Liebherr R 984 C Litronic High Rise 1138 Machine for Industrial Operating Manual SN 50200 - PDF

en

Operating manual Machine for Industrial Applications R 984 C Litronic High Rise from serial number 50200

Document identification ORIGINAL OPERATING MANUAL Id. number:

11140259

Edition:

06 / 2014

Valid for:

R 984 C Litronic High Rise from serial number 50200

Author:

LHB - Technical documentation department

Product identification Manufacturer:

LIEBHERR Hydraulikbagger GmbH

Type:

R 984 C Litronic High Rise

Type no.:

1138

Conformity:

CE

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

Operating manual

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

This will also be helpful when ordering spare parts.

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

Year of manufacture: . . . .

Delivery date: . . / . . / . .

MJFCIFSS

R 984 C Litronic High Rise / 11140259

Introduction

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

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

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

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

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

Maintenance including inspection, servicing and repair.

Transport or loading of the machine.

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

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

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

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

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

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

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

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Operating manual

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

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

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

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

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

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R 984 C Litronic High Rise / 11140259

Operating manual

Table of contents 1

Product description ....................................................................................................................................... 1-1 1.1 1.2 1.3 1.4 1.5

2

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

2.4

3

Design and overview ............................................................................................................................. 1-1 Vibration emissions................................................................................................................................ 1-2 Sound emission ..................................................................................................................................... 1-3 EC Declaration of Conformity ................................................................................................................ 1-4 Technical data ....................................................................................................................................... 1-5

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........................................................................................................................................ 2-9

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

3.2

3.3

3.4

Operating and control elements............................................................................................................. 3-1 3.1.1 Overview of operator's platform................................................................................................ 3-1 3.1.2 Keyboard .................................................................................................................................. 3-3 3.1.3 Monitoring display .................................................................................................................... 3-6 3.1.4 Main screen and operator's menu ............................................................................................ 3-8 3.1.5 Information symbols on the main screen................................................................................ 3-10 Control ................................................................................................................................................. 3-21 3.2.1 Entering and exiting machine ................................................................................................. 3-21 3.2.2 Safety lever ............................................................................................................................ 3-26 3.2.3 Operator seat ......................................................................................................................... 3-26 3.2.4 Sun blind ................................................................................................................................ 3-30 3.2.5 Emergency exit through rear window ..................................................................................... 3-31 3.2.6 Inside lighting ......................................................................................................................... 3-31 3.2.7 Fire extinguisher (optional equipment)*.................................................................................. 3-32 3.2.8 Windscreen wiper ................................................................................................................... 3-32 3.2.9 Lighting................................................................................................................................... 3-34 3.2.10 Heating and air-conditioning system ...................................................................................... 3-35 Operation ............................................................................................................................................. 3-41 3.3.1 Safety instructions .................................................................................................................. 3-41 3.3.2 Camera system ...................................................................................................................... 3-42 3.3.3 Starting machine .................................................................................................................... 3-45 3.3.4 Switching off diesel engine..................................................................................................... 3-51 3.3.5 Jump start procedure ............................................................................................................. 3-51 3.3.6 Horizontal alignment of the machine ...................................................................................... 3-52 3.3.7 Travel operation ..................................................................................................................... 3-53 3.3.8 Operating instructions for travel gear ..................................................................................... 3-56 3.3.9 Travel alarm system (optional equipment) ............................................................................. 3-57 Working with the machine.................................................................................................................... 3-57 3.4.1 Safety Instructions .................................................................................................................. 3-57 3.4.2 Sensor-controlled low idle automatic...................................................................................... 3-61 3.4.3 Working position ..................................................................................................................... 3-61 3.4.4 Operating the working attachment ......................................................................................... 3-62 3.4.5 Swivelling the uppercarriage .................................................................................................. 3-64 3.4.6 Halting the uppercarriage ....................................................................................................... 3-64 3.4.7 Lowering the working attachment when diesel engine is shut off........................................... 3-66

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Operating manual

3.5

3.6

3.7 4

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

4.3

4.4

4.5

5

3.4.8 Mechanical stick cylinder shut-off ........................................................................................... 3-67 3.4.9 Turning, swivelling locking and releasing attachment............................................................. 3-71 Installation and removal of attachment parts ....................................................................................... 3-72 3.5.1 Safety Instructions .................................................................................................................. 3-72 3.5.2 Attachment of grapple to industrial stick ................................................................................. 3-73 3.5.3 Industrial stick with hydraulic quick-change adapter (optional equipment)............................. 3-74 3.5.4 LIKUFIX MH 110 quick-coupling system (optional equipment) .............................................. 3-80 General working methods .................................................................................................................... 3-85 3.6.1 Tips for the proper operation of the machine preventing damage and wear .......................... 3-85 3.6.2 Preparation ............................................................................................................................. 3-86 3.6.3 Working with grapples ............................................................................................................ 3-87 3.6.4 Loading operation ................................................................................................................... 3-87 3.6.5 Load lifting operation .............................................................................................................. 3-88 3.6.6 Overload warning system (optional equipment) ..................................................................... 3-89 3.6.7 Hoist cylinder warning system ................................................................................................ 3-90 Transport and assembly ...................................................................................................................... 3-91

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

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

5.2

5.3

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 5.2.3 Undercarriage ........................................................................................................................... 5-8 5.2.4 Platform service unit ................................................................................................................. 5-8 5.2.5 Electric slewing crane (special equipment)............................................................................... 5-9 5.2.6 Mechanical slewing crane (special equipment) ...................................................................... 5-12 5.2.7 Attachment points for fall-arrest equipment ............................................................................ 5-13 Cleaning machine ................................................................................................................................ 5-14

