrest

Control

Integrated into control console whose position can be adjusted relative to the operator seat

Monitoring system

Menu-driven request of current operating statuses through LCD display. Automatic monitoring, display and warning signals (acoustic and visual); storage of deviating operating statuses, e.g. engine overtemperature, insufficient engine oil pressure, low hydraulic oil level

Air-conditioning system

Equipped with automatic A/C system as standard, combined cooling/heating unit, additional dust filter in fresh and recirculated air circuits

EW model

Heavy and extra-side model

Drive

Liebherr swash plate oil motor

Gearbox

Liebherr planetary gear

Travel speed

0 - 2.9 km/h

Travel gear

Maintenance-free, chain pitch 280 mm

Running rollers / support rollers

12/2

Track pads

Flat track pads

Parking brakes

Wet multi-disc brake (negative acting)

Brake valves

Integrated into control valve

copyright by R 984 C Litronic / 11140260

Operating manual

Product description Technical data

Design

Extra-strong sheet steel panels with reinforced section for heavy-duty operation. Heavy-duty stable support of attachment and cylinders. Excellent strength even under heavy loads.

Hydraulic cylinders

Liebherr cylinders with special coating and guide system and end-of-travel cushioning

Bearing points

Low-maintenance, sealed

Lubrication

Lincoln "Centromatic" automatic central lubrication system for this model

copyright by R 984 C Litronic / 11140260

Product description

Operating manual

Technical data

copyright by R 984 C Litronic / 11140260

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.

Potential dangers in connection with work on or with the machine are labelled with safety notes and signs as follows: , and .

These terms have the following meaning:

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.

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

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 that must be met before the subsequent procedures can be carried out.

Identifies a Identifies the

of a procedure or activity.

copyright by R 984 C Litronic / 11140260

Safety notes, signs

Operating manual

Proper use

with a working attachment (e.g. grapple) designed for the loosening, taking up, transporting and moving of earth, clay, stones and other materials. be equipped with specific safety devices (see chapter "Load lifting work"). ents and possibly safety equipment. The mounting and operation of such attachments is only permitted with the approval of the manufacturer of the basic machine, whose instructions must be strictly adhered to. sport of persons is deemed improper. maintenance schedules is an integral part of proper use.

with the operating instructions before starting the machine. may concern special options for the machine). perate, maintain or repair the machine.

The legal minimum age must be observed. 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. should only operate or work on the machine under the constant supervision and guidance of an experienced person. periodically to ensure that they observe safety instructions and guidelines given in the operating manual. ing 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. site.

especially sure that they are free of dirt, oil, ice and snow. : 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. not use the steering column, the control panel or the joysticks as handholds.

copyright by R 984 C Litronic / 11140260

Operating manual

Safety notes, signs Safety instructions

provided to climb off or on the machine. 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). h the emergency exit. manual, if no other instructions are available for maintenance and repairs: attachment to the ground.

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

Insure that all required safety signs are in place and legible. ange any safety-related systems of components without the specific approval of LIEBHERR. engine. Persons with a pacemaker must keep clear of the vicinity of the running diesel engine (minimum distance 50 cm). electrical connection of the solenoid valve-controlled injection pumps.

long as it is not safely resting on the ground or properly supported. required load.

a suitable alignment tool. ay 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. pressure. Avoid contact with any components containing coolant. Danger of severe burns. ator cap on the expansion tank is cool enough to touch. Turn the cap carefully to relieve the pressure. allow your skin to come into contact with hot oil or components containing hot oil. gloves when handling batteries. Avoid sparks and naked flames. attachment, bucket or grapple to assist in any operation. secured to remain open during the service operation.

copyright by R 984 C Litronic / 11140260

Safety notes, signs

Operating manual

Signs on the machine

ne prior to filling the tank. ll defects, such as loose connections, blown fuses and burned out light bulbs, burned or frayed cables. when filling the tank or loading the batteries. ing to the operating instructions. ine except in appropriate storage tanks.

prevent vibration, rubbing and heat build up. insufficiently ventilated areas. system or flame glow systems. location and use of fire extinguishers on the machine as well as the local fire reporting procedures and fire fighting possibilities.

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.

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.

copyright by R 984 C Litronic / 11140260

Operating manual

Safety notes, signs Signs on the machine

Fig. 2-1

Position of the signs on the machine

The signs indicate the following:

Before starting the machine, put on the safety belt.

Functions of not specifically labelled operating devices.

copyright by R 984 C Litronic / 11140260

Safety notes, signs

Operating manual

Signs on the machine

Indicates the permissible lift loads that can be attached to the end of the stick, depending on its actual extension.

All safety and accident prevention instructions in the operating manual must be strictly adhered to.

Before leaving the operator seat, tilt the safety lever upwards.

The working attachment can reach the operator's cab! Proceed with extreme caution when retracting the attachment.

copyright by R 984 C Litronic / 11140260

Operating manual

Safety notes, signs Signs on the machine

Provides information on work to be carried out in connection with lubricants and specifies the test, lubrication and change intervals.

Indicates the position of the loading and tie-down points and the respective weight of the machine.

The values are maximum values. The actual values might deviate from those indicated on the signs.

Pull the handle at the inside of the rear window to remove the rubber insert. Push the rear window outwards.

Indicates tie-down points.

The use of the tie-down points depends on the chosen method of transport. For more information, refer to chapter "Transport".

Risk of injury!

Do not stand inside the danger area of the machine while it is in operation.

When jump-starting the machine, strictly adhere to the instructions in the operating manual.

copyright by R 984 C Litronic / 11140260

Safety notes, signs

Operating manual

Signs on the machine

Before opening the bonnet, shut down the engine.

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:

Fig. 2-2

ID tag of the machine

copyright by R 984 C Litronic / 11140260

Fig. 3-1

Operator's platform

Safety lever of servo control

Operator seat

Heating and air-conditioning system Engine monitoring system

Horn Control console / central lubrication system

Slewing gear lubrication, roof panel wiper, stick cylinder shut-down

Control console / emergency operation

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Operating and control elements

Radio*

Operating hours counter

Air outlet

Fuse box

* optional equipment

Fig. 3-2

Operator's platform seen from the operator

Left joystick

Right joystick

Ignition switch Keyboard

Monitoring display Travel pedal, right

Travel pedal, left

Positioning slewing brake*

Cigarette lighter, 24 V socket

Push buttons for special functions*

* optional equipment

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Operating and control elements

Fig. 3-3

Keyboard

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Operating and control elements

The switch is assigned several functions that are operated by repeat actuation:

Windscreen washing solution is sprayed onto the window while the windscreen wiper is on.

The switch is assigned several functions that are operated by repeat actuation: witched on (interval mode).

Applies/releases the mechanical slewing gear brake.

May only be used when the uppercarriage is not in motion.

The overload warning system warns the machine operator with a visual signal (screen icon) and an acoustic signal (buzzer sound) when the permissible maximum load is reached. The warning signals should ensure that the permissible load is not 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.

The control console allows operators to activate the rotators of the working tools (e.g. grapple), the quick-change adapters and similar functions.

The idle automatic function automatically reduces the engine speed without actuation of the joystick or the travel pedals, saving fuel and reducing noise. By touching the joystick or the pedals, the engine speed returns to the initial level.

-

Activates the auxiliary headlight.

Activates the cold start system. When the button is pressed, ether is sprayed into the intake section of the diesel engine.

While the engine is running or at operating temperature, the cold start system cannot be actuated.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Operating and control elements

Activates the beacon.

-

Four different modes can be selected by pressing the switch. The active mode is indicated by the LED below the respective letter. : LIFT mode (sensitive lifting of loads) : FINE mode (precision operation) : ECO mode (economical operation) : POWER mode

Indicates the preselected engine speed (10 speeds).

Increases the nominal speed of the diesel engine.

Reduces the nominal speed of the diesel engine.

Applies or releases the parking brake. While working with the machine, the parking brake must be released.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Operating and control elements

Fig. 3-4

Monitoring display

Analogue indicator Check display

no function assigned Temperature indicator - cooling water

Main screen

Temperature indicator - cooling water in red zone

Screen menu control

Fuel gauge

Indicator light - motor oil pressure

Indicator - critical fuel level

Indicator light - battery Indicator light - Direction indicator

BACK button DOWN button

Indicator light - parking brake

UP button

Indicator light - accumulator pressure of operating brake

MENU button

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Operating and control elements

Display must be in green range during operation.

In the event of overheating, the red LEDs

at the edge of the

display flashes.

The buzzer is on in the operator's cab.

Be sure to interrupt work as soon as possible.

Let the engine run on at high idle speed.

The alarm message remains displayed for more than 60 seconds.

Immediately switch the engine to low idle gear.

Let the engine run at low idle speed for 3 to 5 minutes.

Switch off the engine.

Find and eliminate cause.

The lit LEDs indicate the current fuel is left in the tank.

When the red LEDs

are on, there are only 100 litres of fuel in the tank (reserve).

The indicator light is on, if the engine oil pressure drops below the preset value.

The buzzer is on in the operator's cab.

When this indicator light is lit, error code E 501 is logged.

Immediately switch the engine to low idle speed.

Switch off the engine.

The indicator light is on as soon as the ignition key is in contact position.

The indicator light is off when the engine is started.

During engine operation, the indicator light is on, if the V-ribbed belt or the electrical charging system is defective.

Immediately switch the engine to low idle speed.

Let the engine run at low idle speed for about 5 seconds.

Switch off the engine.

Find and eliminate cause.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Operating and control elements

Fig. 3-5

Menu control for screen

The screen can be navigated with the following 4 buttons: : button : button : button : button * = switch-over between main and submenus

Use these buttons to move from the operator's menu to the submenus (and back) or browse through pages.

Simultaneously press buttons and (more contrast) or contrast).

The value set at this point is stored in the system.

Simultaneously press buttons and (brighter) or The value set at this point is stored in the system.

(less

(less bright).

There is a light sensor at the top left of the monitoring display. It controls the brightness of the main screen with respect to the ambient brightness. Automatic brightness control is based on the basic setting entered with the buttons. The display is automatically dimmed when the environment gets darker.

Switch off ignition.

Simultaneously press and hold buttons

and

.

Switch on the ignition again.

Do not release the buttons before end of self-test.

The main screen is displayed as soon as the machine is started and until the operator's menu is called up.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Operating and control elements

Fig. 3-6

Display: main screen

Symbols / time

Error codes

Information

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

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

For a description of the warning symbols, see chapter "Malfunctions".

Indicates the error code (E xxx) of current electrical faults (line faults, sensor faults, etc.). As soon as a fault condition displayed in field SY is confirmed as "new", the display returns to the main screen.

Certain error codes are accompanied by a warning symbol in the description of the warning symbols, see chapter "Malfunctions".

field. For a

Up to 7 error codes can be shown at any time. If there are more than 7 faults, an arrow is displayed beside the error code field, indicating that there are more faults than can be displayed.

Press the and/or button.

The display scrolls through the list in the selected direction.

If the error indicated is not eliminated immediately, there is a danger people get hurt or equipment gets damaged.

Make sure all faults are dealt with without delay.

Depending on the error (level of urgency), a buzzer signal is issued (continuous signal or sequence of short signals).

When an error code is displayed the symbol for the acknowledgement of errors is shown in the field.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Operating and control elements

Press the button.

The error message is acknowledged and stored.

The buzzer is switched off.

Indicates the operating hours of the machine, the daily counter and the currently selected working tool.

The ® indicates that limitation settings are activated.

This field shows information regarding the current status of the machine (symbol or text).

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

The following symbols are shown in the

field:

This symbol is on during the pre-heating process.

This symbol is displayed for approx. 2 seconds on the main screen when the preheating process is completed.

This symbol is displayed when the diesel engine is started in emergency mode. It indicates that the speed can be adjusted manually with the speed controller .

After the ignition has been switched on, the indicator lights and the keyboard perform an self-test.

After the self-test is completed, the system indicates with a graphic sign whether a service check is due. This symbol temporarily replaces the operating hours counter.

This symbol is displayed, if a machine malfunction ( accompanied by a buzzer signal.

) occurred. It is

This symbol is displayed when the emergency control function is activated.

This symbol is displayed when the emergency control function is activated.

This symbol is displayed when the emergency control function is activated.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Operating and control elements

This symbol is displayed, if the maximum permissible load capacity of the machine is reached.

This symbol appears when the switch (overload warning system) is activated in a machine that does not features an overload warning system.

Fig. 3-7

Main screen

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

Press the button on the main screen.

The operator's menu is displayed.

The list of the accessible submenus is indicated by symbols.

Fig. 3-8

Operator's menu

Press the arrow buttons and/or .

The previous or next menu 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.

The menu showing a black background is selected.

Press the button.

The submenu of the selected function is displayed.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Operating and control elements

Press the button.

The submenu is closed.

Reset daily operating hours counter

Confirmation of service interval

ings for working tool (optional equipment) Operating hours, machine data

Status of hydraulic pumps and electrical inputs/outputs

Detected and saved errors

Time

Fig. 3-9

Resetting the daily operating hours counter

Press the Option

button. is not stricken through and is highlighted in black.

Press the button.

The operating hours counter is reset.

The and buttons and the

symbol are no longer visible.

Press the button.

The submenu is closed.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Operating and control elements

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 button.

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

Press the button.

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

Service has not been carried out: Press the button.

The submenu is closed.

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

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).

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Operating and control elements

Fig. 3-11

Tool Control menu

= oil volume 1

= oil volume 2 (from A 934 B LI)

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

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

Press the or button.

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

Press the button.

Your selection is confirmed.

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

Press the 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

Main screen, display of selected working tool

Selected option (attachment)

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

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Operating and control elements

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

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

Fig. 3-13

button until the desired page is displayed.

Engine operating hours menu

Page 1 indicates the operating hours of:

low idle speed L

Fig. 3-14

Machine movement hours menu

Page 2 indicates the operating hours of:

Page 3 indicates the operating hours of: ear (no activation from model A 934) t controlled with foot pedals

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Operating and control elements

Fig. 3-15

Technical data

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

Press the button.

The display returns to the operator's menu.

Fig. 3-16

Pressure and flow limitation currents menu

Repeatedly press the

button until the desired page is displayed.

Page 1 shows the pressure and flow reduction values of the hydraulic system. If there are not limitations, all values are set to 100 % (figure to the left).

If the machine is operated with pressure and flow limitation, the currently applied settings are displayed (figure to the right). Examples of application: operation of working tools with Tool Control (optional equipment) or other internal hydraulic settings aimed at optimising operating statuses.

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

For the consumer used here, the oil flow rate (EV1, EV2, EV3 ) is reduced to 55 %, 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 flow reduction is activated, the ® symbol is displayed on the main screen (if enabled).

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Operating and control elements

Fig. 3-17

Power control, speed control currents menu

Page 2 shows the current of the power control solenoid.

Page 3 shows the current of the speed control of the diesel engine.

Fig. 3-18

Electrical inputs

Pages 4 to 5 provide an overview of the status of the various electrical inputs. The values are provided primarily for a quick system diagnosis, e.g. by LIEBHERR customer service technicians. "

" indicates that the input is not activated.

"

" indicates that the input is activated.

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

M4/time indicates the set delay time for the windscreen wiper interval mode. B19/ time indicates the set delay time for the low idle automatic function.

Press the button.

The display returns to the operator's menu.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Operating and control elements

Fig. 3-19

Errors menu

This menu offers 3 choices for selection: to obtain a list of the machine errors detected by sensor devices. to obtain a list of the electrical wire faults of the LCD display stored during operation. to obtain a list of the machine errors displayed when the service plug is connected.

Press the and/or buttons.

The preceding or next error type is highlighted in black.

Press the button.

The submenu highlighted in black is displayed.

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

Fig. 3-20

and

buttons

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

Select

.

Press the button.

The first page of the submenu is displayed.

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

Press the

or

button to select the desired error code.

Press the 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.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Operating and control elements

Press the button.

The first page of the submenu is displayed.

Press the the or

button again to select a different error type. Alternatively, press button to select a new error code.

s*: Error was announced by a buzzer signal and confirmed by the operator with pressing the button. The duration is indicated in seconds. m*: Error was announced by a buzzer signal and confirmed by the operator with pressing the button. The duration is indicated in minutes.

Menu

Fig. 3-21

shows only operating errors assigned the

error code.

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

Select list Press the 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 button.

Select a different fault type, if required.

Fig. 3-22

Service operation error list menu

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Control

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

Repeatedly press the

Fig. 3-23

button until the operator's menu is displayed.

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

or

button.

Press the button.

The next figure to the left is highlighted.

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

Press the button.

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

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

When accessing or exiting the machine, ensure that the safety lever is moved up.

Always access and exit the machine using the provided climbing aids.

Ensure that your body is resting on at least 3 points: While ascending or descending, you must at all times remain in contact with the access devices with at least 3 limbs (2 hands + 1 foot, or 2 feet + 1 hand).

Do not use operating elements as handles.

Never jump from the machine.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Control

Fig. 3-24

Climbing aids

Operator's cab (standard model)

Elevating operator's cab*

* optional equipment

Fig. 3-25

Cab door

Door handle

Door locking mechanism

Inside door handle

Lever of door locking mechanism

To access or exit the elevating operator's cab (optional equipment), lower it fully.

Position the uppercarriage and the undercarriage in such a way that the steps and ladders are aligned with each other.

Mount the machine/descend from the machine facing the ladder.

Press the lock at the door handle

and open the door.

Enter the cab, sit down on the operator seat and close the door.

To keep the door open during machine operation: Swivel the door back by 180° and secure it with the locking mechanism .

If necessary, adjust the operator seat and steering column.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Control

Shut down the machine and push the safety lever upwards.

Push down the door handle

at the door lock.

Open the door and exit the cab.

Close the door.

The door is secured with the locking mechanism .

Move the lever outward.

The door is now released.

Close the door.

The height of the operator's cab can be adjusted steplessly.

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.

Fig. 3-26

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 button

or

to lift

or lower

operator's cab.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Control

If the above buttons and fail to work , the elevated operator's cab can be lowered with the buttons for . Buttons for emergency lowering are located both inside and outside the operator's cab.

Press and hold the button .

The operator's cab is moved downwards as long as the button is pressed.

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

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

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

Only access the operator's cab after it has been fully lowered.

Fig. 3-27

Emergency lowering of the operator's cab from the outside

The operator's cab can also be lowered from outside the cab.

Press and hold the button .

The operator's cab is moved downwards as long as the button is pressed.

Fig. 3-28

Safety lever

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Control

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

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: . joysticks or pedals) does not result in movement of the machine.

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 while seated on the operator seat, move the safety lever to its bottom position.

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.

Therefore do not adjust the seat while the engine is running.

Before adjusting the operator seat, fold the safety lever upwards.

Fig. 3-29

Standard operator seat (left) and seat with air suspension (right, optional equipment)

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Control

Fig. 3-30

Adjusting armrest

Turn knurled screw in direction .

The angle of the armrest is adjusted upwards.

Turn knurled screw in direction .

The angle of the armrest is adjusted downwards.

Fig. 3-31

Adjusting seat and backrest

Seat inclined backwards: Pull the lever release the lever.

Seat inclined forward: Pull the lever the lever.

Backrest: Pull the lever lever.

up, adjust the angle of the seat and release

up, adjust the angle of the backrest and release the

copyright by R 984 C Litronic / 11140260

up, adjust the angle of the seat and

Control, operation

Operating manual

Control

Fig. 3-32

Horizontal adjustment

Pull the lever

upwards and move the seat in horizontal direction.

Pull the lever direction.

upwards and move the seat with the control console in horizontal

Fig. 3-33

Adjusting seat suspension

Adjust the seat suspension to suit your body weight by turning the turning knob.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Control

Fig. 3-34

Switching bar at air-cushioned operator seat

Press the button weight.

( or ) to adjust the suspension system to suit your body

Press the button

( or ), to add or release air from the lumbar cushion.

Press the button

( or ), to add or release air from the upper lumbar chamber.

Operate the switch

to switch the seat heating on or off.

The seat heating switches off automatically when the set temperature is reached.

Fig. 3-35

Seat belt

The seat belt is an inertia seat belt. It is thus not necessary to adjust the belt length.

Pull the belt from the reeling mechanism .

When the belt is pulled with a jerk, it might lock.

Push the locking piece into the buckle

copyright by R 984 C Litronic / 11140260

so that it engages.

Control, operation

Operating manual

Control

In the event of an accident, seat belts significantly reduce the risk of injury.

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

Ensure that the seat belt is not twisted.

To ensure proper safety, regularly check the seat belt and replace it without delay if you detect any damage to parts.

To open the buckle , push the lock button down, using your thumb.

The reeling mechanism automatically pulls in the belt.

Fig. 3-36

Sun blinds 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.

Pull the sun blind down, holding it by the cross bar The sun blind can be individually adjusted.

.

Press the switch (red).

The sun blind is automatically rolled up.

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.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Control

Fig. 3-37

Emergency exit through rear window

Pull the latch

at the inside of the rear window to remove the rubber seal .

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

Fig. 3-38

Inside lighting

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

Set the rocker switch to position .

The light is switched on.

Set the rocker switch to position .

The light is switched off.

Switch position

is not assigned a function.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Control

Fig. 3-39

Fire extinguisher / first aid kit

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

To switch on the windscreen wiper, actuate the switch

.

Press the switch.

Interval mode The left LED is on.

Press the switch again.

Continuous mode The left LED is off, the right LED is on.

Press the switch again.

The windscreen wiper is switched off.

The red LED is off.

To adjust the interval for the windscreen wiper, actuate the switch range: 2 to 10 seconds.

. Adjustment

Press and hold the switch until the windscreen wiper is switched off.

Continue pressing and holding the switch.

The left LED flashes.

Release the switch when the desired interval time is reached.

The interval time is set to the new time.

To switch on the windscreen washer system, actuate the button

.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Control

Press and hold the button.

Windscreen detergent solution is sprayed through the nozzles onto the windscreen.

The wiper is on in continuous mode.

Release the button.

Washing spray is stopped.

The windscreen wiper runs in continuous mode for another approx. 3 seconds.

To switch on the wiper for the cap roof, actuate the switch

.

Turn the switch to the left.

The wiper is on in continuous mode.

Turn the switch to the right and hold it there.

Windscreen detergent solution is sprayed through the nozzles onto the roof panel.

The wiper is on in continuous mode.

Turn the switch to its neutral position.

The windscreen wiper is switched off.

Fig. 3-40

Windscreen detergent tank

This tank is located at rear of the operator's cab.

Add conventional windscreen detergent through the filling opening (arrow).

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Control

Fig. 3-41

Arrangement of the lighting devices

Revolving deck headlight

Attachment headlight

Front roof headlight* Rear roof headlight

Beacon* Headlight on counter weight*

* optional equipment

The headlights are switched on with the switch

.

Press the switch.

The revolving deck headlight is on.

The left LED is on.

Press the switch again.

The revolving deck headlight is off and attachment headlight is on.

The left LED is off; the right LED is on.

Press the switch again.

The revolving deck headlight and attachment headlight are on.

The right and left LEDs are on.

Press the switch again.

The revolving deck headlight and attachment headlight are off.

The rear roof headlight is switched on with the switch

.

Press the switch.

The roof headlight is on.

The indicator light in the switch is on.

Press the switch again.

The roof headlight is off.

The indicator light in the switch is off.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Control

The auxiliary headlight is switched on with the switch

.

Press the switch.

The auxiliary headlight is on.

The LED is on.

Press the switch again.

The auxiliary headlight is off.

The LED is off.

The beacon is switched on with the switch

.

Press the switch.

The beacon flashes.

The LED is on.

Press the switch again.

The beacon is off.

The LED is off.

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.

Fig. 3-42

Air conditioning control unit

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

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Control

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

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

will be displayed if the control unit identifies an error.

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

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 .

Fig. 3-43

Control unit self-test

Switch on the system by pressing key .

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 symbol is displayed.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Control

Fig. 3-44

Example: increase the temperature

The desired cab temperature is displayed on-screen.

Press key

to increase the temperature.

Press key

to reduce the temperature.

Example: Press key

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 ).

Fig. 3-45

Manually adjusting the heating performance

Press key to manually adjust the heating performance.

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

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

Use keys

or

to increase/reduce heating performance.

Press key twice in quick succession to restart automatic mode.

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

Fig. 3-46

A/C operation and REHEAT function

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Control

Press key .

A/C operation is switched on, symbol 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 again.

A/C operation is switched off, symbol

is no longer displayed.

Press REHEAT key if you need to defog the cab.

Symbol is displayed.

The REHEAT function automatically switches off again after 10 minutes.

Fig. 3-47

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 Symbol Symbol

to open / close the fresh air flap. indicates that the fresh air flap is closed. is no longer displayed when the fresh air flap is open.

Press key to manually set the fan speed.

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

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

Use keys or to increase/reduce fan performance.

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

Symbols and are no longer displayed.

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

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Control

Fig. 3-48

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

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

To obtain optimum comfort: During control console During console .

, open the air outlets in the legroom area and (if required) for windscreen . , open the air outlets in the rear cab wall

, on right

and right control

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

The air flow is regulated by pressing keys air outlets.

Fig. 3-49

-

and using the rotating and lockable

Air outlet symbols

Press key .

Symbol is displayed.

Air outlets are opened.

Press key again to re-close the ventilation flaps.

Symbol is no longer displayed.

Air outlets are closed.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Control

Press key .

Symbol is displayed.

Air outlet is opened.

Press key again to re-close the ventilation flaps.

Symbol is no longer displayed.

Air outlet is closed.

Press key .

Symbols and Air outlets and

are displayed are opened.

Press key again to re-close the ventilation flaps.

Symbols and are no longer displayed Air outlets and are closed.

Press key .

Symbol is displayed.

Air outlet is opened.

Press key again to re-close the ventilation flaps.

Symbol is no longer displayed.

Air outlets are opened.

The displayed temperature can be switched from

to

.

Press and hold key .

Press key The temperature is displayed in

.

Repeat this procedure to switch the temperature display to

Fig. 3-50

.

Auxiliary heater operation

Switch on the auxiliary heater When the air conditioning system is switched on: the text (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.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Operation

rm a thorough walkaround inspection.

remain unlocked. he inside and outside mirrors are clean.

Secure all doors and windows to prevent unintentional movement. and the other items to ensure comfortable and safe working conditions. e machine must be in working order.

and instruments for proper function, bring all controls into neutral position and insure that the safety lever is in the raised position. located near the machine.

if you have not received any other instructions. indicators, gauges, warning devices and controls for their proper indication. ilated area, if the area is enclosed. If necessary, open doors and windows in the building to provide ample fresh air. cause a slow reaction of the controls.

chock or block wheels when parking on a slope.

gear brake. the operating instructions and move the

secure the machine against any unauthorized use.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Operation

operating manual. disabled machine from a hazardous location. towing the machine, check all cables, hooks and couplers for safety and stability. ensile strength and must be attached to the undercarriage at the designated tiedown attachment points.

permissible speed and distance. service.

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.

If necessary, reduce the engine power (performance mode).

Also pay close attention to the engine and hydraulic oil temperature.

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

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

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

Positions of the locks: see chapter "Maintenance".

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:

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Operation

openings. * For instructions on how to complete these tasks, refer to chapter "Maintenance".

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):

Fig. 3-51

Keys in different colours

Programmed ignition key (blue)

Master key (red)

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.

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.

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

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.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Operation

Fig. 3-52

Battery main switch

Turn battery main switch to position

Fig. 3-53

(ON).

Ignition

Neutral position Ignition position

Contact position Parking position

Turn battery main switch to position

(ON).

Turn the ignition key to contact position .

The ignition is switched on.

As soon as the system is switched on, it completes a of the control panel keyboard and the indicating instruments: All indicator lights, with the exception of the two LEDs of the switch are briefly on.

The LIEBHERR logo is shown on the monitoring display.

During the

, observe the indicating instruments.

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.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Operation

Fig. 3-54

Service interval request

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

The

symbol disappears after about 8 seconds.

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

before starting the engine again.

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

Turn ignition key to ignition position

.

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

The indicator lights and must be off.

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

Press the switch (SF1) while starting the engine.

The cold-start function is activated.

The LED is on.

Ether is sprayed into the suction section of the diesel engine, facilitating starting.

If the machine is to be started at temperatures below -20 °C, we recommend equipping the machine with one starter aid available from LIEBHERR.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Operation

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 is on.

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.

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.

Fig. 3-55

Speed adjustment and mode functions

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

By pressing the switch , you can select between 4 different modes. The active mode is indicated by the letter below the LED. : LIFT mode (speed step 5 - extremely sensitive lifting of loads) : FINE mode (speed step 10 - grading work) : ECO mode (speed step 8 - economic operation) : POWER mode (speed step 10)

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Operation

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 .

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

The respective LED is permanently on.

In modes (maximum torque) and , the diesel engine operates at maximum power. In modes and , 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.

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

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.

Increase speed: Press switch .

Speed is increased by one step.

The speed indicator changes accordingly (increasing).

Reduce speed: Press switch .

The speed is reduced by one step.

The speed indicator changes accordingly (decreasing).

A flashing LED above the switch 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.

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.

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.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Operation

The diesel engine and turbo charger might be damaged by incorrect switching off.

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 .

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

Let the diesel engine run for minimum 2 to 3 minutes in idle mode.

Turn the ignition key to position

to shut down the engine.

Remove the ignition key.

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.

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.

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.

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".

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Operation

Fig. 3-56

Travelling straight ahead

Idler

Travel drive

Left travel pedal

Right travel pedal

Risk of accident!

For forward travelling, ensure that the front idler is located at the front of the machine and the travel drive is at the rear of the machine.

Check the travel path to ensure that it is not obstructed and can be travelled safely.

Push both pedals forward (

Push both pedals down (

Fig. 3-57

and

and

).

).

Turning at standstill

Push the left pedal down (

).

Simultaneously push the right pedal forward (

copyright by R 984 C Litronic / 11140260

).

Control, operation

Operating manual

Operation

Push the right pedal down (

).

Simultaneously push the left pedal forward (

).

In order to protect the drives against excessive wear, turning at standstill should be avoided, if possible.

Fig. 3-58

Turning machine with one chain

Push the right pedal forward (

Push the left pedal forward (

).

).

During travel, applying different forces to the two pedals results in a change of direction.

Fig. 3-59

Manual steering of travel gear

For particularly accurate manoeuvring, the travel gear must be steered manually.

Attach the supplied manual levers ( and ) to the travel gear pedals.

The travel gear can now be steered by hand.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Operation

The max. achievable travel speed is set with the switch two speed steps:

. The machine features

(position 1): Maximum drawing pull at moderate speed. (position 2): Reduced drawing pull at maximum speed.

Press the switch .

Switching over from normal to fast travel is activated.

LED 1 in the switch is on.

During travel, the system automatically switches between normal and fast travel, provided that the ground conditions permit this (LED 2 is on). On difficult terrain, the system switches back to normal travel and LED 2 is off.

Press the switch again.

The switchover function is deactivated.

LED 1 in the switch is off.

When the switchover function is deactivated, the machine can only be operated in normal travel mode.

Quick release of the travel pedals causes the machine to come to an abrupt halt.

The operator might find it difficult to remain seated in the cab. The machine might vibrate or swing! There is thus an increased risk of accidents!