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Operating manual

5.4 5.5

5.6

5.7

5.8

5.9

5.10

5.11

5.12

5.13

Care for rubber components................................................................................................................ 5-15 Fuels, lubricants and process chemicals ............................................................................................. 5-15 5.5.1 General information ................................................................................................................ 5-15 5.5.2 Filling volumes, lubricating chart ............................................................................................ 5-16 Lubricants and fuels............................................................................................................................. 5-18 5.6.1 Diesel fuels............................................................................................................................. 5-18 5.6.2 Engine oils .............................................................................................................................. 5-19 5.6.3 Coolant ................................................................................................................................... 5-20 5.6.4 Hydraulic oils .......................................................................................................................... 5-21 5.6.5 Axle oil .................................................................................................................................... 5-23 5.6.6 Gear oils ................................................................................................................................. 5-24 5.6.7 Transmission oils.................................................................................................................... 5-25 5.6.8 Pump distributor gear oils....................................................................................................... 5-25 5.6.9 Energy recuperation cylinder oils ........................................................................................... 5-26 5.6.10 Greases.................................................................................................................................. 5-27 5.6.11 Windscreen washer fluid ........................................................................................................ 5-27 5.6.12 Lubricants and care products for electrical and mechanical systems .................................... 5-28 Diesel engine ....................................................................................................................................... 5-28 5.7.1 Checking the oil level ............................................................................................................. 5-28 5.7.2 Changing engine oil................................................................................................................ 5-29 Cooling system .................................................................................................................................... 5-30 5.8.1 Checking and cleaning the cooling system ............................................................................ 5-31 5.8.2 Checking coolant level ........................................................................................................... 5-31 5.8.3 Changing coolant ................................................................................................................... 5-31 5.8.4 Coolant ................................................................................................................................... 5-32 5.8.5 Changing water filter .............................................................................................................. 5-33 Fuel system ......................................................................................................................................... 5-33 5.9.1 Refuelling ............................................................................................................................... 5-33 5.9.2 Fuel tank maintenance ........................................................................................................... 5-37 5.9.3 Fuel filter................................................................................................................................. 5-38 Dry air filter .......................................................................................................................................... 5-38 5.10.1 Checking suction vacuum ...................................................................................................... 5-39 5.10.2 Cleaning pre-filter ................................................................................................................... 5-39 5.10.3 Replacing filter cartridges....................................................................................................... 5-40 5.10.4 Checking the clean air lines ................................................................................................... 5-41 Hydraulic system ................................................................................................................................. 5-42 5.11.1 Test position ........................................................................................................................... 5-43 5.11.2 Checking the oil level in the hydraulic tank ............................................................................ 5-43 5.11.3 Releasing the pressure from the hydraulic system................................................................. 5-44 5.11.4 Replacing the breather filter ................................................................................................... 5-44 5.11.5 Emptying and refilling the hydraulic tank ................................................................................ 5-45 5.11.6 Return filter ............................................................................................................................. 5-46 5.11.7 Control oil filter, control circuit ................................................................................................ 5-47 5.11.8 Bleeding hydraulic pumps ...................................................................................................... 5-48 5.11.9 Removing the suction hose .................................................................................................... 5-49 5.11.10 Replacing the feed line filter ................................................................................................... 5-50 5.11.11 High-pressure filter ................................................................................................................. 5-50 5.11.12 Bypass oil filter (optional equipment) ..................................................................................... 5-51 5.11.13 Maintenance of hydraulic cylinders ........................................................................................ 5-53 5.11.14 Replacing hydraulic hoses ..................................................................................................... 5-54 Oil change in components ................................................................................................................... 5-55 5.12.1 General instructions ............................................................................................................... 5-55 ...................................................................... 5-55 5.12.3 Pump distributor gear ............................................................................................................. 5-56 5.12.4 Travel gear ............................................................................................................................. 5-57 Travel gear........................................................................................................................................... 5-57 5.13.1 Cleaning drive gear ................................................................................................................ 5-58 5.13.2 Checking fixtures of components ........................................................................................... 5-58

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Operating manual

5.14

5.15

5.16

5.17

5.18

5.19

5.20 5.21

5.22

5.13.3 Checking chain tension .......................................................................................................... 5-59 5.13.4 Tensioning chain .................................................................................................................... 5-59 5.13.5 Releasing chain ...................................................................................................................... 5-60 5.13.6 Changing lubrication nipple .................................................................................................... 5-61 Electrical system .................................................................................................................................. 5-61 5.14.1 Notes regarding the electrical system .................................................................................... 5-61 5.14.2 Battery main switch ................................................................................................................ 5-61 5.14.3 Battery care ............................................................................................................................ 5-62 5.14.4 Slip ring body .......................................................................................................................... 5-63 Heating and air-conditioning system.................................................................................................... 5-64 5.15.1 Recirculated and ambient air filter .......................................................................................... 5-64 5.15.2 Heating system ....................................................................................................................... 5-65 5.15.3 air-conditioning system ........................................................................................................... 5-65 Compressed-air system ....................................................................................................................... 5-66 5.16.1 Compressed air accumulator and antifreeze pump ................................................................ 5-66 5.16.2 Compressed air unit of central lubrication system .................................................................. 5-67 Automatic lubrication of the machine ................................................................................................... 5-68 5.17.1 Semi-automatic lubrication system of slewing gear................................................................ 5-68 5.17.2 Automatic central lubrication system ...................................................................................... 5-68 Manual lubrication of the machine ....................................................................................................... 5-72 5.18.1 Attachments (optional equipment) .......................................................................................... 5-72 5.18.2 Industrial stick with hydraulic quick-change adapter............................................................... 5-73 5.18.3 LIKUFIX MH 110 quick-coupling system ................................................................................ 5-73 Couplings of the quick-change adapter systems (optional equipment) ............................................... 5-74 5.19.1 Hydraulic coupling .................................................................................................................. 5-74 5.19.2 LIKUFIX electric coupling ....................................................................................................... 5-75 Travel and swing brakes ...................................................................................................................... 5-76 General maintenance tasks ................................................................................................................. 5-76 5.21.1 Replacing wear parts .............................................................................................................. 5-76 5.21.2 Replacing teeth on digging tool .............................................................................................. 5-76 5.21.3 Welded parts on the machine ................................................................................................. 5-78 Inspection and maintenance schedule................................................................................................. 5-79

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1 Product description 1.1 Design and overview

Fig. 1-1

Overview

1 3

Uppercarriage Platform

2 4

Undercarriage Right drive

5

Left drive

6

Industrial boom

7 9

Boom cylinder Stick cylinder

8 Industrial stick 10 Grapple

11 Access to uppercarriage

12 Access to undercarriage

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Product description

Operating manual

Vibration emissions

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

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

Whole-body vibration If the machine is operated according to the manufacturer instructions, the weighted (frequency-rated) effective vibration shown for specific machine applications in the table below apply. These values conform to the specifications in the technical report 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".

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

Crawler excavator

Mobile excavator

Typical working cycles

x-axis

y-axis

z-axis

1

2

3

1

2

3

1

2

3

Excavator

0.14

0.31

0.49

0.08

0.19

0.31

0.13

0.30

0.47

with hydraulic hammer

0.16

0.38

0.59

0.09

0.22

0.35

0.27

0.55

0.83

Use for mining

0.31

0.46

0.61

0.19

0.30

0.41

0.29

0.61

0.93

Transfer travel

0.21

0.34

0.48

0.09

0.23

0.37

0.56

0.79

1.02

Excavator

0.19

0.37

0.56

0.09

0.25

0.41

0.16

0.29

0.42

Transfer travel

0.21

0.29

0.38

0.24

0.38

0.52

0.42

0.61

0.80

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

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Operating manual

Product description Sound emission

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

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

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

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Product description

Operating manual

EC Declaration of Conformity

1.4 EC Declaration of Conformity

Fig. 1-2

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

Only for customers in member states of the European Union: a EC Declaration of Conformity has been shipped together with your machine. You will find this document in the machine documentation.