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

If possible, avoid quick braking manoeuvres.

The hydrostatic travel drive acts as a working brake.

Slowly release the travel pedals.

The pedals automatically return to their neutral positions.

The travel drive is stopped, and the machine is slowed down.

When travelling on slopes, the brake valves prevent excessive acceleration of the machine. They thus ensure that the permissible travel speed is not exceeded.

When the travel pedals are in neutral position, the machine is secured and cannot roll away. Approximately five seconds after the pedals have been released, the is applied automatically. The working attachment can still be moved.

If the parking brake is to be applied before this happens automatically, press the switch (SF).

Press the switch .

The LED in the switch is on.

The parking brake is applied.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Operation

Press the switch again.

The LED in the switch is off.

The parking brake is released.

While working with the machine, the parking brake must be released.

Non-compliance with the instructions below might void the warranty.

New travel gears must be run in. The travelling behaviour over the first metres affects the quality of the moving travel gear parts and reduces subsequent wear. Correct running in improves the running performance.

During the first travelling operation, start the machine with great care and accelerate it only slowly.

During the first operating hours, travel only at slow speeds and avoid long journeys.

The service life of the travel gear depends primarily on the operating conditions.

Frequent travelling and working on uneven ground results in increased wear and can cause additional maintenance expenses.

As a rule, travelling operation of the machine should be kept to a minimum. Ideally, travelling operation should not exceed 5 % per operating hour. Avoid travelling over long distances and turning at small turning angles.

For the purpose of this machine, a "long distance" is tion of more than 3 minutes When travelling long distances, the temperature in the travel gear is significantly increased, which results in a higher wear of the moving parts.

To prevent overheating of the travel gear, the machine should not travel more than 200 m per operating hour.

If the machine must be moved across a longer travelling distance, monitor the temperature of the drive components. We recommend employing an assistant to operate a thermometer.

If the temperature of a moving part of the travel gear (drive, chains, support rollers) exceeds the ambient temperature by more than 20 °C, abort the travelling operation.

Continue the journey only after the parts have cooled down sufficiently.

Alternatively, you might consider taking measures that prevent overheating of the travel gear or speed up the cooling of the parts, such as spraying the travel gear with water. To do this, we recommend keeping a large volume of water ready on the site (for example in a tanker).

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Working with the machine

Fig. 3-60

Travel alarm system

Actuate the travel pedal or .

The travel alarm system is automatically switched on.

An acoustic signal (warning signal) is generated.

Press the button at the right joystick.

The travel alarm system is switched off.

The travel alarm system can be switched off earliest 10 seconds after travel start.

If a travel pedal is actuated again, the travel alarm system is reactivated.

iliarize 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. ce to overhangs, edges, embankments and an unsecured substrate. reduced visibility and changing ground conditions. und utilities before you dig. Observe the required clearance distances to any underground utilities. power lines and use caution when working near them. Observe the required clearance distances to any power lines.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Working with the machine

secured. equipment has all required lighting and marking, and observe any applicable load limitations. s of poor visibility or darkness.

are carried out immediately. ear of all personnel before beginning work. operating manual. long as the machine is still moving. while the diesel engine is running. d and be aware of any stability limitations these loads may create. depends on the attached equipment as well as the substrate. as close as possible to the ground.

EXCEPTION: see WHEN LOADING AND UNLOADING

uphill, never sideways on a slope. e permitted speed or you could lose control over the machine.

Shift to a lower gear to allow the engine to control the maximum speed of the machine. rock protection is present. clearings, hoisting operations, etc. overview of and whenever necessary, ask for assistance of a guide. Have only one person signal you. operator. The guide must position himself within view of the operator or be in voice contact with him. nt combination, there can be a danger of collision cylinders. To avoid damage, utmost attention is required when the bucket teeth enter this range.

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: e changed machine characteristics and surrounding conditions.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Working with the machine

aking, acceleration, changes in travel direction. he undercarriage is not travelling. en on the load, lifted it and turned the uppercarriage in travel position. ons, ensure, that you have appropriate windscreen protection.

The protective screen (FOPS) must be installed if there is a danger of falling objects from overhead. being handled. en working with machines with grapples require a properly instructed and trained operator. sufficient training and practical experience.

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. 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. ite levelling and tip over!

For that reason, the following rules must be strictly observed: When driving the machine:

ound is solid and even! Potholes and uneven road surfaces endanger the stability of the machine. centre of gravity) and surrounding conditions. aking, acceleration, changes in travel direction.

slowly!

In material handling operation: position, the machine must be supported on outriggers and horizontally aligned. capacity of ground). Sinking of an outrigger below ground level would result in devastating consequences!

machine as practical. Note: be aware of the hazard of grapple swing when moving a load toward the operator cab. stated in the load chart.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Working with the machine

uppercarriage to the undercarriage in such a way that the steps and ladders are aligned. three points of contact with the machine. 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. close the door and fasten the safety belt. and climbing up the machine. undercarriage in such a way that the steps and ladders are aligned. support. Climb down until you can close the door safely. Always guide the door by hand when closing the door.

manner of utilization. Especially the following parameters have a significant influence: braking, control of operating elements of the machine during travel as well as working. ation 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: ent parts and auxiliary devices for the corresponding tasks.

weight and the size of the operator. that the characteristics of the seat remain as specified by the seat manufacturer. ition of the machine, especially regarding: Tire pressure, brakes, steering, mechanical connections, etc. machine in a jerky manner. el route to avoid vibration impacts.

ain where the machine is working and travelling in good order:

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Working with the machine

able terrain conditions, keep machines available and allow for sufficient time. are frequently used for travel, consider use of auxiliary ride control systems, and also monitor speed to minimize buildup of "pitching" vehicle movement.

The low idle automatic function reduces the engine speed after a preset delay to idle speed when no hydraulic function is actuated for a specified period of time. This helps save fuel and reduces the noise level.

By touching the joystick or the pedals, the engine speed returns to the initial level.

The low idle automatic function is activated with the switch Press the switch.

Low idle automatic is activated.

The LED is on.

Press the switch again.

Low idle automatic is deactivated.

The LED is off.

Press and hold the switch until the desired time has lapsed.

The LED flashes.

Release the switch.

The LED is on.

The low idle automatic function is activated.

The delay time is saved.

Fig. 3-61

Working position of the machine

copyright by R 984 C Litronic / 11140260

:

Control, operation

Operating manual

Working with the machine

Idler

Travel drive

Before carrying out any work with the machine, place it on level and firm ground with sufficient load-bearing capacity.

If necessary, prepare the working area and remove obstacles.

If possible, all work with the machine should be carried out through the idler

Fig. 3-62

.

Operating working attachment

The machine is equipped with 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 ( ) controls the stick and swivelling movements: and : Stick is extended or retracted. and : Uppercarriage is swivelled to the left or right.

The right joystick ( ) controls the boom and grapple movements: and : Grapple is closed or opened. and : Boom is lifted or lowered

The stick is moved by operating the left joystick .

Pulling the joystick backwards : Stick moves in direction Pushing the joystick forward .

Stick moves in direction

The boom is moved by operating the right joystick .

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Working with the machine

Pulling the joystick backwards : Boom is lifted.

Pushing the joystick forward : Boom is lowered.

Risk of injury to persons standing in the danger area.

Do not allow auxiliary personnel hand-guide the grapple!

Moving the joystick to the left : Grapple is closed.

Moving the joystick to the right : Grapple is opened.

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

The attachment can be operated in two different modes. The machine operator can determine the operating characteristics of the hydraulics for the "Retract stick" function.

In "Stick passive" mode, the stick is retracted without pressure solely by gravity. This is done without any hydraulic power. As a result, there is a greater hydraulic reserve available for the other parts of the attachment.

In "Stick active" mode, the stick is retracted with pressure (i.e. driven).

To switch between the two modes, actuate the switch

.

Before switching mode, stop all movements of the attachment.

Select the operating mode as required for the task at hand.

The light in the switch is off.

The "Retract stick" movement is completed without hydraulic pressure.

The light in the switch is on.

The "Retract stick" movement is completed with hydraulic pressure.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Working with the machine

In passive mode, the stick can only be lowered to its lowest point, where it is in a nearly vertical position (see figure).

To retract the stick further, you must select the "Stick active" mode.

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

The uppercarriage is swivelled by operating the left joystick .

Move the joystick to the left : Uppercarriage is swivelled to the left.

Move the joystick to the right : Uppercarriage is swivelled to the right.

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.

Move the left joystick to its neutral position: Uppercarriage is slowed down hydraulically.

Move the left joystick in the opposite direction: Uppercarriage is stopped with the maximum hydraulic force.

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 : The slewing gear brake is applied.

The LED in the switch is on.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Working with the machine

Press the switch again: The slewing gear brake is released and is operated in The LED in the switch is off.

Fig. 3-63

mode.

Semi-automatic slewing gear brake

The slewing gear brake in semi-automatic mode is operated by means of the switch at the right joystick.

Press the switch down.

The slewing gear brake is applied automatically, if the uppercarriage is not rotating or if it has come to a standstill.

Press the switch up.

The slewing gear brake is released.

The LED in the switch is always on when the brake is applied.

If the slewing gear brake cannot be released with the switch , this might be due to the following: The slewing gear brake has been applied before the brake was set to semiautomatic mode. In this case, it can only be released by actuating the switch again.

Ensure that the uppercarriage is stationary.

Press the switch .

The slewing gear brake is applied.

The LED in the switch is on.

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

The uppercarriage must not swivel.

The slewing gear brake is working properly.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Working with the machine

Fig. 3-64

Positioning slewing brake

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

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

Do not use the positing slewing brake as a working brake, but only for special halting and parking manoeuvres of the slewing gear.

The uppercarriage should normally be slowed down hydraulically.

Operate the pedal .

The uppercarriage is slowed down in its movement.

Fig. 3-65

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

.

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

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Working with the machine

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.

Fig. 3-66

Example of attachment

Rotor (e.g. for rotating grapple) Locking bolts of a hydraulic quick-change adapter system Movement of direction Press the respective push button to turn (swivel) the attachment or to operate the hydraulic quick-change adapter system. The buttons are located on the right or left joystick (depending on machine equipment).

Fig. 3-67

Push button on the joystick

Actuation at left joystick (standard) Actuation at right joystick (optional equipment) Actuation at left and right joystick (operational equipment) Left and right push buttons

Risk of injury!

Never let anybody move the attachment (e.g. grapple) by hand.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Installation and removal of attachment parts

The auxiliary function is activated with the switch

.

Press the switch .

Auxiliary function is activated.

The LED in the switch is on.

Press and hold the button .

The attachment turns (swivels) to the left.

The locking bolts are extended.

Press and hold the button .

The attachment turns (swivels) to the right.

The locking bolts are retracted.

machine without prior written approval by LIEBHERR. LIEBHERR must be provided with the required technical documentation necessary for this purpose.

and securely supported.

described in this operating manual). carrying capacity. 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. and turn the safety lever upward. lic lines are properly attached and that all fittings and connections are properly tightened. openings in the hydraulic circuit to prevent dirt infiltration. Permit only authorized persons near the machine or the lifting device.

pulling device to push out the pins on the attachment. held by another person.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Installation and removal of attachment parts

from the tool box in the threaded bore of the pin and hit the screw only. 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.

Fig. 3-68

Attaching grapple to industrial stick

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.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Installation and removal of attachment parts

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 .

Insert the bolts

and secure them with the plate .

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 pipelines.

and

(for the supply of the grab cylinders) to the

For grapples with hydraulic rotator, also connect the hydraulic hoses the pipelines for this auxiliary equipment.

and

to

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.

Fully open the grabs and place the grapple in a vertical position on level ground.

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 and carefully drive out the bolt . To do this, you might have to start the diesel engine and lift the attachment slightly from the ground.

The industrial stick with hydraulic quick-change adapter allows for the fast and easy exchange of working tools.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Installation and removal of attachment parts

with the functions and operation of the quick-change adapter (without attached working tools). s, ensure that no persons are located in the working area of the tool. and only if absolutely necessary. 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.

The alarm signals can be triggered if a locking pin 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. 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. the working tool.

Fig. 3-69

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.).

Fig. 3-70

Industrial stick with hydraulic quick-change adapter

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Installation and removal of attachment parts

Industrial stick Lock pin

Suspension system of working tool Half shell at suspension tackle

Fig. 3-71

Control elements, releasing (R)

Fig. 3-72

Control elements, locking (L)

Push button / quick-coupling system Push button / release (lock pin is retracted)* Push button / locking (lock pin is extended)* For safety reasons, two control elements must be operated simultaneously to move the lock pin.

With one hand, press the button hand (two-hand control).

and then press the button

You can then release the button buttons or (holding function).

, and continue to operate the lock pin with the

*

or

with the other

Standard equipment; with other options of the "Rotate grapple" function (optional equipment), the operation can be carried out by means of the left or right joystick.

The

must be activated (switch

, LED on).

Press and hold the button .

The quick-coupling system is activated.

Press and hold the right button .

The buzzer sounds.

The lock pins are retracted.

The "quick-change adapter" icon appears on the screen.

The quick-change adapter is released.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Installation and removal of attachment parts

Press and hold the left button .

The buzzer is off.

The lock pins are extended.

The "quick-change adapter" icon on the screen disappears.

The quick-change adapter is locked.

This symbol, together with a buzzer warning sound, indicates that the quick-coupling system is not properly locked.

The working tool must be securely positioned on the ground or secured in a frame.

The working 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 (if installed).

Fig. 3-73

Releasing and attaching working 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.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Installation and removal of attachment parts

Fig. 3-74

Locking

Lock the quick-change adapter.

Release all buttons.

If in place: Loosen the locking screw (optional equipment) at the suspension (unless the locking screw is loosened, the working tool cannot be moved freely).

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).

The safe mounting of the working tool must be checked with a proper visual inspection.

The working tool must be in a stable position.

If required, a support structure (frame) must be in place.

After the working tool is released, it is fully disconnected from the machine. The working tool might become dislodged and cause serious injury.

Before releasing the quick-coupling system, place the working tool on the ground.

Switch off the magnet system (if installed).

Fully open the jaws of grapples.

Place the working tool without load on the ground, or on a suitable frame.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Installation and removal of attachment parts

Fig. 3-75

Tightening the locking screw, disconnecting the lines and releasing

If in place: Tighten the locking screw (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).

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 dismantling of grapple).

Release the quick-change adapter.

Release all buttons.

Fig. 3-76

Disconnecting working tool

Move the industrial stick in such a way that the front side is removed from the half shells.

Attach the other working tool.

To switch off the buzzer, lock the quick-change adapter without attaching a working tool.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

General working methods

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 .

The buzzer is switched off.

The "quick-change adapter" icon remains displayed.

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.

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 .

The buzzer is switched off.

The "quick-change adapter" icon remains displayed.

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.

In order to prolong the service life of the machine and to prevent avoidable damage, observe the following instructions: s attachment is used to hammer against a hard material to remove it. Repeated impact of the working attachment against

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation General working methods

hard materials results in damage to the steel structure and the machine components. 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. r drilling material is not permitted. 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.

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 fully retracted (in end position)

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. 3-77

Permissible working range for hydraulic cylinders

Possible swivel range

Permissible working range with 10 ° distance to end position

Limit range Hydraulic cylinder

Boom or stick

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

General working methods

Fig. 3-78

Safe working: observe machine range and danger zone

Risk to life and limb when the machine is swivelled.

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

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.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation General working methods

Risk to life and limb or damage to the machine by swinging grapple: the operator's cab and injure the operator. ct 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.

There is always a risk that the machine might topple over! Sinking of a travel gear into the ground would have devastating consequences!

Therefore always check the ground to ensure that it has the necessary load capacity.

Carry out all movements with increased caution.

Do not travel with suspended loads. Before setting the machine in travelling motion, lower the load to the ground (empty the grapple).

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. 3-79

Loading operation

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

General working methods

Carefully lift the load.

Keep the load as close as possible to the undercarriage, while keeping a sufficient safety distance to the machine and 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).

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.

Load lifting operation includes all manoeuvres where loads attached to the machine with lifting tackle (cables, chains, etc.) are lifted, transferred and lowered, whereby the load must be attached manually to the machine. Loading operations thus also include lifting and lowering of pipelines, shaft rings and vessels.

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:

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.

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.

The pipe fracture safety valve must conform to the requirements laid down in ISO 8643.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation General working methods

The overload warning system warns the machine operator with a visual signal on the screen and an acoustic signal (warning sound) when the permissible maximum load is reached.

The overload warning system therefore helps prevent dangerous situations where the permissible load 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.

It remains however 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. Always strictly adhere to the applicable 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.

The maximum loads indicate the load with which the uppercarriage can be rotated by 360°, provided that the machine is standing on firm and level ground.

The load lift values in the table correspond to max. 75 % of the tip load or 87 % of the hydraulic lifting power 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.

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.

The load values also depend on any attached tools and attachments.

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.

The overload warning system consists of a pressure switch connected to the piston side of the boom cylinder.

If the hydraulic pressure in the boom cylinder reaches the limit value, the pressure switch generates a signal. As a result, a warning symbol is displayed on the screen and an audible warning sound is produced.

The chosen limit values take into account the stability factors of the machine.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

General working methods

The overload warning system does not disable the machine as soon as a permissible load moment is exceeded. The operator is only informed that the limit value is exceeded.

If the overload warning system has been triggered, do not increase the load or reach.

Press the switch .

The overload warning system is activated.

The LED in the switch is on.

Before each shift, the machine operator must check whether the overload warning system is working properly: Lift the boom and extend the boom cylinder to the stop.

Continue moving the joystick in direction "lifting boom".

The warning symbol must now appear on the screen.

The buzzer must sound.

The overload warning system warns the machine operator with a visual signal on the screen and an acoustic signal (warning sound) when the permissible maximum load is reached.

The overload warning system therefore helps prevent dangerous situations where the permissible load 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.

It remains however 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. Always strictly adhere to the applicable 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.

The maximum loads indicate the load with which the uppercarriage can be rotated by 360°, provided that the machine is standing on firm and level ground.

The load lift values in the table correspond to max. 75 % of the tip load or 87 % of the hydraulic lifting power 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.

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.

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Transport and assembly

The load values also depend on any attached tools and attachments.

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.

The overload warning system consists of a pressure switch connected to the piston side of the boom cylinder.

If the hydraulic pressure in the boom cylinder reaches the limit value, the pressure switch generates a signal. As a result, a warning symbol is displayed on the screen and an audible warning sound is produced.

The chosen limit values take into account the stability factors of the machine.

The overload warning system does not disable the machine as soon as a permissible load moment is exceeded. The operator is only informed that the limit value is exceeded.

If the overload warning system has been triggered, do not increase the load or reach.

Press the switch .

The overload warning system is activated.

The LED in the switch is on.

Before each shift, the machine operator must check whether the overload warning system is working properly: Lift the boom and extend the boom cylinder to the stop.

Continue moving the joystick in direction "lifting boom".

The warning symbol must now appear on the screen.

The buzzer must sound.

Due to the machine weight and dimensions, the machine is normally delivered as a disassembled unit for assembly on site. To assemble the machine, follow the instructions in the assembly guidelines of LIEBHERR.

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Transport and assembly

All work in connection with the assembly, dismantling and transport of the machine must be carried out by trained LIEBHERR technicians or partners authorised by LIEBHERR. If you need to transport, assemble and modify the machine, contact the service department.

Before transporting the machine or loading it onto a transport vehicle, complete the following steps: Hold wheel chocks ready.

Remove dirt, ice and snow from the chains, ramps and loading platforms.

Dismantle the attachment, if required.

Risk of accident!

It is forbidden to stand on the lifted machine!

Improper loading can result in shifting of the load.

Employ only experienced personnel with the attachment of the load and the guiding of the crane operator.

The signaller must be positioned within sight of the crane operator. Alternatively, the signaller and the operator might be in contact through walkie-talkies or similar devices.

Ensure that the crane tackle is sufficiently long.

Use only suitably dimensioned lifting gear. We recommend using special lifting gear available from LIEBHERR.

Fig. 3-80

Attachment of machine with gooseneck boom

copyright by R 984 C Litronic / 11140260

Operating manual

Control, operation Transport and assembly

Dismantle the attachment.

Switch off the diesel engine.

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.

Attach the lifting tackle to the points provided.

Carefully lift the machine with the crane and place it on the transport vehicle.

To restart the machine, strictly adhere to the instructions in the operator's manual.

Fig. 3-81

Securing the machine

If the machine begins to shift or becomes dislodged during transport, there is a risk of serious accidents.

Secure the machine against shifting.

To do this, used tie-down cables or chains.

Secure the machine by placing cables or chains diagonally through the tie-down eyelets of the undercarriage (at front and rear) (see Fig. 3-81).

copyright by R 984 C Litronic / 11140260

Control, operation

Operating manual

Transport and assembly

copyright by R 984 C Litronic / 11140260

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 Identify the cause of the malfunction and eliminate it or have it eliminated.

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.

E001

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 radiator for dirt, contact LIEBHERR customer service

E 002 E 003 E 004 E 005 E 006 E 007 E 009

copyright by R 984 C Litronic / 11140260

Malfunctions

Operating manual

Error code list

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 radiator 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

Change 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

E 042

Slewing gear fine control not working

Cable defect at valve

Monitoring of hydraulic oil cooling does not work

Cable defect at valve

Contact LIEBHERR customer service

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 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 reduced

No CAN bus connection between keyboard and control system

Change 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 control to emergency mode, 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 011 E 012 E 013 E 014 E 015 E 016 E 017 E 018 E 022 E 023

E 309 E 319 E 321 E 322

Software incompatibility between keyboard and display Engine speed cannot be adjusted through the keyboard, hydraulic performance reduced

Hardware coding does not match software coding No known machine type received from keyboard

Change diesel engine and hydraulic pump to emergency mode, contact LIEBHERR customer service

Unknown hardware coding

copyright by R 984 C Litronic / 11140260

Operating manual

Malfunctions Error code list

E 442

Failure of idle automatic at left joystick, 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 455

Incorrect actuation of slewing gear brake

Speed sensor, slewing gear, short circuit, earth contact or wire break

Contact LIEBHERR customer service

E 456

Incorrect fuel display

Fuel sensor, short circuit, earth contact or wire break

Visual inspection of fuel level, contact LIEBHERR customer service.

E 443 E 445 E 446 E 454

E 458

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.

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 3 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 3 minutes; 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 3 minutes; 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 3 minutes; 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 3 minutes; 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 3 minutes; check hydraulic oil cooler for dirt; contact LIEBHERR customer service

E 511

Symbol is displayed

Overvoltage at control keyboard

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 field:

This symbol, together with a buzzer warning sound, indicates that the quick-change adapter is not properly locked.

copyright by R 984 C Litronic / 11140260

Malfunctions

Operating manual

Engine diagnostic system

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.

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.

The engine monitoring system monitors the diesel engine and records malfunctions and unfavourable operating conditions. The results are displayed on the control console in the form of error codes.

The indicator lights inform the operator of malfunctions and also allow him/her to call up the logged error codes.

After the ignition has been switched on, the indicator lights perform an auto-test. All indicator lights are briefly switched on and off again, provided there is no pending malfunction.

Fig. 4-1

Control console, engine diagnostic system

STOP

Lit in the event of faults that might result in a serious operating failure or damage to the diesel engine.

Switch off the diesel engine.

Contact the customer service department.

Start the diesel engine only after the fault has been eliminated.

WARNING

Lit in the event of unfavourable operating conditions. These can result in the failure of certain functions or loss of power. In such an event, the engine monitoring system might reduce the engine speed and power.

The diesel engine remains in operation, but should be examined as quickly as possible.

Contact the customer service department.

PROTECTION

Double function: indicator light + switch.

Is lit, if an error code has been logged. The indicator light is only switched off after the fault has been eliminated.

Press the switch to view the error codes.

Contact the customer service department.

copyright by R 984 C Litronic / 11140260

Operating manual

Malfunctions Engine diagnostic system

Special equipment: If the engine protection shut-down function has been activated, the diesel engine is automatically shut down to prevent damage.

The engine monitoring system reduces the power or speed in the event of

The motor monitoring system automatically shuts down the diesel engine in the event of

In the event of a fault, shut down the diesel engine.

Contact the relevant customer service department of LIEBHERR or of the engine manufacturer (Cummins).

The customer service department has detailed error code lists that allow for the accurate system diagnosis of the diesel engine.

Logged error codes are indicated in the form of flashing sequences of the indicator lights when the switch is pressed. To proceed to the next error code, actuate the rotary switch.

Switch off the ignition and switch it on again.

Press the switch.

If no error codes are logged, all indicator lights flash once.

If there are error codes, the indicator light flashes once, and the indicator switch subsequently flashes repeatedly, indicating the individual digits of the error code. After each digit sequence, the indicator light flashes once.

Fig. 4-2

Example: Flashing sequence for error code 235

copyright by R 984 C Litronic / 11140260

Malfunctions

Operating manual

Troubleshooting

Count the flashing signals to determine the error code (see example).

Turn the switch in direction or .

The display changes to the next or the previous error code.

The flashing signals are continued until another error code is selected or until the error code indication is switched off.

To switch off the error code indication, actuate the

switch again.

For detailed information, see operating manual of the engine manufacturer (Cummins).

Starter fails to turn

Starter turns slowly

Diesel engine fails to start

Engine starts, but stops immediately or runs irregularly

Diesel engine emits grey or black fumes

Main fuse defective

Replace fuse

Battery connections loose or corroded

Clean and tighten loose connections

Battery voltage too low

Charge or replace battery

Starter circuit open, or contacts corroded

Contact LIEBHERR customer service

Starter defective

Contact LIEBHERR customer service

Battery voltage too low

Charge or replace battery

Battery connections loose or corroded

Clean and tighten loose connections

Ambient temperature too low

Take measures required for winter operation

Fuel tank nearly/completely empty

Add fuel and bleed fuel system

Underpressure in the tank

Remove tank lid

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

Heating flange defective (at low temperatures)

Check heating flange; replace, if necessary

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 actual ambient temperature

Dry air filter dirty

Clean or replace main filter element

Air in fuel system

Bleed fuel system

Bleeding valve in fuel tank blocked

Clean

Fuel line, pre-filter or strainer in fuel tank blocked

Bleed and clean fuel system

Fuel line kinked

Check line and repair, if required

Dry air filter dirty

Clean or replace filter element

Injection nozzles jammed or no injection

Contact LIEBHERR customer service

Turbo charger defective

Contact LIEBHERR customer service

copyright by R 984 C Litronic / 11140260

Operating manual

Malfunctions Troubleshooting

White steam emitted by diesel engine

Blue exhaust fumes

Water in combustion room

Contact LIEBHERR customer service

Injection too late

Contact LIEBHERR customer service

Heating flange defective (at low temperatures)

Check heating flange; replace, if necessary

Oil level too high

Correct oil level

Lubricating oil in combustion chamber

Contact LIEBHERR customer service

Crankcase ventilation defective

Contact LIEBHERR customer service

Diesel engine knocking

Combustion problems

Contact LIEBHERR customer service

Diesel engine knocking

Excessive valve play

Contact LIEBHERR customer service

Injection nozzles damaged or carbonised

Contact LIEBHERR customer service

Diesel engine does not reach full speed

Poor engine performance

Diesel engine too hot

Damaged bearing

Contact LIEBHERR customer service

Piston ring worn or broken

Contact LIEBHERR customer service

Speed not set to maximum value

Set speed to maximum value

Injection unit settings incorrect

Contact LIEBHERR customer service

Dry air filter dirty

Clean or replace filter element

Insufficient fuel supply

Clean or replace fuel filter; check lines, drain water from tank

Fuel system defective (blockage, leakage)

Inspect for leakage, change filter; contact LIEBHERR customer service

Intercooling pressure too low

Visual inspection for loose clamps, defective seals and damaged hoses; clean air filter

Intercooling air temperature too high (power reduced by engine control unit)

Clean intercooling air cooler; contact LIEBHERR customer service

Coolant temperature too high (power reduced by engine control unit)

Check coolant level; check radiator for dirt, clean if necessary; check fan and thermostat; contact LIEBHERR customer service

Fuel temperature too high (power reduced by engine control unit)

Contact LIEBHERR customer service

Injection nozzles jammed or no injection

Contact LIEBHERR customer service

Diesel engine compression too low

Contact LIEBHERR customer service

Fault in electronic components

Contact LIEBHERR customer service

Insufficient amount of coolant

Add coolant, check for tightness

Water pump defective

Repair

Thermostats fail to work

Replace thermostats

Radiator dirty

Cleaning radiator

Coolant temperature sensor defective

Contact LIEBHERR customer service

Oil level too low

Adjust oil level

Oil pressure indicator defective

Change oil pressure switch

Diesel engine uses too much oil

Leak in diesel engine

Retighten screws; replace seals, if required

Oil in coolant or coolant in oil

Leakage in cooling system or diesel engine

Contact LIEBHERR customer service

Unusual noises / noise at exhaust side

Leakage in exhaust gas system

Check / repair exhaust gas system

Unusual noises / noise from hydraulic pumps

Shut-off valve at the hydraulic tank closed

Open shut-off valve

Hydraulic pumps take in air

Check oil level in the hydraulic tank, check suction lines for leakage

Insufficient oil pressure in diesel engine Immediately switch off the diesel engine

Immediately switch off the diesel engine

copyright by R 984 C Litronic / 11140260

Malfunctions

Operating manual

Troubleshooting

Modes E and P show poor performance

No performance adjustment by means of proportional solenoid valve

Operate machine in emergency mode

Hydraulic oil temperature too high

Radiator dirty

Cleaning radiator

Fan or fan control defective

Eliminate fault / contact LIEBHERR customer service

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 safety lever down Switch on servo control

Slewing gear brake activated

Move safety lever down Release slewing gear brake

No working movement

Servo control not working

Move safety lever down Switch on servo control

No servo pressure

Contact LIEBHERR customer service

No pump high pressure

Contact LIEBHERR customer service

Machine fails to travel forward or back

Safety lever moved up

Move safety lever down

Machine moves too slowly

Travel pedals dirty Super-Finish activated with switch installed).

Emergency control activated

(if

Clean travel pedals Deactivate Super-Finish (if installed); switch off emergency control and switch machine to standard operating mode; contact LIEBHERR customer service

Oil escaping at running rollers, support rollers or idler

Seal defective

Replace seal

Poor chain alignment at idler

Excessive play of idler guide system at the running roller frame

Adjust pay of idler guide system

Chain jumps from guides

Insufficient chain tension / 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

Cleaning drive

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 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

copyright by R 984 C Litronic / 11140260

Operating manual

Malfunctions Fuses and relays

Speed cannot be adjusted through keyboard (mode and arrow keys)

Idle automatic is activated

Grab the joystick or deactivate the idle automatic

Excavator electronics for speed adjustment not working

Switch hydraulic pump to emergency mode, contact LIEBHERR customer service

No signal from speed sensor Idle automatic without function; speed fails to drop

Permanent sensor signal Idle automatic is deactivated

Contact LIEBHERR customer service Activate idle automatic

Slewing gear brake cannot be released with switch

Fault in electrical system of excavator

Actuate emergency mode control Caution: The keyboard is disabled; contact LIEBHERR customer service

No warm air escaping from heating system

Shut-off valves (if installed) of coolant line on the diesel engine closed

Open shut-off valve

Diesel engine too cold

Warm up diesel engine to its normal operating temperature

Heating blower not working

No power

Check fuse and cable; replace or repair if required

Blower motor defective

Replace blower motor

Low air circulation rate in operator's cab

Ambient air filter / recirculation air filter contaminated

Clean air intake openings; replace ambient air filter

Air outlets closed

Open air outlets

Cylinder responds to load

Piston seal on cylinder defective

Service hydraulic 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

Additional function not activated

Release additional function

Lines not connected

Connect lines

Incorrect or bridged fuses do not provide the protection required for the safety of the machine operator and the electrical equipment.