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Operating manual

Product description Technical data

1.5 Technical data See technical description on the following pages.

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Product description

Operating manual

Technical data

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

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

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

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

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

These terms have the following meaning: Danger!

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

Caution!

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

Note!

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

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

Identifies a procedure or activity.

Identifies the result of a procedure or activity.

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2-1

Safety notes, signs

Operating manual

Proper use

2.2 Proper use designed to loosen, lift, transport and disperse soil, stones and other material, whereby the load is normally transported with the machine being stationary during the process. be equipped with specific safety devices (see section "Load-lifting work"). attachments and possibly also special safety devices. 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. oper. In particular, is is forbidden to transport persons with the machine, to travel with the machine with attached loads and to operate it in explosive atmospheres or in contaminated environments. maintenance schedules is an integral part of proper use. operation of the machine.

2.3 Safety instructions 2.3.1

General safety instructions with the operating instructions before starting the machine. erstood supplemental instructions (this 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.

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Operating manual

Safety notes, signs Safety instructions

especially sure that they are free of dirt, oil, ice and snow.

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

2.3.2

Crushing and burn prevention 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.

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2-3

Safety notes, signs

Operating manual

Signs on the machine

sparks and naked flames. in any operation. sure that the side doors are properly secured to remain open during the service operation.

2.3.3

Fire and explosion prevention 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.

2.4 Signs on the machine 2.4.1

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

Danger!

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

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

Always replace missing and illegible signs without delay.

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R 984 C Litronic High Rise / 11140259

Operating manual

Safety notes, signs Signs on the machine

2.4.1.1

Uppercarriage

Fig. 2-1

Positions of the signs on the uppercarriage

The signs indicate the following: 1: Seat belt Before starting the machine, put on the safety belt.

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2-5

Safety notes, signs

Operating manual

Signs on the machine

2: Operating symbols Describe the functions of the operating devices that are not individually labelled.

3: Load lift chart Indicates the permissible lift loads that can be attached to the end of the stick, depending on its actual reach.

4: Accident prevention When operating the machine, always strictly adhere to the accident prevention instructions included in the operating manual.

4: Accident prevention, safety lever Before leaving the operator seat, tilt the safety lever upwards.

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Operating manual

Safety notes, signs Signs on the machine

4: Accident prevention, attachment The working attachment can reach the operator's cab! Proceed with extreme caution when retracting the attachment.

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

6: Engine shut-down Before opening the bonnet, shut down the engine.

7: Slewing gear release Indicates the "Slewing gear release" button at the access ladder. By pressing this button, the machine operator confirms that no persons other than himself/herself are located on the machine.

After pressing a second button in the operator's cab, the slewing gear is released and the uppercarriage can be swivelled.

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

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2-7

Safety notes, signs

Operating manual

Signs on the machine

9: Prohibition sign It is prohibited to access the marked area.

10: Attachment point for lifting Indicates the attachment points for lifting and assembly.

Caution: These points are designed to bear individual parts and cannot carry the total weight of the machine.

2.4.1.2

Undercarriage

Fig. 2-2

Positions of the signs on the uppercarriage

The signs indicate the following:

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Operating manual

Safety notes, signs Signs on the machine

1: Tie-down point Indicates the tie-down points for transport and assembly.

Caution: These points are designed to bear individual parts and cannot carry the total weight of the machine.

2: Attachment point for lifting Indicates the attachment points for lifting and assembly.

Caution: These points are designed to bear individual parts and cannot carry the total weight of the machine.

3: Point of danger Risk of injury!

Do not stand inside the danger area of the machine while it is in operation. During operation of the machine, no persons other than the machine operator may be standing on the machine.

4: Bell Indicates the bell buttons at the access doors. When the button is pressed, a ring sound is audible in the operator's cab.

2.4.2

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

The ID tag of the machine is located at the front of the uppercarriage. It contains the following information:

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2-9

Safety notes, signs

Operating manual

Signs on the machine

Fig. 2-3

ID tag of the machine

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R 984 C Litronic High Rise / 11140259

3 Control, operation 3.1 Operating and control elements 3.1.1

Overview of operator's platform

Fig. 3-1

Operator's platform

1

Safety lever of servo control

3 5

Heating and air-conditioning system 4 Engine monitoring system 6

2

Horn Control console / central lubrication system

7

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

Control console - emergency operation

8

Operator seat

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3-1

Control, operation

Operating manual

Operating and control elements

9

Radio*

10 Operating hours counter

11 Air outlets

12 Fuse box

* optional equipment

Fig. 3-2

Operator's platform seen from the operator

13 Left joystick

14 Right joystick

15 Ignition switch 17 Keyboard

16 Monitoring display 18 Travel pedal, right

19 Travel pedal, left

20 Positioning slewing brake*

21 Box level S5/6 Push buttons for special functions*

22 Cigarette lighter, 24 V socket

* optional equipment

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Operating manual

Control, operation Operating and control elements

3.1.2

Keyboard

Fig. 3-3

Keyboard

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3-3

Control, operation

Operating manual

Operating and control elements

S10 - Headlights of revolving deck, roof and attachment The switch is assigned several functions that are operated with repeat actuation: dlights are automatically switched off after 3 minutes. light is switched off immediately. The revolving deck and roof headlights are switched off after 3 minutes.

S11 - Windscreen washer system Windscreen washing solution is sprayed onto the window while the windscreen wiper is on.

S14 - Windscreen wiper The switch is assigned several functions that are operated with repeat actuation:

S17 - Slewing gear brake Applies/releases the mechanical slewing gear brake.

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

S18 - Overload warning system (optional equipment) 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 signal 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.

S19 - Release auxiliary function (grapple rotator) The control console allows operators to activate the rotators of the working tools (e.g. grapple), the quick-change adapters and similar functions.

S20 - Low idle automatic 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.

S21 - no function assigned

S22 - Auxiliary headlight (optional equipment) Activates the auxiliary headlight S36 - Cold start system Activates the cold start system. When the button is pressed, ether is spray into the suction section of the diesel engine.

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

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Operating manual

Control, operation Operating and control elements

S41 - Beacon (optional equipment) Activates the beacon.

S56 - no function assigned

S85

no function assigned

S86 - Power selection (mode) Four different modes can be selected by pressing the switch. The active mode is indicated by the letter below the LED. L: LIFT mode (sensitive lifting of loads) F: FINE mode (precision operation) E: ECO mode (economical operation) P: POWER mode P4 - Display of engine speed Indicates the preselected engine speed (10 speeds).

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

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

S354 - Parking brake Applies or releases the parking brake. While working with the machine, the parking brake must be released.