Use only original fuses.

Never bridge electrical fuses.

If necessary, order replacement fuses from LIEBHERR.

copyright by R 984 C Litronic / 11140260

Malfunctions

Operating manual

Fuses and relays

Before exchanging a fuse or relay, set the battery main switch to position

Fig. 4-3

(OFF).

Fuse box E50

The fuse box E50 is located behind the door to the engine compartment.

Remove the lid of the fuse box and close it after the fuse has been replaced.

15 A

Diesel engine

80 A

Main fuse

7.5 A

Reserve

7.5 A

Heating and a/c system terminal 15

15 A

Heating and a/c system terminal 30

15 A

Reserve

15 A

Reserve

15 A

Reserve

15 A

Reserve

15 A

Reserve

50 A

Flywheel Starter relay Engine stop relay Cylinder shut-down relay Cold start system relay Diesel engine ON (12 V for operating hours counter) relay Relay E5 Relay E150 Main relay terminal 15 Headlight relay

copyright by R 984 C Litronic / 11140260

Operating manual

Malfunctions Fuses and relays

Fig. 4-4

Fuses and ESP02 relay board

The A1010 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 problem has been rectified.

15 A

Reserve

15 A

Reserve

15 A

Reserve

15A

Pre-heating, control of windscreen wiper/washer system, beacon*, rotating grapple*

7.5 A

Windscreen wiper

7.5 A

Emergency speed adjustment

7.5 A

Keyboard and display

15 A

Safety lever, solenoid valves of pilot pressure system, slewing gear brake, fast travel, additional pressure stage

15 A

Speed-adjustment motor, excavator control

25 A

Attachment headlight, revolving deck headlight, auxiliary headlight*

15 A

Reserve

15 A

Reserve

7.5 A

Ignition, starter, voltage converter, radio*, engine stop*

15 A

Cab lighting, cigarette lighter, horn

15 A

Reserve Emergency control, engine stop* relay Horn relay Cab roof headlight relay Float position relay Emergency mode flow reduction relay

* optional equipment

copyright by R 984 C Litronic / 11140260

Malfunctions

Operating manual

Emergency operation

In certain situations, it might be necessary to restore a function that failed before the machine is properly repaired. Depending on the type and extent of the malfunction, this might be achieved by setting the machine to emergency mode.

In emergency mode, certain control electronics and control elements are bypassed so that certain functions can be controlled directly. This mode allows for the temporary limited operation of the machine.

Emergency mode is designed for use in emergency situations only.

Due to the reduced functionality of the machine in emergency mode and the associated risks, this mode may only be used in exceptional situations (see Tab. 41). :

Control

Short-term continuation of operation until repair can be performed (it is always recommended to carry out repairs without delay)

Hydraulic pump

Move the machine away from the construction site or a dangerous position (immediate repair is required)

Tab. 4-1

Emergency mode, purpose

In emergency mode, certain safety functions of the control system are disabled.

This can lead to accidents or damage to the machine.

Use the 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.

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:

These functions may be combined with each other.

The control panel for emergency control operation is located in the rear section of the right control console.

copyright by R 984 C Litronic / 11140260

Operating manual

Malfunctions Emergency operation

Fig. 4-5

Control panel in the right control console

Fig. 4-6

Control panel for emergency control

Emergency control switch / speed adjustment

Speed controller

Emergency control switch / machine control

Emergency control switch / central lubrication system

The emergency speed adjustment caters for the following failures: and If the diesel engine is in emergency mode, the engine speed can be adjusted with the regulator .

Set the switch

to position .

Start the diesel engine with the ignition key.

The indicator light is on.

The symbol is shown at the display.

The speed adjustment is in emergency mode.

Adjust the speed with the regulator .

Turn the regulator clockwise to increase speed.

Turn the regulator counter-clockwise to reduce the speed.

copyright by R 984 C Litronic / 11140260

Malfunctions

Operating manual

Emergency operation

The emergency machine control caters for the following situations:

In emergency machine control mode, the servo control system and the slewing gear brake cannot be operated with the normal switches, 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). There is thus an increased risk of accidents!

Therefore, use the emergency machine control mode if this is absolutely necessary.

Use the emergency machine control option only to remove the machine from the danger zone.

Fig. 4-7

Emergency control screen

Move the safety lever up.

Set the switch to position .

Emergency control mode is now on.

The emergency mode symbols are shown in the screen (see Fig. 4-7).

The servo control and the slewing gear brake can now be operated with the safety lever.

Move safety lever down.

The slewing gear brake is released.

The servo control is activated.

The emergency mode for the central lubrication system is used in the event of a failure of the central lubrication system due to a control fault.

Move the switch cycle.

briefly to the left or right to initiate a complete lubricating

If the central lubrication system is in working order, the actuation of the switch initiates an additional lubricating cycle.

Set the switch to position .

A lubricating cycle is completed.

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. This function is activated/deactivated at the control oil unit. It bypasses the control electronics so that the hydraulic pump can be operated at an only slightly reduced output rate.

copyright by R 984 C Litronic / 11140260

Operating manual

Malfunctions Emergency operation

The control oil unit can be accessed from the engine compartment.

Fig. 4-8

Control oil unit, emergency operation of hydraulic pump

Switch off the diesel engine.

Disconnect the plug connector

.

Remove the cotter pin .

Move the lever into a horizontal position (emergency position).

The hydraulic pump is switched to emergency operation.

Start the diesel engine.

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.

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 chains for towing.

Tow the vehicle with a adequately dimensioned towing rod or steel cable.

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.

copyright by R 984 C Litronic / 11140260

Malfunctions

Operating manual

Emergency operation

Fig. 4-9

Towing the machine

Ensure that the towing rod or steel cable used for towing is of a sufficient tensile strength.

Move the working attachment as close as possible to the machine and lift it a little off the ground.

Position the working attachment in such a way that the towing vehicle is not obstructed and cannot be damaged during towing.

Attach the towing rod or steel cable to the hook on the undercarriage.

Towing speed: max. 1 km/h

copyright by R 984 C Litronic / 11140260

ied out by trained expert technicians. spections as contained in this operating manual. op is available to perform these tasks, and note the designated qualifications of the personnel responsible for each inspection. 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. rements 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. addition to a protective helmet and safety boots, for certain jobs protective goggles and gloves are also necessary. om the machine during maintenance.

work. Make sure he knows the person who is in charge of the work. with the working equipment lowered and the diesel engine turned off, unless described otherwise in the operating manual. maintenance operations, especially when working under the machine. Remove the ignition key and set the main battery switch to position 0. required torque specification. re-attached and inspected directly upon conclusion of the operations.

, 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.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Safety instructions

keep the machine clean and to clean it regularly. schedule. and level ground.

slewing ring seating with tower and slewing ring. cylinder, upper slewing ring seating, cab bearing, mounting of slewing gear and counterweight. e. g. boom, stick, quick change adapter, digging tool and grapple. and pin connections, steps, ladders and mounting elements. spected 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. ately. 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.

LIEBHERR. Prior to any welding, cutting or grinding, clean the machine and surrounding area to remove dust and flammable materials.

emical substances, always observe the applicable safety regulations for the corresponding product. disposal of operating and service fluids as well as exchange parts. scalding).

fting 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.

The guide must position himself within view of the operator or be in voice contact with him.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Safety instructions

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. the machine is properly supported. Never use metal-on-metal support. equipment unless it has been properly and securely supported. ways that any shifting weight will not endanger the stability of the machine and avoid metal to metal contact. specially trained expert personnel. and secure the uppercarriage to the undercarriage with the locking pin.

to detect leaks. Wear work gloves. 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.

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.

voltage systems.

connect the supply cable to the ground to discharge any stored energy. short circuit them. Insulate adjacent, current carrying parts. out any arc welding work on the machine.

ergy and operate at high pressures.

Only specially trained personnel may work on pressure accumulators.

operating manual prior to working on a hydraulic accumulator.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Safety instructions

mechanical work on them.

burning. application before use. the pressure accumulators. Make sure that the marking remains visible.

ecked 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. process. For that reason, their service life is limited. and impermissible use are the most frequent causes of failure. ranges of permitted use can shorten the service life (for example in high temperatures, frequent work cycles, extremely high impulse frequencies, multi shift operation). inspection: and cracks);

under pressure or not under pressure, or in bends (e.g. separation of layers, blisters or bubbles); allation instructions; ich reduce the strength of the fitting or the hose / fitting connection; h reduces function and strength;

y, observe correct connection points. pressure hoses, always attach the screws of half clamps or full flange on both ends of hose first and then tighten. end with the bent fitting first when tightening the flanges, then the end with the straight fitting. ntre of the hose may only be installed and tightened thereafter. ps, covers and protective devices are properly mounted. This prevents vibration and damage during operation. structures is prevented. the outer hose diameter to the other parts is recommended. The distance should not be less than 10 to 15 mm (1/2 inch).

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Access points for maintenance

able parts (e.g. from boom to stick), check for hose interference and kinking over the complete range of motion.

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.

or example welding, cutting or drilling)

any kind are prohibited without the expressed, written approval of LIEBHERR.

Fig. 5-1

Access points at uppercarriage

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Access points for maintenance

1

Engine bonnet

Diesel engine, radiator

2

Engine bonnet

Diesel engine, radiator, control valve block, control oil unit

3

Bonnet

Compensation vessel of cooling system

4

Hydraulic tank

Return filter, breather filter

5

Lubrication box

Grease tank, pump unit and compressed air system components of central lubrication system

6

Engine compartment door

Diesel engine, hydraulic pumps

7

Engine compartment door

Bypass oil filter

8

Battery compartment door

Batteries, battery main switch, dry air cleaner, compressed air system components of central lubrication system

9

Radiator door

Radiator

10

Fuel tank

Tank lid

The machine is equipped with several access doors for maintenance. Some of the access doors are secured with locking handles or screws.

For fast intervention in the event of an emergency, the locks in the handles must be opened prior to starting the machine.

Access doors might inadvertently close and cause injury to persons.

When opened, lock the access doors using the provided locking mechanism.

Fig. 5-2

Door locking mechanism

In order to prevent inadvertent movement of the access doors (e.g. by wind), they must be fully opened and locked (arrow) with the locking mechanism.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Access points for maintenance

Fig. 5-3

Locking mechanism for bonnet

Open the locks , open the bonnet and fold it up.

Secure the bonnet with the holder .

All bonnets are held in place with gas pressure springs. Older gas pressure springs might become weak, so that the bonnet might close inadvertently.

Therefore always secure the open bonnet with the locking mechanism .

Fig. 5-4

Access points, bottom side of undercarriage

Diesel engine

Hydraulic pumps

Radiator

Radiator

Some of the drain valves of the units cannot be reached from the engine compartment. They are however accessible through openings in the base of the uppercarriage. To access them, remove the respective cover plate and secure it again after the maintenance task is completed.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Cleaning machine

Risk of injury from dropping cover plates. The risk of injury is increased in machines with heavy cover plates (optional equipment).

Never lift or mount the cover plates on your own. Always work in teams of at least two people.

Before loosening or tightening the screws place a support under the cover plate.

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.

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 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).

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,

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.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Care for rubber components

If required, renew the preservation layer (anti-corrosion protection) on components and surfaces.

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

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.

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.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Fuels, lubricants and process chemicals

Diesel engine

Liebherr Motoroil 10W-40 low ash

58.0

Adhere to the instructions of the engine manufacturer (see Cummins manual) Hydraulic system (system capacity / oil change volume / tank capacity)

Liebherr Hydraulic Basic 68 Liebherr Hydraulic Basic 100 Liebherr Hydraulic HVI Liebherr Hydraulic Plus Liebherr Hydraulic Plus Arctic

1970 / 1100 / 800

Slewing gear mechanism

Liebherr Gear Basic 90 LS

31.5

Travel gear

Liebherr Gear Basic 90 LS

2 x 20

Pump distribution gear

Liebherr Gear Basic 90 LS

10.5

Central lubrication system, lubrication points on machine and attachment

Liebherr Universalfett 9900

-

Lubrication system of slewing gear

Liebherr spray paste

-

-

Hinges, joints, locks

Engine oil

-

-

* = approximate values

Fuel tank

Conventional diesel fuel

1585

Coolant

Corrosion inhibitor and antifreeze agent Adhere to the instructions of the engine manufacturer (see Cummins manual)

88.0

Windscreen washer system

Conventional windscreen cleaning agent or denatured alcohol

-

3.0

* = approximate values

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Fuels, lubricants and process chemicals

Fig. 5-5

Lubrication chart

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Lubricants and fuels

Diesel engine, check oil level Gearbox, 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. 5-1

Key to lubrication chart

Maximum sulphur content

5000 ppm1)

Viscosity at 60 °C

460 µm

Minimum cetane number

45

Tab. 5-2

Minimum quality requirement

Do not mix diesel fuel with fuel additives.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Lubricants and fuels

Liebherr Motoroil 5W- 30 Liebherr Motoroil 10W-40 Liebherr Motoroil 10W-40 low ash2) Tab. 5-3

Liebherr recommendation

1) The sulphur content of the fuel determines the change interval in dependence on the quality of the engine oil.

2) For machines with diesel particulate filters, use low ash engine oil (LH-00-ENG3A

LA).

LH-00-ENG3A LH-00-ENG3A LA Tab. 5-4

Minimum quality requirement

If engine oils from other manufacturers are used, information on the change intervals must be obtained from the respective manufacturer or supplier.

Adverse factors affect the change interval of the engine oil.

Adapt change interval of the engine oil.

Adverse factors are:

The sulphur content of the fuel determines the change interval in dependence on the quality of the engine oil.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Lubricants and fuels

Up to 15 ppm

1000h

2000h

15 ppm to 300 ppm

500h

1000h

300 ppm to 2000 ppm

500h

500h

2000 ppm to 5000 ppm

250h

250h

Tab. 5-5

Change interval of engine oil

Make sure that water used meets following requirements: (WHO) from 2006.

DCA 4 (Diesel Coolant Additives 4)

Fleetguard, Cummins Filtration

Caltex XL Corrosion Inhibitor Concentrate

Chevron Texaco

Chevron Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free (ECLC)

Chevron Texaco

Havoline Extended LIFE Corrosion Inhibitor

Chevron Texaco

Total WT Supra

Total, Paris

Tab. 5-6

Liebherr recommendation with 50:50 mixing ratio

Concentrate

Liebherr Antifreeze OS Concentrate

PremixA)

Liebherr Antifreeze OS Mix

Tab. 5-7

Liebherr recommendation

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Lubricants and fuels

Up to -50°C

40% water 60% anti-freeze and corrosion protection agent

Up to -37°C

50% water 50% anti-freeze and corrosion protection agent

Tab. 5-8

Mixing ratio

A) Premix= premix (50% water and 50% anti-freeze and corrosion protection agent)

See global Liebherr specificat If coolant from other manufacturers are used, information on the change intervals must be obtained from the respective manufacturer or supplier.

Liebherr mineral oil 15 to 55°C

Liebherr Hydraulic Basic 100

10 to 45°C

Liebherr Hydraulic Basic 68

-20 to 40°C

Liebherr Hydraulic HVI 3)

-25 to 45°C

Liebherr Hydraulic Plus

-40 to 30°C

Liebherr Hydraulic Plus Arctic

Tab. 5-9

Liebherr recommendation

3) PAO= poly-alpha-olefin

See global Liebherr specificat If hydraulic oils or filters from other manufacturers are used, information on the change and replacement intervals must be obtained from the respective manufacturer or supplier.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Lubricants and fuels

Normal application (Oil analysis optional)

l

Every 250h, at least once a year

Every 1000h, at least once a year

Upon handover, then every 250h, at least once a year

Upon handover, then every 1000h, at least once a year

Liebherr Hydraulic Basic 68 Liebherr Hydraulic Basic 100 Liebherr Hydraulic HVI Eco-friendly application (oil analysis mandatory)

Liebherr-PAO biodegradable Liebherr Hydraulic Plus Liebherr Hydraulic Plus Arctic

Tab. 5-10 Oil analysis

Liebherr return filter

Every 250h, additionally at every hydraulic oil change

Every 1000h, additionally at every hydraulic oil change

Liebherr breather filter

Every 500h, additionally at every hydraulic oil change

Every 2000h, additionally at every hydraulic oil change

Liebherr bypass filter

If necessary, every 2000h

(Option)4) Liebherr bypass filter (option) integrated in return filter4)

If necessary, every 2000h

Tab. 5-11 Filter replacement 4)

For eco-friendly applications, a bypass filter is mandatory.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Lubricants and fuels

Liebherr mineral oil

Every 3000h

Every 6000h

Every 4000h6)

Every 8000h

Liebherr Hydraulik Basic 68 Liebherr Hydraulic Basic 100 Liebherr Hydraulic HVI Liebherr-PAO biodegradable Liebherr Hydraulik Plus Liebherr Hydraulik Plus Arctic Tab. 5-12 Oil change 5)

Change oil after negative oil analysis.

6)

For eco-friendly applications, oil analysis is mandatory.

Machine with Kessler axles LT-D! Use gear oil Liebherr Gear Basic 90 LS or gear oil in line with specification API GL-5 and MIL-L_2105 D.

-30 to 50°C

Liebherr Gear Basic 90 LS

-35 to 50°C

Liebherr Gear Plus 20W-40

-35 to 50°C

Liebherr Gear MF80W

Tab. 5-13 Liebherr recommendation

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Lubricants and fuels

API: GL-5 MIL-L: 2105 D ZF: TE-ML 05C, 05D Tab. 5-14 Minimum quality requirement If axle oils from other manufacturers are used, information on the change intervals must be obtained from the respective manufacturer or supplier.

Gear oils specified in the chart are not suitable for following transmissions:

-30 to 50°C

Liebherr Gear Badic 90 LS

-35 to 50°C

Liebherr Gear Plus 20W-40

-30 to 50°C

Liebherr Gear Hypoid 90 EP

-25 to 50°C

Liebherr Hypoid 85W-140 EP

-40 to 50°C

Liebherr Syntogear Plus 75W-90

Tab. 5-15 Liebherr recommendation

API: GL-5 MIL-L: 2105 D or E, PRF-2105 D or E Tab. 5-16 Minimum quality requirement Adhere to device specifications on ZF approvals.

If gear oils from other manufacturers are used, information on the change intervals must be obtained from the respective manufacturer or supplier.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Lubricants and fuels

Liebherr Motoroil 10W-40 Tab. 5-17 Liebherr recommendation

10W-40

ACAE E4

Tab. 5-18 Minimum quality requirement If gear oils from other manufacturers are used, information on the change intervals must be obtained from the respective manufacturer or supplier.

-25 to 50°C

Liebherr Hypoid 85W-140 EP

-30 to 50°C

Liebherr Gear Basic 90 LS

-30 to 50°C

Liebherr Gear Hypoid 90 EP

-40 to 50°C

Liebherr Syntogear Plus 75W-90

Tab. 5-19 Liebherr recommendation

API: GL-5 MIL-L: 2105 D or E, PRF-2105 D or E Tab. 5-20 Minimum quality requirement If gear oils from other manufacturers are used, information on the change intervals must be obtained from the respective manufacturer or supplier.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Lubricants and fuels

5 to 50°C

Liebherr Hypoid 85W-140 EP

-5 to 50°C

Liebherr Gear Basic 90 LS

-5 to 50°C

Liebherr Gear Hypoid 90 EP

-20 to 50°C

Liebherr Syntogear Plus 75W-90

Tab. 5-21 Liebherr recommendation

API: GL-5 MIL-L: 2105 D or E, PRF-2105 D or E Tab. 5-22 Minimum quality requirement Make sure the following conditions are met: If gear oils from other manufacturers are used, information on the change intervals must be obtained from the respective manufacturer or supplier.

Tab. 5-23 Liebherr recommendation

See Liebherr specification for energy recuperation cylinder oils.

If energy recuperation cylinder oils from other manufacturers are used, information on the change intervals must be obtained from the respective manufacturer or supplier.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Lubricants and fuels

From -20°C

Liebherr Universalfett 9900

From -55°C

Liebherr Universalfett Arctic

Tab. 5-24 Liebherr recommendation

Soap-based (lithium complex

At least every 3 years

Pumpable in line with KP 2 K (DIN 51502) VKA welding force: 2300N (DIN 51350/4, ASTM D 2596) For R984: VKA welding force: 5500N (DIN 51350/4, ASTM D 2596)

Tab. 5-25 Minimum quality requirement

Liebherr recommends commercially available windscreen washer fluid with antifreeze.

Use mixture of water and denatured alcohol.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Diesel engine

Contact spray for slip rings

Cramolin

Lubricant for pistons, piston nuts and for mounting piston rod bearings on hydraulic cylinders

Gleitmo 800

Special corrosion inhibitor for mounting recesses of sealing elements on hydraulic cylinders

Rostilo Trap CFX

Tab. 5-26 Liebherr recommendation

Risk of burns from hot engine oil!

Avoid skin contact with hot oil or parts containing oil.

When changing the engine oil or the oil filter cartridges, proceed with great caution.

The maintenance tasks for the diesel engine are described in detail in the enclosed operating manual of the engine manufacturer (Cummins). The information in this document complements this operating manual, referring specifically to the operating conditions of the diesel engine in Liebherr machines.

Fig. 5-6

Dip stick

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Diesel engine

Ensure that the machine is in a horizontal position.

Switch off the diesel engine.

Wait a few minutes until the engine oil has collected in the oil pan.

Pull out the dip stick and clean with a clean cloth.

Insert the dip stick to the stop.

Pull out the dip stick again and check the oil level.

The oil level must be between the

and

marks.

If necessary, add engine oil until the level reaches the

mark.

Ensure that the machine is in a horizontal position.

The engine oil must be warm (increased fluidity).

The diesel engine can be accessed from the engine compartment. The oil pan and the oil filter cartridges can be accessed through an opening at the bottom of the upper carriage.

Remove the cover plate of the diesel engine and replace it after completion of the maintenance tasks.

Fig. 5-7

Filler neck, drain valve

Drain valve

Drain hose

Filler neck

Oil filter cartridges (see Fig. 5-8)

protect the V-ribbed belt against escaping engine oil.

Open the filler neck .

Remove the cover cap from the drain valve Screw the drain hose

to the drain valve of the oil pan.

copyright by R 984 C Litronic / 11140260

on the oil pan.

Maintenance

Operating manual

Cooling system

Collect the engine oil in a suitable container.

Disconnect the drain hose and replace the cover cap of the drain valve.

Fig. 5-8

Oil filter cartridges

The oil filter cartridges are located behind the fuel filters and can be accessed from the bottom.

Loosen and remove the oil filter cartridges

using a strap spanner.

Clean the sealing surfaces of the filter bracket.

Apply oil to rubber seal rings of the new oil filter cartridges.

Screw in the new oil filter cartridges until the seal rings touch the filter head.

Tighten the oil filter cartridges strap spanner.

by 1/2 to 3/4 revolutions, using the oil filter

Add engine oil through the filler neck (max) on the dipstick.

until the oil level reaches the upper mark

Seal the filler neck.

Start the diesel engine and check the oil pressure.

Switch off the diesel engine after 2 to 3 minutes.

Check the oil level again and add engine oil, if necessary.

Risk of scalding from hot coolant.

During machine operation, the engine cooling system is hot and pressurised.

Do not touch any parts containing coolant. Avoid contact with the coolant.

Check the coolant level only after the lid of the filler neck has cooled down.

The coolant must be changed when the engine is cold.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Cooling system

The maintenance tasks for the cooling system are described in detail in the enclosed operating manual of the engine manufacturer (Cummins). The information in this document complements this operating manual, referring specifically to the operating conditions of the diesel engine in Liebherr machines.

The machine is equipped with a combined cooling system for coolant, oil and intercooling air.

A clean cooling system is a prerequisite for optimum cooling.

It is also necessary to regularly check the engine, fan and radiator for damage and to clean these parts.

If there is leakage at the pressure-relief valve (lid of expansion vessel), replace it.

Check the state and tightness of the coolant hoses, and the connecting hoses between the coolant radiator and the engine.

Fig. 5-9

Checking expansion tank and coolant level

The expansion tank can be accessed through an opening in the bonnet.

To open the screw lid, turn it by 180°.

In this position, release any excess pressure, if necessary. When the tank is depressurised, carefully turn the lid further to remove it.

When cold, the coolant level must reach the lower end of the dip tube below the filler neck.

If necessary, add coolant.

Close the screw lid.

After coolant has been added, switch on the engine and let it run for a short time, while the heating is on. Then check the coolant level again.

When changing the coolant, observe the following instructions:

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Cooling system

the cooling circuit. contact position.

Fig. 5-10

Radiator drain valves

The drain valves and at the bottom of the radiator can be accessed when the cover plates are removed. Drain the coolant by connecting drain hoses to the valves.

For detailed information, see operating manual of the engine manufacturer (Cummins).

The system must be filled with corrosion inhibitor and antifreeze agent at all times.

Upon delivery, the coolant contains antifreeze agents for temperatures down to 37 °C (corresponds to approx. 50 % antifreeze agent).

The mixing ratio of the antifreeze agent must be regularly checked in the course of routine maintenance.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Fuel system

Fig. 5-11

Water filter

The water filter contains a corrosion inhibitor in the form of a paste additive. This additive improves the corrosion protection properties of the coolant.

Close the stop valves (see arrows) at the filter housing.

Screw out the filter cartridge.

Apply a little oil to the seal ring of the new filter cartridge.

Screw in the new filter cartridge until the seal ring touches the filter head.

The filter cartridge is easily damaged.

Do not use any tools when tightening the filter cartridge.

Tighten the filter cartridge

completing 1/2 - 3/4 revolution.

Open the stop valves.

Danger of explosion!

Avoid open flames when working on the fuel system and when refuelling.

Do not smoke.

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.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Fuel system

To minimise condensation in the tank, keep the fuel level as high as possible.

The indicator

indicates the fuel level in the tank.

When the red bars are on, there is very little fuel left in the tank.

If the fuel level is low, refuel before starting work.

Fig. 5-12

Tank lid

Remove the tank lid .

Refill fuel through the strainer.

Fig. 5-13

Draining water from the fuel tank

The water in the fuel tank located in the uppercarriage must be drained off every day.

Depending on the fuel quality and the conditions under which the machine is operated, the interval may be prolonged to one week.

The tank base is equipped with a water drain valve .

Place a suitable container under the machine.

Open the water drain valve.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Fuel system

Drain off the water until fuel begins to escape.

Close the water drain valve.

Fig. 5-14

Fuel tank

Drain the water from the fuel tank.

Place a suitable container under the tank.

Remove the tank lid

and the water drain valve

Regularly check the fuel tank and the strainer If required, replace the strainer

Fig. 5-15

and drain off the fuel. for dirt.

and/or rinse out the fuel tank.

Fuel filter

Fuel filter The fuel filters

Electronic fuel filter and

must be changed regularly.

The water in the electronic fuel filter must be drained off every day. Depending on the fuel quality and the conditions under which the machine is operated, the interval may be prolonged to one week.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Dry air filter

For detailed information, see operating manual of the engine manufacturer (Cummins).

Fig. 5-16

Dry air filter

The engine can only be protected from abrasion caused by dust and thus excessive wear, if the air filter is regularly cleaned or replaced.

The dry air filter is designed in such a way that it provides excellent protection with relatively long maintenance intervals.

By blowing out the housing, dirt can be blown into the suction area, resulting in increased wear to the diesel engine.

Do not clean the housing by blowing it out with compressed air.

Fig. 5-17

Underpressure indicator

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Dry air filter

The underpressure indicator stores the maximum reached underpressure at the filter output during operation. The component can be accessed from the engine compartment.

If the red indicator strip is visible in the alarm window , the maximum permissible underpressure of 50 mbar has been reached.

When the red indicator strip is visible, replace the main element.

To delete the stored underpressure value, press the reset button .

Fig. 5-18

Pre-filter

Pre-filter

Clamp

Clamp The pre-filter is located at the bottom of the dry air filter.

The pre-filter must be removed and inspected every month and cleaned, if necessary.

Release the clamps

and .

Remove and clean the pre-filter .

Replace the pre-filter and tighten the clamps.

Frequent removal and remounting of the main element might result in damage to the seals between the filter element and the filter housing.

Replace the main element only if the maximum permissible underpressure is reached, or at least once every year.

The filter cartridges should not be cleaned (e.g. by washing with water) as this would impair the filter's effectiveness. Always replace dirty filter cartridges.

Change the safety element every third time the main element is replaced, or at least once every year.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Dry air filter

Before installing a new cartridge, carefully clean the seal and the seal padding in the housing.

Fig. 5-19

Changing the filter cartridges

Main element

Wing screw

Safety element

Mounting screw

Switch off the engine, screw off the wing screw

and remove the main element .

Clean the inside of the air filter housing and the sealing surface in the vessel with a damp cloth.

Insert the new main element , and ensure that it is positioned tightly and firmly in its seat.

Tighten the wing screw

by hand.

Remove the main element .

Unscrew the mounting screw

and remove the safety element .

Carefully clean the inside of the air filter housing with a damp cloth.

Clean the sealing surfaces in the housing and examine them for damage.

Carefully insert the new safety element .

Tighten the mounting screw

by hand.

Insert the new main element its seat.

and ensure that it is positioned tightly and firmly in

Tighten the wing screw

by hand.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Dry air filter

Fig. 5-20

Checking the clean air line

The clean air lines can be accessed from the engine compartment. Then connect the components of the suction system: Connection of dry air filter and turbocharger Connection of turbocharger and intercooling air cooler Connection of intercooling air cooler and engine suction pipe Each time you replace the filter cartridge, check the clean air lines for damage and leakage.

If necessary, retighten clamps of the lines.

Fig. 5-21

Please note that certain clamps may not be retightened.

Clamp

Clamp with spring pack

Clamps with spring packs ( , see arrow) can compensate changes in diameter.

Retightening might interfere with this function.

Do not retighten clamps with spring packs.

If necessary, retighten the clamps .

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Hydraulic system

Maintenance work on the hydraulic system is mainly limited to the hydraulic filter. All other components of the unit do not require any special maintenance or servicing.

The network of pipes and hoses must however be inspected regularly for leaks.

Fine jets of high-pressure liquid might penetrate the skin and cause injury. At operating temperature, the hydraulic oil is hot and might be under pressure. Hot hydraulic oil can cause serious injury.

Before carrying out any work on the hydraulic system, you must fully depressurise it.

Do not use your bare hands to check the equipment for leaks.

Avoid skin contact with hot oil or components containing hot oil.

Cleanliness is of particular importance for the proper working of the hydraulic system.