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3-5

Control, operation

Operating manual

Operating and control elements

3.1.3

Monitoring display

Fig. 3-4

Monitoring display

A B

Analogue indicator Check display

H24 P2

no function assigned Temperature indicator - cooling water

C

Main screen

P2.1 Temperature indicator - cooling water in red zone

D

Screen menu control

P3

H2

Indicator light - motor oil pressure P3.1 Indicator - critical fuel level

H12 H19

Indicator light - battery S349 BACK button Indicator light - Direction indicator S350 DOWN button

H20

Indicator light - parking brake

S351 UP button

H23

Indicator light - accumulator pressure of operating brake

S352 MENU button

Fuel gauge

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Operating manual

Control, operation Operating and control elements

3.1.3.1

Section A: monitoring of diesel engine P2 Display: diesel engine coolant temperature Display must be in green range during operation.

In the event of overheating, the red LEDs P2.1 at the edge of the P2 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.

P3 Display: fuel reserve The lit LEDs indicate the current fuel is left in the tank.

When the red LEDs P3.1 are on, there are only 100 litres of fuel in the tank (reserve).

H2

Indicator light: low engine oil pressure

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.

H12

Indicator light: battery

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.

H19

no function assigned

H20

no function assigned

H23

no function assigned

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3-7

Control, operation

Operating manual

Operating and control elements

H24

3.1.3.2

no function assigned

Section B: Menu control for screen

Fig. 3-5

Menu control for screen

The screen can be navigated with the following 4 buttons: S349: button BACK S350: button DOWN S351: button UP S352: button Menu* * = 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.

3.1.3.3

Section C: Screen Changing contrast settings: Simultaneously press buttons MENU and UP (more contrast) or DOWN (less contrast).

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

Setting brightness of main screen Simultaneously press buttons MENU and UP (brighter) or DOWN (less bright).

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

Note!

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.

Resetting brightness and contrast to default settings: Switch off ignition.

Simultaneously press and hold buttons UP and DOWN. Switch on the ignition again.

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

3.1.4

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

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Control, operation Operating and control elements

Fig. 3-6

3.1.4.1

Display: main screen

SY

Symbols / time

EC

Error codes

INF

Information

TI

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

Using the main screen Field SY 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".

Field EC 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 SY field. For a description of the warning symbols, see chapter "Malfunctions".

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 UP and/or DOWN button.

The display scrolls through the list in the selected direction.

Danger!

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).

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

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Operating manual

Operating and control elements

Press the BACK button.

The error message is acknowledged and stored.

The buzzer is switched off.

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

The ® indicates that limitation settings are activated.

Field INF 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.

3.1.5 Symbol

Information symbols on the main screen

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

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

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

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

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

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

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

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

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Symbol

Description Hoist cylinder warning system: Danger This symbol is displayed, if the actual load is near the load limit of the hoist cylinders. It warns the operator that a further increase of the load could result in a sudden lowering of the attachment.

The operator must reduce the reach of the attachment or lower the load to the ground without extending the reach.

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

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

The machine must only be operated in emergency mode for limited periods.

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

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

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

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

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

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

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

3.1.5.1

Operator's menu Changing to operator's menu:

Fig. 3-7

Main screen

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

Press the Menu button on the main screen.

The operator's menu is displayed.

The list of the accessible submenus is indicated by symbols.

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Control, operation

Operating manual

Operating and control elements

Fig. 3-8

Operator's menu

Scrolling through the operator's menu: Press the arrow buttons UP and/or DOWN. 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.

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

Press the Menu button.

The submenu of the selected function is displayed.

Press the BACK button.

The submenu is closed.

Symbol

Description 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

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Operating manual

Control, operation Operating and control elements

Reset menu for daily operating hours counter

Fig. 3-9

Resetting the daily operating hours counter

Use this menu to reset the daily operating hours counter.

Press the UP button.

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

Press the Menu button.

The operating hours counter is reset.

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

Press the BACK button.

The submenu is closed.

Menu: Service interval confirmation

Fig. 3-10

Service interval menu

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

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

"500 Hrs").

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

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

Service has been carried out: Press the UP button.

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

Press the Menu button.

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

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Operating manual

Operating and control elements

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

The submenu is closed.

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

A

Caution!

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

Fig. 3-11

Tool Control menu

EV1 = oil volume 1 EV6 = pressure

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

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

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

Press the UP or DOWN button.

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

Press the Menu button.

Your selection is confirmed.

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

To exit the submenu: Press the BACK button.

The submenu is closed.

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

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

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Operating manual

Control, operation Operating and control elements

Fig. 3-12 1

Main screen, display of selected working tool

Selected option (attachment)

2

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

Note!

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

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

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

Fig. 3-13

Engine operating hours menu

Page 1 indicates the operating hours of:

low idle speed L

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Control, operation

Operating manual

Operating and control elements

Fig. 3-14

Machine movement hours menu

Page 2 indicates the operating hours of: lled by means of joysticks Page 3 indicates the operating hours of: ar (no activation from model A 934)

Fig. 3-15

Technical data

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

To exit the menu: Press the BACK button.

The display returns to the operator's menu.

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Control, operation Operating and control elements

Menu: Status of hydraulic pumps and electrical inputs/outputs

Fig. 3-16

Pressure and flow limitation currents menu

Repeatedly press the Menu 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).

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.

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Control, operation

Operating manual

Operating and control elements

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.

To exit the menu: Press the BACK button.

The display returns to the operator's menu.

Menu: errors (operating errors and electrical system errors)

Fig. 3-19

Errors menu

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

E-elec. to obtain a list of the electrical wire faults of the LCD display stored during operation. list S-Exxx to obtain a list of the machine errors displayed when the service plug is connected.

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

The preceding or next error type is highlighted in black.

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Operating manual

Control, operation Operating and control elements

Press the Menu button.

The submenu highlighted in black is displayed.

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

Machine errors list Exxx:

Fig. 3-20

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

Select list Exxx.

Press the Menu button.

The first page of the submenu is displayed.

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

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

Press the Menu button again.

The second page of the submenu is displayed.

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

Press the BACK button.

The first page of the submenu is displayed.

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

Note!

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

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Control, operation

Operating manual

Operating and control elements

Wire fault list E-elec.:

Fig. 3-21

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

Select list E-elec.

Press the Menu button.

The submenu is displayed.

It contains a list of all electrical faults with codes.

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

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

Press the BACK button.

Select a different fault type, if required.

Other error list S-Exxx:

Fig. 3-22

Service operation error list menu

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

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

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Control, operation Control

Menu: Time

Fig. 3-23

Adjusting the time settings

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

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

Press the Menu button.

The next figure to the left is highlighted.

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

Press the BACK button.

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

3.2 Control 3.2.1

Entering and exiting machine Danger!

When accessing or exiting the cab, workers might slip or fall from the machine.

Persons might be injured by parts of the rotating uppercarriage. This can lead to serious injury or even death.

If you wish to work with the machine, access it on your own and unaccompanied by other people.

Never allow other persons to approach the machine or access it while it is in operation.

Do not access the machine while it is in operation.

Ensure that only the machine operator has a key to the access doors.

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

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

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

Do not use operating elements as handles.

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Control

3.2.1.1

Access system Safety concept The access system has been devised to enhance the operational safety of the machine by preventing unauthorised persons from accessing the platform. From the outside, the access doors to the platform can only be opened with a key.

When an access door is opened, the slewing gear is automatically locked, so that the uppercarriage cannot be swivelled. After the access door has been closed, the slewing gear remains locked and is only released when the person who has accessed the machine presses two buttons, confirming that he/she is the only person standing on the machine.

Emergency procedure: The access doors can be quickly opened from the inside by pressing down the door handle. No key is required.

If the machine operator is unable to exit the machine and must be rescued, a helper can access the machine as follows: A key box with glass panel is mounted beside each access door. Break the glass and remove the emergency key for the access door.

Change of machine operator The machine must only be accessed after the machine operator has shut down the diesel engine. The machine operator must then climb down to one of the access doors, open it to let the other person in and exit the machine. The machine operator who has just accessed the machine must again press the two buttons to release the slewing gear.

Pressing door buzzer Each door is equipped with a door buzzer. When this button is pressed, a buzzer signal is audible in the operator's cab. Persons who wish to access the platform while the machine operator is in the cab must signal this by pressing the buzzer button.

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Operating manual

Control, operation Control

Overview

Fig. 3-24

Access route, access system

A Access to platform

B Access door to platform

C Platform E Operator's cab

D Access to uppercarriage

Climbing onto machine

Fig. 3-25

Access door to platform; access to uppercarriage

B Access door to platform 1 Button "Slewing gear release"

D Access to uppercarriage

Climb one of the climbing aids A to an access door B. Open the access door B using the key.

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Control, operation

Operating manual

Control

Close both access doors B. Proceed across the platform C and the climbing aid D to the operator's cab.

Releasing slewing gear: After the access door B has been opened or the ignition has been started, the machine operator must press two buttons to confirm that no other person is standing on the machine. Subsequently, the slewing gear is released.

Enter the operator's cab E and switch on the ignition.

Descend to platform C. Ensure that no persons other than the machine operator are standing on the machine.

At the climbing aid D , press the button 1.

Enter the operator's cab E again.

Confirm that you have entered the operator's cab: press the button OK. The slewing gear is released.

Buzzer/key box

Fig. 3-26

Buzzer and key box at the access door.

B Access door to platform

1

Buzzer button

2

3

Key box

Hammer

Access the machine only after the diesel engine has been shut down.

Press the buzzer button 1.

A buzzer sound is audible in the operator's cab.

Emergency access: Using the hammer 2, break the glass of the key box 3 and remove the key.

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3.2.1.2

Entering and exiting operator's cab

Fig. 3-27 1 3

Cab door

Door handle Inside door handle

2 4

Locking mechanism Lever of locking mechanism

Entering cab: Press the lock at the door handle 1 and open the door.

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

Close the door.

If necessary, adjust the operator seat and steering column.

To keep the door open: Swivel the door back by 180° and secure it with the locking mechanism 2.

Exiting cab: Shut down the machine and push the safety lever upwards.

Push down the door handle 3 at the door lock.

Open the door and exit the cab.

Close the door.

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

Move the lever 4 outward.

The door is now released.

Close the door.

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Control, operation

Operating manual

Control

3.2.2

Safety lever

Fig. 3-28

Safety lever

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

Caution!

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

When the safety lever is tilted up, a number of machine functions are disabled or otherwise modified: . 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.

3.2.3

Operator seat Danger!

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

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

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

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

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Control, operation Control

Fig. 3-29

3.2.3.1

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

Adjusting armrest

Fig. 3-30

Adjusting armrest

Turn knurled screw in direction a.

The angle of the armrest is adjusted upwards.

Turn knurled screw in direction b.

The angle of the armrest is adjusted downwards.

3.2.3.2

Adjusting seat and backrest

Fig. 3-31

Adjusting seat and backrest

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Control, operation

Operating manual

Control

Seat inclined backwards: Pull the lever 1 up, adjust the angle of the seat and release the lever.

Seat inclined forward: Pull the lever 2 up, adjust the angle of the seat and release the lever.

Backrest: Pull the lever 3 up, adjust the angle of the backrest and release the lever.

3.2.3.3

Adjusting horizontal seat position

Fig. 3-32

Horizontal adjustment

Pull the lever 1 upwards and move the seat in horizontal direction.

Pull the lever 2 upwards and move the seat with the control console in horizontal direction.

3.2.3.4

Adjusting seat suspension

Fig. 3-33

Adjusting seat suspension

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

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Control, operation Control

3.2.3.5

Switching bar (air-cushioned operator seat, optional equipment)

Fig. 3-34

Switching bar at air-cushioned operator seat

Adjusting vibration absorption: Press the button 1 (+ or -) to adjust the suspension system to suit your body weight.

Adjusting lumbar support: Press the button 2 (+ or -), to add or release air from the lumbar cushion.

Press the button 3 (+ or -), to add or release air from the upper lumbar chamber.

Switching on seat heating: Operate the switch 4 to switch the seat heating on or off.

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

3.2.3.6

Wearing/taking off seat belt

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 2 from the reeling mechanism 1.

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

Push the locking piece into the buckle 3 so that it engages.

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Control, operation

Operating manual

Control

Danger!

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 4, push the lock button down, using your thumb.

The reeling mechanism 1 automatically pulls in the belt.

3.2.4

Sun blind

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.

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

The sun blind can be individually adjusted.

Press the switch 2 (red).

The sun blind is automatically rolled up.

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

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

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Control, operation Control

3.2.5

Emergency exit through rear window

Fig. 3-37

Emergency exit through rear window

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

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

3.2.6

Inside lighting

Fig. 3-38

Inside lighting

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

Set the rocker switch to position 1.

The light is switched on.

Set the rocker switch to position 0.

The light is switched off.

Switch position 2 is not assigned a function.

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Control, operation

Operating manual

Control

3.2.7

Fire extinguisher (optional equipment)*

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

3.2.8 3.2.8.1

Windscreen wiper Front windscreen wiper Continuous/interval mode: To switch on the windscreen wiper, actuate the switch S14.

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.

Adjusting interval for interval mode: To adjust the interval for the windscreen wiper, actuate the switch S14. Adjustment range: 2 to 10 seconds.

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.

Switching on windscreen washer system: To switch on the windscreen washer system, actuate the button S11.

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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.

3.2.8.2

Wiper for cab roof To switch on the wiper for the cap roof, actuate the switch S218.

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.

3.2.8.3

Windscreen detergent tank

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).

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Control, operation

Operating manual

Control

3.2.9

Lighting

Fig. 3-41 1 3

Arrangement of the lighting devices

Revolving deck headlight Attachment headlight

2

Rear roof headlight

Revolving deck headlight, roof headlight, attachment headlight The headlights can be switched on with the switch S10. The revolving deck and roof headlights remain switched on for 3 minutes after they are switched off at the switch.