For this reason, the following intervals must be strictly adhered to:

Fig. 5-22

Position for the checking of the oil level in the hydraulic tank

To check the oil level or to add oil to the system, place the machine in a horizontal position. The working attachment must be positioned as follows: Fully open the grapple jaws.

Fully lift the boom.

Position stick at an angle of approx. 10° from the horizontal position.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Hydraulic system

Fig. 5-23

Sight glass of the hydraulic tank

The oil level can be checked through the sight glass located at the rear of the hydraulic tank. When the machine is in check position, the level must be close to the centre mark in the sight glass.

The upper mark retracted.

indicates the maximum oil level when all cylinders are fully

The lower mark extended.

indicates the minimum oil level when all cylinders are fully

If the oil level drops below the lower mark , the minimum level is reached and the respective warning symbol is shown at the display.

If required, add oil through the return filter until the level reaches the centre mark.

Fig. 5-24

Depressurising the hydraulic system, breather filter

The breather filter can be rotated by hand when the safety pin necessary, use an open end spanner to turn the filter.

Lower the working attachment to the ground.

Switch off the diesel engine.

copyright by R 984 C Litronic / 11140260

is inserted. If

Maintenance

Operating manual

Hydraulic system

Operate the pilot control units (joystick and pedals) in all directions (while the ignition key is in contact position).

Turn the breather filter by one full revolution.

The hydraulic system is gradually being depressurised.

After completion of the maintenance task, retighten the breather filter .

The hydraulic system is depressurised.

Change the breather filter (see Fig. 5-24) each time you change the hydraulic oil.

In areas with excessive production of dust, observe the special instructions for the filter change.

Fig. 5-25

Draining and filling hydraulic oil

Top view

Rear view

Bottom view

Breather filter

Return filter lid

Drain valve

If possible, empty and refill the hydraulic system using a filler unit.

The hydraulic system is depressurised.

Remove the lid

from the return filter.

Screw the drain hose onto the drain valves let the oil drain into a suitable container.

and

at the bottom of the tank and

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Hydraulic system

The hydraulic system is depressurised.

Remove the lid

from the return filter.

Add oil through the filter cartridge until it reaches the centre mark in the sight glass.

Tighten the breather filter .

Replace the lid

of the return filter.

Hydraulic components can be damaged, if the system is not bled!

Bleed the hydraulic pumps after each hydraulic oil change.

Regularly drain the condensate from the system.

Place a suitable container under the machine.

Connect the drain hose to the drain valves and (see Fig. 5-25) until the oil flowing into the container does not contain any water.

Fig. 5-26

Return filter

Lid Hex head screw

Magnetic rod Seal ring

Filter cartridge The magnetic rod must be cleaned and the filter cartridge must be replaced at prescribed intervals (see inspection and maintenance schedule).

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Hydraulic system

In areas with excessive production of dust, observe the special instructions for the filter change.

The hydraulic system is depressurised.

Loosen the screws rod .

on the lid

and remove the lid

together with the magnetic

Carefully clean the magnetic rod

removing any persistent dirt.

Remove the spent filter cartridge

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.

Ensure that the filter cartridge is positioned vertically in the tank.

Mount a new seal ring .

Carefully centre the lid damaged.

in the filter cartridge. Ensure that the seal ring

is not

The filling opening of the hydraulic tank is equipped with a protective cylinder. It prevents foreign particles entering the hydraulic tank. If required, the protective cylinder can be removed from the filling opening.

After a filter change, you must also change the pressure filter of the control oil unit.

Fig. 5-27

Control oil unit

Control oil unit

Control oil filter

Mounting stud

Filter cartridge

Filter cartridge seal ring

Filter pot

Seal of filter pot

Accumulator

The control oil unit can be accessed from the engine compartment.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Hydraulic system

The filter cartridge cannot be cleaned.

Replace the cartridge each time you open the filter pot.

The hydraulic system is depressurised.

Place a suitable container to collect the hydraulic oil under the bleed point.

Screw off the filter pot

of the pressure filter

and pull out the filter cartridge .

Clean the filter pot .

Apply a little hydraulic oil to the threads and sealing faces at the filter pot the control oil unit as well as to the sealing rings and .

Carefully place the new filter cartridge Screw in the filter pot

and at

onto the mounting stud .

to the stop and tighten it by hand.

Regularly inspect the pipelines and the connections of all units (pumps, pressure accumulators, pressure-relief valve, pressure filter, etc.) for leakage.

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.

Hydraulic pumps that were not bled might be damaged during operation, and can lead to limited functioning of the hydraulic unit.

Always bleed the hydraulic pumps if air has been trapped in the system as a result of work carried out on the hydraulic system.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Hydraulic system

Fig. 5-28

Hydraulic pumps

Hydraulic pump P3

Hydraulic pump P2

Hydraulic pump P1

Hydraulic pump / fan drive

Hydraulic pump / slewing gear The hydraulic system is depressurised.

The hydraulic pumps must be bled in the prescribed sequence. Start with the pump installed at the lowest point (no. 1), and finish with the pump located at the highest point (no. 5).

Open the leak oil hose at the hydraulic pumps 1, 2, 3 and 5. At the hydraulic pump 4, open the screw plug (see arrows).

Place a suitable container to collect the hydraulic oil under the bleed point.

Open the leak oil hose or the screw plug a little to allow the air to escape.

The hydraulic pump is being bled.

As soon as the hydraulic oil escapes without bubbles, tighten the screw plug or leak oil hose connection.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Hydraulic system

Fig. 5-29

Suction hose, shut-off valve

The shut-off valve of the suction hose has two positions: open closed The hydraulic system is depressurised.

If the suction hose is to be disconnected at the pump or at the hydraulic tank, close the shut-off valve .

Place a suitable container to collect the hydraulic oil under the machine.

Drain the hydraulic oil from the pump and suction hose.

After completion of the repair, turn the shut-off valve to its initial position engage it.

Fig. 5-30

and

Feed line filter of the slewing gear circuit

The cartridges of the feed line filters attached to the slewing gear pump must be changed at prescribed intervals.

The hydraulic system is depressurised.

Place a suitable container to collect the hydraulic oil under the machine.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Hydraulic system

Unscrew the filter pot.

Remove the filter cartridge and insert a new one.

Mount the filter pot.

Fig. 5-31

High-pressure filter

The high-pressure filter of the hydraulic circuit is accessible from the engine compartment. The filter cartridge must be inspected at the prescribed intervals and each time a hydraulic unit is replaced. If necessary, the cartridge must be cleaned.

Fig. 5-32

High-pressure filter details

Head section Seal ring

Filter pot Filter cartridge

Seal ring

The hydraulic system is depressurised.

Place a suitable container to collect the hydraulic oil under the machine.

Unscrew the filter pot .

Remove the filter cartridge .

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Hydraulic system

Wash the filter cartridge

with petrol or replace it.

Clean the filter pot

and the head section .

Mount the filter pot

with the filter cartridge .

Start the diesel engine and move the working attachment for a short period of time (approx. 1 minute).

Switch off the diesel engine and check the connections at the filter pot and filter head for leaks.

The bypass oil filter is designed to remove small particles and water from the hydraulic system.

The filter cartridge must be replaced each time the return filter is changed, or at least every 6 months.

Where environmentally friendly hydraulic oils are used, LIEBHERR prescribes the use of bypass oil filters.

The machine can be equipped with two bypass oil filters. They are installed behind a cover to the side of the engine compartment (see Fig. 5-33).

Fig. 5-33

Location of installation of bypass oil filter

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Hydraulic system

Fig. 5-34

Bypass oil filter

Screw

Washer

Lid Filter cartridge

O-ring Filter housing

Switch off the engine.

Release the pressure from the hydraulic system.

Remove the screw

and the lid .

Remove the spent filter cartridge direction while lifting it slightly.

by turning it at the carrying straps in clockwise

Wait until the oil has been drained off, then remove the filter cartridge collect dripping oil in a suitable container.

Check the inlet and outlet of the filter housing necessary.

and

for dirt deposits and clean it, if

Remove the new filter cartridge from the packaging while leaving the cardboard mantle attached to the cartridge.

If the packaging is damaged, there is a risk that moisture has entered the filter cartridge, shortening its service life.

Ensure that the packaging of the new filter cartridge is not damaged.

Insert the new filter cartridge .

Fill the filter housing Clean the lid Replace the lid of 50 Nm.

with the same hydraulic oil as is used in the machine.

and insert a new O-ring . and secure it with the screw . Tighten the screw with a torque

Start the machine and check the bypass oil filter for leakage.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Hydraulic system

Fig. 5-35

Piston rod bearing

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.

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.

Defective hydraulic hoses can cause serious accidents and injury to persons.

Always replace defective hydraulic hoses (bubbles, moisture, damaged surface, etc.) without delay.

Install the new hydraulic hose in such a way that it is not exposed to torsion loads during operation.

Ensure that the hydraulic hose is not twisted during installation.

The mounting bolts of the SAE fittings must be tightened with the prescribed tightening torques (see below).

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Oil change in components :

M8

22

31

M10

44

62

M12

76

108

M14

122

172

M16

187

264

M20

-

350

M10

45

M12

70

M14

120

M16

170

M20

250

M10

65

M12

110

M14

180

M16

250

M20

450

Ensure that the machine is in a horizontal position.

Switch off the diesel engine.

Before draining the oil, wait some time so that the oil can collect in the unit.

The oil should be drained while it is at operating temperature.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Oil change in components

Fig. 5-36

Oil change in slewing gear mechanism

Filler neck Dip stick

Drain valve

The drain valve is accessible through an opening at the front of the revolving deck.

The oil is added through the filler neck.

Open the filler neck .

Lift the cover in front of the drain valve .

Connect the drain hose to the drain valve container.

and let the oil drain into a suitable

Disconnect the drain hose.

Add oil through the filler neck .

Check the fill level with the dip stick .

Add oil until the oil level reaches the

copyright by R 984 C Litronic / 11140260

mark on the oil dip stick .

Maintenance

Operating manual

Oil change in components

Fig. 5-37

Oil change in the pump distributor gear

Oil filler neck

Dip stick

Drain valve

Switch off the diesel engine.

Wait a few minutes until the engine oil has collected in the pump.

Pull out the dip stick Insert the dip stick Pull out the dip stick

and clean with a clean cloth. to the stop. again and check the oil level.

The oil level must be between the

and

marks.

If necessary, add gear oil until the level reaches the

mark.

Remove the screw cap at the drain valve .

Connect the drain hose to the drain valve container.

and let the oil drain into a suitable

Disconnect the drain hose.

Replace the screw cap at the drain valve .

Add oil through the filler neck

until it reaches the

mark on the dipstick.

Upon the first start-up of the diesel engine, the oil cooler of the pump distribution gear is filled with oil. The equivalent oil volume is thus missing in the pump distribution gear.

Start the diesel engine and let it run for 30 seconds.

Switch off the diesel engine and add the required oil volume.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Travel gear

Fig. 5-38

Travel gear - changing oil

Before the oil change, ensure that the machine is at operating temperature:

To drain off oil or to add oil, position the chassis in such a way that the screw plugs and are in the positions indicated in the drawing.

Place a suitable collecting vessel under the screw plug .

Remove the screw plug .

Remove the screw plug or .

Collect the escaping oil in the vessel.

Close the screw plug .

Add oil through the opening

until the oil level reaches the opening.

Insert and tighten the screw plugs

and .

The drive is maintenance-free, unless the running face or the flange requires regeneration or until all travel gear parts are completely worn.

The lifetime design of the support rollers, running rollers and idlers prolongs the service life of the drive gear, while the metal seals protect it against dirt.

Do not use the engine force to remove dried sludge, mud, stones or other foreign objects from the travel gear, as this can result in serious damage to the machine.

Do not start the machine, if large objects (e.g. stones, pieces of timber, metal parts, wire, etc.) are jammed in the travel gear.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Travel gear

After operation (i.e. after each shift), clean the dirty travel gear parts.

Clean and lubricate the sliding surfaces of the chain tensioners.

If the ambient temperature is below zero, place the machine on planks to prevent the chains from becoming frozen to the ground.

To prevent serious damage to the equipment , never attempt to move the machine when it is frozen to the ground. Frozen chains can be freed by carefully heating the base plates.

Fig. 5-39

Fixtures of travel gear components

Carry out regular visual inspections of the securing screws of the base plates and the drives in order to find any loose bolts.

Remove the cover

.

Check the tightening torques (see table).

1

Base plates

2300

2

Travel drive

2100

3

Tumbler wheel

2100

4

Hydraulic motor

960

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Travel gear

Fig. 5-40

Checking chain tension

Under normal operating conditions, the dip between the two support rollers should be between .

Release the chain by moving the machine forward and back.

Place the measuring rod onto the section between two support rollers.

Measure the distance plate.

between the measuring rod lower edge and the base

If necessary, tension the chain.

Fig. 5-41

Tensioning chain

As the travel gear is exposed to normal wear, the chain tension must be regularly checked and retightened, if necessary.

Remove the lid

from the longitudinal member of the undercarriage.

Screw the high pressure hose

to the hand grease gun.

Open the high pressure hose grease tensioner.

to connect it with the lubrication nipple

Add grease until the chain is sufficiently tensioned.

Check chain tension.

copyright by R 984 C Litronic / 11140260

of the

Maintenance

Operating manual

Travel gear

Fig. 5-42

Releasing chain

Risk of injury from slackening chain or expelled grease.

When releasing the chain, always wear protective goggles and gloves.

The lubrication nipple

may not be loosened.

When releasing the chain, keep your head away from the running roller frame.

When loosening the lubrication nipple extension 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.

Park the machine on level ground.

Turn lubrication nipple extension by a few revolutions until grease escapes from the longitudinal groove of the lubrication nipple extension.

As soon as the desired chain tension is reached, tighten the lubrication nipple extension .

After adjustment, move the machine forward and back and then check the chain tension again.

Release the chain as described in section "Releasing chain".

As soon as no grease escapes from the longitudinal groove of the lubrication nipple extension ,(see Fig. 5-42): Fully unscrew the lubrication nipple extension.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Electrical system

Fully screw in and tighten the preassembled unit (lubrication nipple extension and lubrication nipple ).

Tension the chain as described in section "Tensioning chain".

Regularly inspect the electrical system of the machine for defects.

Defects such as loose connections, chaffed cables or poorly fixed clamps must be replaced without delay.

Identify the cause for blown fuses and broken incandescent lamps, eliminate it and replace the fuse or the lamp.

Before carrying out any work on the electrical equipment, or carrying out electric arc welding work disconnect the batteries.

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. 5-43

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 (off).

The battery might discharge itself during prolonged standstills.

Prior to prolonged standstills, switch the battery main switch to position

copyright by R 984 C Litronic / 11140260

(off).

Maintenance

Operating manual

Electrical system

Battery acid is highly corrosive.

When working on the battery, always wear protective goggles and gloves.

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. 5-44

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 be fed through rubber hoses 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 in the hoses.

in such a way that there are not kinks or blocked sections

Always replace damaged vent hoses.

Regularly clean the pole heads and cable terminals acid-proof grease.

and apply a thick layer of

From time to time, check the acid density using a battery tester If the battery is fully charged, the

.

.

If the battery tester shows a lower value, the battery is discharged to some degree and might need to be recharged.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Heating and air-conditioning system

Fig. 5-45

Slip ring body

The slip ring body is installed at the centre of the slewing gear. It connects the electrical components in the uppercarriage to the electrical consumers in the undercarriage. The slip ring body can be accessed from the uppercarriage.

Slip ring bodies are easily damaged by humidity, and insufficient care can lead to the formation of an oxide layer 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 .

Remove the housing .

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 .

Tighten the lock nuts

Fig. 5-46

with a uniform torque.

Recirculated air filter

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Heating and air-conditioning system

Fig. 5-47

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).

To remove the recirculated air filter forward.