Press the switch.

The revolving deck and roof headlights are on.

The left LED is on.

Press the switch again.

The attachment headlight is on.

The revolving deck and roof headlights are switched off after a delay time of 3 minutes.

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

Press the switch again.

All headlights (revolving deck, roof and attachment) are on.

The right and left LEDs are on.

Press the switch again.

The attachment headlight is immediately switched off.

The revolving deck and roof headlights are switched off after a delay time of 3 minutes.

The right and left LEDs are off.

Remote control All headlights can be switched on simultaneously by means of the remote control device. This facilitates accessing the operator's cab, for example in unfavourable light conditions.

Press the ON button.

All headlights (revolving deck, roof and attachment) are on.

All headlights are automatically switched off after 3 minutes.

The LED of the remote control is on.

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Control, operation Control

Press the OFF button.

The LED of the remote control is off.

The headlights are on for 3 minutes before they are slowly dimmed. They cannot be switched off with the remote control device. The OFF button can only be used to switch off the LED of the remote control (to save battery power).

Roof headlights The roof headlights can be switched on independently from the other headlights by actuating the switch S275.

Press the switch.

Roof headlights on.

The indicator light in the switch is on.

Press the switch again.

Roof headlights off.

The indicator light in the switch is off.

Auxiliary headlight (optional equipment) The auxiliary headlights are switched on with the switch S22.

Press the switch.

Auxiliary headlights on.

The LED is on.

Press the switch again.

Auxiliary headlights off.

The LED is off.

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

Press the switch.

The beacon flashes.

The LED is on.

Press the switch again.

The beacon is switched off.

The LED is off.

3.2.10

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

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Control, operation

Operating manual

Control

Fig. 3-42

Air conditioning control unit

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

Note!

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

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Operating manual

Control, operation Control

Note!

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

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

Switch on the control unit:

Fig. 3-43

Control unit self-test

Switch on the system by pressing key 4.

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

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

Adjusting the cab temperature:

Fig. 3-44

Example: increase the temperature

The desired cab temperature is displayed on-screen.

Press key 2 to increase the temperature.

Press key 3 to reduce the temperature.

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

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

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Control, operation

Operating manual

Control

Manually adjusting the heating performance:

Fig. 3-45

Manually adjusting the heating performance

Press key 7 to manually adjust the heating performance.

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

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

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

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

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

Switching a/c operation on and off:

Fig. 3-46

A/C operation and REHEAT function

Press key 1.

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

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

Press key 1 again.

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

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

Symbol 14 is displayed.

The REHEAT function automatically switches off again after 10 minutes.

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Operating manual

Control, operation Control

Recirculated air and fresh air, fan speed:

Fig. 3-47

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 8 to open / close the fresh air flap.

Symbol 13 indicates that the fresh air flap is closed.

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

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

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

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

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

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

Symbols 21 and 22 are no longer displayed.

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

Changing the air supply:

Fig. 3-48

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

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

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Control, operation

Operating manual

Control

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

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

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

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

Fig. 3-49

Air outlet symbols

Press key 9.

Symbol 16 is displayed.

Air outlets d are opened.

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

Symbol 16 is no longer displayed.

Air outlets d are closed.

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

Symbol 17 is displayed.

Air outlet b is opened.

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

Symbol 17 is no longer displayed.

Air outlet b is closed.

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

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

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

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

Open / close windscreen ventilation flap: Press key 12.

Symbol 18 is displayed.

Air outlet c is opened.

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

Symbol 18 is no longer displayed.

Air outlets c are opened.

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

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Operating manual

Control, operation Operation

Press and hold key 8.

Press key 3 The temperature is displayed in ° Fahrenheit.

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

Auxiliary heater operation (option):

Fig. 3-50

Auxiliary heater operation

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

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

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

3.3 Operation 3.3.1 3.3.1.1

Safety instructions Bringing the machine into service 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.

3.3.1.2

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

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Control, operation

Operating manual

Operation

located near the machine.

if you have not received any other instructions. controls for their proper indication. ventilated 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.

3.3.1.3

Shutting down the machine chock or block wheels when parking on a slope.

gear brake.

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

3.3.1.4

Towing the machine 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.

3.3.2

Camera system Due to the machine design and dimensions, the field of vision from the operator's cab might be somewhat restricted. The camera system is designed to increase the field of vision of the operator and is installed in addition to the mirrors. The machine operator can thus see areas that are not directly visible from the cab. The monitor in the operator's cab shows the image captured by the selected camera.

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Operating manual

Control, operation Operation

Danger!

The camera system is only an auxiliary tool and might not capture certain obstacles.

In addition, the image might be slightly distorted. It does not warn the operator if there are persons or obstacles in the danger area.

Please note: the machine operator to monitor the working area and the path of travel of the machine. ly by using the camera system! For the attachment of loads, the machine operator must always have a direct view of the load and the signaller. the aid of a signaller.

Fig. 3-51

Monitoring range of the cameras

1 Monitor in operator's cab B Rear camera *

A Front camera C Stick camera*

Special equipment

Cameras A and B are attached to the platform and allow for the monitoring of the areas in front of and behind the machine. The cameras must be switched on during travel, and the monitor must be switched to the camera that captures the path of travel.

Camera C (special equipment) is attached to the bottom side of the stick. It enables the operator to monitor the area around the grapple and assists him/her in the handling of goods. The camera is intended to be used in addition to a direct view of the working attachment.

Monitoring travel path: Switch on the camera system before putting the machine in motion.

Activate camera A or B. Adjust the monitor image so that it matches the direction of travel and shows the route.

In the event of a failure of the camera system, the machine must be moved with the aid of a signaller.

Agree clear hand signs with the signaller or establish voice contact.

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Control, operation

Operating manual

Operation

Monitoring grapple: Activate camera C. Adjust the monitor image so that you can see the working tool.

Adjusting camera:

Fig. 3-52 1

Camera (shown without protective cover)

Camera

2

Screw

The cameras for the machine can be accessed from the platform. To access the camera at the stick, you might need some auxiliary equipment. Use only suitable devices (e.g. lifting platform).

The camera is encased in a protective cover. The screws are accessible through openings in the protective cover.

Lower the working attachment and thus the camera attached to the stick to the lowest possible position.

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

Loosen the screws.

Turn the camera to the desired angle.

Tighten the screws.

Switch on the monitor and check the image.

If necessary, readjust the camera position.

Note!

Depending on the equipment, the stick might feature several mounting points for the camera. The mounting point for the camera must suit the working tool you wish to use.

If the camera needs to be attached to another position on the stick, contact the LIEBHERR customer service centre.

For detailed information, refer to the operating manual of the camera manufacturer.

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Operating manual

Control, operation Operation

3.3.3 3.3.3.1

Starting machine General Note!

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

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

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

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

3.3.3.2

Tasks to be completed prior to machine start Caution!

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

Before starting the machine, open all locks of the hydraulic 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".

Caution!

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

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

Before starting the machine, carry out the following routine procedure:

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

3.3.3.3

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

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

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

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Control, operation

Operating manual

Operation

Fig. 3-53 1

Keys in different colours

Programmed ignition key (blue)

2

Master key (red)

Note!

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

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

Start the machine with a blue programmed key.

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

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

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

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

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

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Operating manual

Control, operation Operation

3.3.3.4

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

Fig. 3-54

Battery main switch

Turn battery main switch to position 1 (ON).

Switching on the ignition:

Fig. 3-55 0 2

Ignition

Neutral position Ignition position

1 P

Contact position Parking position

Turn battery main switch to position 1 (ON).

Turn the ignition key to contact position 1.

The ignition is switched on.

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

The LIEBHERR logo is shown on the monitoring display.

During the self-test, observe the indicating instruments.

Note!

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

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Control, operation

Operating manual

Operation

Service interval indication

Fig. 3-56

Service interval request

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

The service check symbol disappears after about 8 seconds.

3.3.3.5

Starting diesel engine Note!

Incorrect starting can damage the diesel engine!

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

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

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

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

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

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

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

The indicator lights H2 and H12 must be off.

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

Starting engine at low ambient temperatures: Press the switch S36 (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.

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Control, operation Operation

3.3.3.6

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

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

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

Note!

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

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

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

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

3.3.3.7

Power selection (MODE) and speed adjustment

Fig. 3-57

Speed adjustment and mode functions

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

Selecting engine power (mode): By pressing the switch S86, you can select between 4 different modes. The active mode is indicated by the letter below the LED. L: LIFT mode (speed step 5 - extremely sensitive lifting of loads) F: FINE mode (speed step 10 - grading work) E: ECO mode (speed step 8 - economic operation) P: POWER mode (speed step 10)

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Control, operation

Operating manual

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 S86.

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

The respective LED is permanently on.

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

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

Note!

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

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

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

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

Speed is increased by one step.

The speed indicator P4 changes accordingly (increasing).

Reduce speed: Press switch S229.

The speed is reduced by one step.

The speed indicator P4 changes accordingly (decreasing).

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

Before continuing with the work, adjust the mode.

3.3.3.8

To be observed after start-up Danger!

Risk of asphyxiation from exhaust gases.

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

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

Caution!

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

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

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

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

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3.3.4

Switching off diesel engine Caution!

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 S229.

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

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

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

Remove the ignition key.

3.3.5

Jump start procedure Danger!

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

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

3.3.5.1

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

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

Start the engine as described above.

Caution!

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

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

3.3.5.2

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

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

Check the electrical functions of the machine.

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

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Control, operation

Operating manual

Operation

3.3.6

Horizontal alignment of the machine

Fig. 3-58

Circular spirit level

The machine is most stable when it is in a horizontal position. The greater the inclination, the lower the stability. For this reason, the angle of inclination for travelling and working is limited.

The angle of inclination is monitored by a circular spirit level installed in the foot room of the operator's cab. If the machine is in a horizontal position, the air bubble is in the centre of the in the liquid in the spirit level. The greater the angle of inclination, the closer the air bubble moves towards the edge of the spirit level.

For machine operation, place it on a level firm surface with no or only minimum slope.

Position the machine in such a way that the air bubble in the circular spirit level is as near as possible to the centre (angle of inclination 0°).

Do not exceed the maximum admissible angle of inclination.

Machine operation

Maximum admissible angle of inclination [°]

Working

2.5

Travelling

5

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3.3.7 3.3.7.1

Travel operation Travelling straight ahead

Fig. 3-59 A

Travelling straight ahead

Idler

B

1a/b Left travel pedal

Travel drive

2a/b Right travel pedal

Caution!

Risk of accident!

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

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

Forward travel: Push both pedals forward (1a and 2a).

Reverse travel: Push both pedals down (1b and 2b).

3.3.7.2

Turning at standstill

Fig. 3-60

Turning at standstill

Turning left (1): Push the left pedal down (1b).

Simultaneously push the right pedal forward (2a).

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Operation

Turning right (2): Push the right pedal down (2b).

Simultaneously push the left pedal forward (1a).

Note!

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

3.3.7.3

Turning machine with one chain

Fig. 3-61

Turning machine with one chain

Turning left (1): Push the right pedal forward (2a).

Turning right (2): Push the left pedal forward (1a).

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

3.3.7.4

Manually steering travel gear

Fig. 3-62

Manual steering of travel gear

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

Attach the supplied manual levers (1 and 2) to the travel gear pedals.

The travel gear can now be steered by hand.

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3.3.7.5

Speed regulation The max. achievable travel speed is set with the switch S21. The machine features two speed steps: Normal travel (position 1): Maximum drawing pull at moderate speed.

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

Press the switch S21.

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 S21 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.

3.3.7.6

Braking Caution!

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.

Applying hydraulic brake: 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.

Applying mechanical brake: 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 parking brake is applied automatically. The working attachment can still be moved.

Applying parking brake: If the parking brake is to be applied before this happens automatically, press the switch S354 (SF).

Press the switch SF. The LED in the switch is on.

The parking brake is applied.

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Operation

Press the switch SF again.

The LED in the switch is off.

The parking brake is released.

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

3.3.8

Operating instructions for travel gear Note!

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

3.3.8.1

Running in 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.

3.3.8.2

Travel gear 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.

3.3.8.3

Long distance 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).

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Control, operation Working with the machine

3.3.9

Travel alarm system (optional equipment)

Fig. 3-63

Travel alarm system

Actuate the travel pedal 1 or 2.

The travel alarm system is automatically switched on.

An acoustic signal (warning signal) is generated.

Deactivating the travel alarm system: Press the button S6R at the right joystick.

The travel alarm system is switched off.

Note!

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.

3.4 Working with the machine 3.4.1 3.4.1.1

Safety Instructions Working with the machine 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.

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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.

3.4.1.2

Use in material handling applications, specifically when travelling with raised loads and attachments 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.

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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.

3.4.1.3

Application of machines with tower elevation 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.

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Control, operation

Operating manual

Working with the machine

3.4.1.4

Additional notes for machines with fixed cab raiser 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.

3.4.1.5

Protection from vibrations 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:

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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.

3.4.2

Sensor-controlled low idle automatic 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 S20: 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.

Adjusting delay time: 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.

3.4.3

Working position

Fig. 3-64

Working position of the machine

A Idler

B Travel drive

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Control, operation

Operating manual

Working with the machine

Before carrying out any work, the machine must first be placed on level and firm ground.

If necessary, prepare the working area and remove obstacles.

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

3.4.4

Operating the working attachment

Fig. 3-65

Operating the working attachment

Caution!

The machine is equipped with PCSA controls as standard.

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

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

The left joystick (1) controls the stick and swivelling movements: a and b: Stick is extended or retracted. c and d: Uppercarriage is swivelled to the left or right.