Open the quick fasteners

by turning them by 90 degrees.

Remove the recirculated air filter Remove the deflector

, tilt the backrest of the operator seat

.

.

Remove the ambient air filter

.

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.

To clean the filter elements / , blow them out with compressed air or wash them in cold or lukewarm water.

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.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Heating and air-conditioning system

Switch on the a/c system every two to three weeks for about 10 minutes, irrespective of the season.

Fig. 5-48

A/c condensers

A/c condenser

Cooler

During the operating period, check the condenser every 500 operating hours: Inspect the condenser

for dirt.

If necessary, clean the condenser: : 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.

During the operating period, the following maintenance tasks must be carried out by a technician specialising in a/c systems: every 500 operating hours:

every 1000 operating hours:

excess pressure switch Annually: r-collector unit.

For this purpose, the a/c system must be drained, inspected for leakage and

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Compressed-air system

refilled. Check the hose lines for chaffing and replace them, if necessary. If required, retighten the hose connections. aps and the defrost thermostat.

Fig. 5-49

Compressed air accumulator and antifreeze pump

Pressure accumulator

Pressure gauge

Water drain valve

Antifreeze pump

During operation, the pressure gauge to 7.2 bar (90 - 105 PSI).

must show the following pressure value: 6.2

If the indicated pressure is outside this range or if the pressure gauge is faulty, contact the LIEBHERR service department.

Condensate tends to collect in the compressed air system. The pressure accumulator is automatically drained each time the system pressure drops. We recommend however regularly draining the pressure accumulator manually (weekly during summer months; daily during winter months).

Press in the pin of the water drain valve

and allow the water to drain off.

Release the pin when the escaping air is dry.

At temperatures below freezing point, the condensate in the accumulator might freeze. To prevent this, antifreeze agent is injected into the accumulator to ensure operational safety of the compressed air system also during the cold season.

Regularly check the fill level of the antifreeze pump (contains approx. 0.25 l of spirit).

Remove the cap of the antifreeze pump

and add antifreeze agent, if required.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Automatic lubrication of the machine

Fig. 5-50

Compressed air unit of central lubrication system

Oil mist lubricator

Air filter

The central lubrication system is operated with compressed air. The compressed air unit of the central lubrication system is located in the lubrication box.

Remove the screw at the bottom of the oil mist lubricator and turn the air filter a few times. Let the condensate drain off into a suitable container.

Remove the filler neck at the oil mist lubricator

and add oil, if necessary.

Max. fill level: 1 cm below upper edge of glass container

The machine is equipped with a semi-automatic lubrication system for the slewing gear. A housing encasing the pinion of the slewing gear mechanism provides a virtually sealed grease-filled box for the lubrication of the pinion and the slewing ring.

This housing is connected to a lubrication pump.

To start a cycle, press the button . As long as the button is pressed, the electric pump continues to deliver grease to the connected lube and bearing points.

Carry out at least one lubricating cycle during every shift.

Press the button

and hold it down for approx. 1 minute.

During the lubricating cycle, move the uppercarriage slowly to complete a full revolution (360°) to lubricate the entire toothed area.

Release the button.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Automatic lubrication of the machine

Rotate the uppercarriage again by a full revolution to further distribute the grease.

Fig. 5-51

Grease tank of slewing gear lubrication system

Check the grease tank once a week. It is located at the front of the hydraulic tank.

Remove the plug, check the fill level and add grease, if necessary.

The machine is equipped with an automatic central lubrication system.

The uppercarriage and the attachment do not need to be lubricated manually. During operation, the machine is automatically lubricated at set intervals. After the preset interval has lapsed, the lubricating pump is automatically actuated and feeds a specific amount of grease to the connected grease nipples.

The lubrication system is installed behind the operator's cab in the lubrication box (see Fig. 5-56). It consists of a grease tank, a pneumatically operated lubricating pump and a control unit that initiates and controls the lubricating cycles. The control console is integrated into the operator's cab.

The lubrication system can be refilled with grease in two different ways: ternal filling pump (optional equipment)

Fig. 5-52

Control console

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Automatic lubrication of the machine

Display Timer key Double function button "additional lubrication / reset"

Fig. 5-53

Display texts

Adjustment range: 1 min to 2 h 59 min; factory setting: 2 h The interval between two lubricating cycles can be adjusted by simultaneously press the buttons and .

Press and hold the button

.

Simultaneously press and hold the button .

The interval is shown on the display , and the interval time is incremented. If the buttons are pressed for a longer period of time, the values increment at a faster rate.

Release the buttons when the desired interval time is displayed.

The new interval time is saved.

Press the button briefly twice. The set interval time (PP) and the time remaining to the next lubricating cycle (rP) are displayed.

Press the button

to release a lubricating cycle before the set interval has lapsed.

Press and hold the button for at least two seconds.

The machine is being lubricated.

Fig. 5-54

Display texts

The display shows the filling level of the grease tank, the operating status of the system and any faults: (lubrication) - A progress bar indicts that a lubricating cycle is in progress (low level) - the grease tank is empty and must be refilled. The text disappears when the grease tank is filled. (high level) - the grease tank is full (error) - fault or malfunction The central lubrication system must be examined and repaired, if necessary. Faults and malfunctions are signalled with a warning sound. Press the button to acknowledge the warning signal.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Automatic lubrication of the machine

The displayed error codes provide additional information for the elimination of the problem.

For more information, see operating manual of the manufacturer of the central lubrication system (Lincoln).

Fig. 5-55

Adding grease to the grease tank

Cover of lubrication box Wing nut

Pump unit Pressure plate

Grease tank

25 kg grease bucket

To refill the grease tank, replace the empty bucket with a full one.

Open and lock the cover of the lubrication box .

Open the wing nuts .

Remove the pump unit

and the pressure plate

.

Remove the empty grease bucket.

Open the new grease bucket Insert the pressure plate

and place it in the box.

and place the pump unit

in its place.

Tighten the wing nuts .

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Manual lubrication of the machine

Fig. 5-56

External filling of the central lubrication system

Cover of lubrication box Overflow

Hose coupling Check pin

The grease tank is filled by means of the external filling pump. The filling hose coupling is located beside the lubrication box at the access ladder to the operator's cab.

Open and lock the cover of the lubrication box .

Remove the dust protection cap from the hose coupling .

Connect the filling hose and switch on the filling pump.

Observe the red check pin in the lubrication box.

The grease tank is full when the check pin begins to move upwards or when grease exits through the overflow .

Overfilling can damage the grease tank.

When the red check pin filling pump.

begins to move upwards, immediately switch off the

Do not block the overflow .

Disconnect the filling hose and replace the dust protection cap.

Certain parts of the working tools, attachments and the undercarriage are lubricated manually. The affected lubricating points are equipped with lubricating nipples.

We recommend using a grease gun, as it reduces the force required and ensures that the grease is squeezed in slowly.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Manual lubrication of the machine

Fig. 5-57

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.

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.

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Manual lubrication of the machine

Fig. 5-58

Lubricating the hydraulic quick-change adapter

Lubricate the quick-change adapter through the lubrication nipples with a grease gun (approx. 2 lubricating strokes).

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.

Fig. 5-59

Lubricating the quick-change adapter

Lubrication nipple / locking bolt

Lubrication nipple / rotator

Lubricate the locking bolts via the lubricating nipple , using a grease gun.* Lubricate the rotator via the lubricating nipple , using a grease gun.* * apply approx. 2 lubricating strokes

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.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Couplings of the quick-change adapter systems (optional equipment)

Fig. 5-60

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.

Remove dirt and clean all coupling parts and sealing surfaces with a clean cloth and oil.

Fig. 5-61

Changing seal ring

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Couplings of the quick-change adapter systems (optional equipment)

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 ( ), 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 ( ).

Squeeze the new seal ring and place it with its open side facing downwards onto the seal washer ( ).

Push the washer into the groove, place the screwdriver onto the centre of the seal ring and remove your hand ( ).

Let the seal ring expand into the groove ( ).

Remove the screwdriver ( ).

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.

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.

Fig. 5-62

Electric couplings

Electric coupling top section

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 contact spray (Cramolin), if necessary.

and

with a dry cloth and apply

Check the electric couplings and the screwed connections for proper fixture.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Travel and swing brakes

Check the contacts of the top section contacts against the spring force.

for play: it must be possible to push in the

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.

Both the travel as well as the swing brakes are spring applied, pressure released multi-disk brakes. They are vented hydraulically and are fully sealed and integrated in the travel or swing gear.

Their use purely as a parking brake makes them wear free and therefore maintenance free.

In addition to the normal maintenance and repair work that is carried out at given intervals, the machine operator and maintenance personnel can also carry out the repairs stated below: unit connections (not, however, on pressure relief valves which are closed off with lead seals at the works). bolted connections on the hydraulic system.

It should be noted that only original LIEBHERR replacement parts are to be used.

This is particularly relevant for hoses and hydraulic lines, which must be preassembled at the works. Contact the works and authorised fitters for all other repairs, particularly when removing the ballast weight.

Welding work on all main components serving the power transmission (such as the undercarriage frame, rotating platform, equipment parts etc.) may only be carried out by the manufacturer or in an authorized workshop.

Disconnect the batteries before starting any electric arc welding work on the machine.

Always disconnect the negative terminal (-) first and reconnect it last.

Switch off the main battery switch!

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Inspection and maintenance schedule

Bearings or sealing elements, could burn if they are carrying high currents.

Move the earthing cable of the welding tool as close as possible to the welding surface so that the welding current cannot flow through components such as the slewing ring, hinges, bearings, sockets, rubber elements or seals.

Careful maintenance is only possible, if the machine is clean. Important visual inspections, e.g. for cracks can only be carried out properly on a clean machine.

Before carrying out any maintenance work, clean the machine (see also chapter "Cleaning").

The daily maintenance tasks of the machine operator include a functional test of the brakes (slewing gear brake, chassis brake) and the electrical and hydraulic system.

Also to be carried out is a daily visual inspection of the motor, hydraulic system and gearbox for leakage.

Initial and single interval Repeat interval Annually, at the start of the cold season When required

Initial and single interval Repeat interval

Check the oil level Visual inspection (leakage, dirt, damage) Drain water and deposit from fuel tank Check oil level in pump distributor gear Replace gear oil in pump distribution gear 1)

Change diesel engine oil Change oil filter insert Change water filter Check crankcase bleeding valve; clean if necessary Change fuel filter

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Inspection and maintenance schedule

Initial and single interval Repeat interval Annually, at the start of the cold season When required

Initial and single interval Repeat interval

Check cable connections Check V-belt tension and state Check speed settings; adjust, if necessary Check intake and exhaust systems for general condition, fixture and leakage Check mounting bolts of engine brackets, oil pan and hose clips for proper mounting 1500

Complete 1500-hour service according to Cummins operating manual

6000

Complete 6000-hour service according to Cummins operating manual (every two years)

Initial and single interval Repeat interval Annually, at the start of the cold season When required

Initial and single interval Repeat interval

Check coolant level Check cooling and heating systems for general condition and leakage Check corrosion inhibitor and antifreeze agent concentration in coolant 3000

Change coolant (at least every 2 years) Liebherr Antifreeze

6000

Change coolant (at least every 4 years) Liebherr Antifreeze OS

Check underpressure indicator of the air filter Cleaning pre-filter Change main element of the dry air filter (according to maintenance indication / annually)

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Inspection and maintenance schedule

Initial and single interval Repeat interval Annually, at the start of the cold season When required

Initial and single interval Repeat interval

Change safety element of the dry air filter (at every third main element change / annually) - do not clean or reuse!

Check fill level of antifreeze pump Drain water from pressure accumulator (daily during winter months, weekly during summer months) Compressed air unit of central lubrication system: drain off water, check oil mist lubricator; add oil, if necessary Check compressor

Check oil level in hydraulic tank Clean magnetic rod in return filter (daily during first 300 operating hours) 2)

Replace filter element in bypass filter (optional equipment) (in machines used in dusty environments: every 250 operating hours)

2)

Replace filter insert in return filter Replace filter cartridge in control oil unit Replace feed oil filter on slewing gear pump Check components for proper mounting Check the hydraulic oil cooler for dirt; clean it, if necessary Drain water from hydraulic tank (max. permissible water content for environmentally friendly fluids: 0.1 %; insert bypass filter, take oil sample) Check hydraulic system for leakage; complete functional 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

Check indicator lights and indicating devices upon start-up Check lighting

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Inspection and maintenance schedule

Initial and single interval Repeat interval Annually, at the start of the cold season When required

Initial and single interval Repeat interval

Check acid density and level, wire terminals and terminal ports of the batteries Spray slip rings of the slewing gear connection with Cramolin contact spray Carry out functional tests of entire unit and all components

Check oil level; check system for leakage Carry out functional test of slewing gear brake Check gearbox and oil motor for proper mounting Change gear oil

Start lubrication system of slewing gear Check fill level in grease tank of lubrication system; add grease, if required Check mounting bolts for press fit; check slewing gear pining meshing

Check oil level; check system for leakage Carry out functional test of travel brake Check gearbox and oil motor for proper mounting Change gear oil

Visually check tension of chain; regulate, if necessary Clean chain (after work) Check fixture of base plates and drive wheels Clean and lubricate slide faces of tensioning mechanism Check idlers, support and running rollers for tightness

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Inspection and maintenance schedule

Initial and single interval Repeat interval Annually, at the start of the cold season When required

Initial and single interval Repeat interval

Complete function test Change or refill grease tank Service entire system; check pumps and control (at least once annually)

Check / add detergent solution in windscreen washer tank Check function of heating Check heating system for leakage Check door and window hinges as well as locks Treat rubber seals of the operator's cab with silicone or talcum powder Treat rubber seals of the access doors in the uppercarriage with silicone or talcum powder Check water inlet valve for contamination, and clean, if necessary; carry out functional test of valve

Regularly switch on air-conditioning system (at least 1x every 14 days) Check condenser for contamination; blow clean, if necessary Clean re-circulated air / 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, if necessary Check electrical lines for chafe marks; check plug connections Complete functional test of excess pressure switch Check cooling performance Replace dryer-collector unit every 12 months; also check cooling circuit for leakage and change coolant and refrigeration oil.

copyright by R 984 C Litronic / 11140260

Maintenance

Operating manual

Inspection and maintenance schedule

Initial and single interval Repeat interval Annually, at the start of the cold season When required

Initial and single interval Repeat interval

Every 12 months, employ a refrigeration technician to carry out a functional test of the air flaps and the defrost thermostat

Lubricate bearing points, using the semi-automatic central lubrication system; Exception: not required in units with fully automatic central lubrication system (optional equipment) Check grease level in the central lubrication system tank; add grease, if required Lubricate bearing positions (undercarriage and working attachments) Lubricate daily when required due to type of use and/or shift operation Inspect teeth for wear 250

Check parts for cracks Check counter weight and tank for proper mounting Check lines and screwed connections for proper fit Attachment points for fall-arrest equipment: check bolts for fixture; visual inspection; replace deformed or corroded parts Check panelling hinges, quick fasteners and gas pressure springs of the caps Instruct operators in the proper use of the equipment Instruct the operator on how the machine must be lubricated according to the lubricating chart and make him aware of potential operator errors

Carry out a functional test of the visual and acoustic warning systems Carry out a visual inspection of the extended lock pins Check hydraulic hoses and wire harness Lubricate lock pins

copyright by R 984 C Litronic / 11140260

Operating manual

Maintenance Inspection and maintenance schedule

Initial and single interval Repeat interval Annually, at the start of the cold season When required

Initial and single interval Repeat interval

Clean mesh filter

Check the 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 Replace motor oil more often, if temperatures and the quality of fuels and oils make this seem advisable.

In the case of applications with excessive dust generation, observe shortened 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).

copyright by R 984 C Litronic / 11140260