The right joystick (2) controls the boom and grapple movements: e and f: Grapple is closed or opened. g and h: Boom is lifted or lowered.

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

Push the joystick back a: Stick moves in direction a Push the joystick forward b.

Stick moves in direction b.

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Control, operation Working with the machine

Moving the boom: The boom is moved by operating the right joystick 2.

Push the joystick back g: Boom is lifted.

Push the joystick forward h: Boom is lowered.

Operating the grapple: Danger Risk of injury to persons standing in the danger zone.

Do not allow auxiliary personnel hand-guide the grapple!

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

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

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

Selecting operating mode of the attachment (optional equipment): 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 working attachment.

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

To switch between the two modes, actuate the switch S499.

Before switching mode, stop all movements of the working attachment.

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

S499

Operating mode

OFF The light in the switch is off.

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

ON The light in the switch is on.

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

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Control, operation

Operating manual

Working with the machine

Fig. 3-66

Stick passive Lowering to lowest point

Note!

In passive mode, the stick can only be lowered to its lowest point, where it is in a nearly vertical position (see Fig. 3-66).

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

3.4.5

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

The uppercarriage is swivelled by operating the left joystick 1.

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

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

3.4.6

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

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

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

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

Mechanical slewing gear brake: The mechanical slewing gear brake can only be released, if the following conditions are met: (see chapter "Entering and exiting machine").

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Control, operation Working with the machine

Caution!

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

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

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

The LED in the switch is on.

Press the switch S17 again: The slewing gear brake is released and is operated in semi-automatic mode.

The LED in the switch is off.

Mechanical slewing gear brake (semi-automatic):

Fig. 3-67

Semi-automatic slewing gear brake

In semi-automatic mode, the slewing gear brake is operated by means of the switch S57 at the right joystick.

Press the switch S57 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 S57 up.

The slewing gear brake is released.

Note!

The LED in the switch S17 is always on when the brake is applied.

If the slewing gear brake cannot be released with the switch S57, this might be due to any of the following causes: s for release are not met (access system, refuelling unit) automatic mode. In this case, it can only be released by actuating the switch S17 again.

Checking the mechanical slewing gear brake: The uppercarriage is stationary.

Press the switch S17.

The slewing gear brake is applied.

The LED in the switch is on.

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

The uppercarriage must not swivel.

The slewing gear brake is working properly.

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Control, operation

Operating manual

Working with the machine

Positioning slewing brake (special equipment):

Fig. 3-68

Positioning slewing brake

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

Note!

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

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

The uppercarriage should preferably be slowed down hydraulically.

Operate the pedal 1.

The uppercarriage is slowed down in its movement.

3.4.7

Lowering the working attachment when diesel engine is shut off

Fig. 3-69

Lowering the working attachment when the diesel engine is off

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

Turn the ignition key to contact position 1.

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

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Control, operation Working with the machine

Note The working attachment can be lowered thanks to the pressure reserve 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 only use the joysticks to lower the working attachment and do not attempt to perform other movements.

3.4.8 3.4.8.1

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

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

In order to assist the machine operator, the range of movement of the stick can be limited by the stick cylinder shut-off function.

If this option is activated, the stick can only be moved within the preset angle range.

The reach of the attachment thus depends on the stick cylinder shut-off point and the angle of the boom.

The stick cylinder shut-off function has two shut-off points: MIN - stops the retracting movement of the stick MAX (optional equipment) - stops the extending movement of the stick

3.4.8.2

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

Danger!

The stick cylinder shut-off is not a safety device in the narrow sense of the word and serves only as a utility for the machine operator!

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

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Control, operation

Operating manual

Working with the machine

Danger!

Despite the stick cylinder shut-off function, there remains a risk of damage to the operator's cab and objects in the vicinity of the machine. The machine might vibrate or swing! Risk of accident!

Possible causes: grapple swinging from its stick, or where the size of a working tool is considerably increased when it is opened. might be extended, depending on the oil temperature, attachment option, retraction speed and load.

Adjust the stick cylinder shut-off so that there is a sufficient safety distance, even if the working tool is oscillating or if the shut-off is delayed.

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

3.4.8.3

Overriding stick cylinder shut-off function Danger!

Risk of injury and damage to equipment!

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

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

If the industrial stick is to be moved beyond the shut-off point, the stick cylinder shutoff function can be overridden. The function can be bridged by means of the key switch S54 and the rocker switch button S55 at the left joystick.

Fig. 3-70

Overriding stick cylinder shut-off function

Overriding inner shut-off point (MIN): Turn the switch 54 to position 1.

The bridging function is activated and can now by switched on.

Press and hold the rocker button S55.

The stick cylinder shut-off function is overridden.

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

Release the rocker button S55 and turn the key switch S54 to position 0.

The bridging function is deactivated.

Overriding outer shut-off point (MAX): Turn the switch 54 to position 2.

The bridging function is activated and can now by switched on.

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Operating manual

Control, operation Working with the machine

Press and hold the rocker button S55.

The stick cylinder shut-off function is overridden.

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

Release the rocker button S55 and turn the key switch S54 to position 0.

The bridging function is deactivated.

3.4.8.4

Adjusting the limit switches

Fig. 3-71

MIN and MAX (optional equipment) shut-off points

This adjustment must be carried out by a trained specialist technician.

The limit switch is located at the fulcrum between the boom and the stick and cannot be accessed without special auxiliary tools. To work safely at this height, use suitable equipment (e.g. lifting platform).

The shut-off point must be adjusted in such a way that there is at all times a safety distance of 3 m between the attachment and the objects to be protected (machine, operator's cab, other objects in the vicinity of the machine).

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Control, operation

Operating manual

Working with the machine

Adjusting inner shut-off point (MIN):

Fig. 3-72

Adjusting limit switch (MIN)

Move the boom upwards.

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

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

Loosen the screws 1.

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

Tighten the screws 1.

Check the stick cylinder shut-off function.

If necessary, repeat the adjustment and check the settings again.

Adjusting outer shut-off point (MAX):

Fig. 3-73

Adjusting limit switch (MAX)

To adjust the settings for a limited forward working range, lower the boom so that the attachment is positioned close to the ground.

Extend the industrial stick all the way to the desired shut-off point (MAX).

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

Loosen the screws 1.

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Control, operation Working with the machine

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

Tighten the screws 1.

Check the stick cylinder shut-off function.

If necessary, repeat the adjustment and check the settings again.

3.4.9

Turning, swivelling locking and releasing attachment

Fig. 3-74

Example of attachment

1 2

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

L/R

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. 3-75

Push button on the joystick

A

Actuation at left joystick (standard)

B

Actuation at right joystick (optional equipment)

C

Actuation at left and right joystick (operational equipment)

R/L

Left and right push buttons

Danger!

Risk of injury!

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

The auxiliary function is activated with the switch S19.

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Press the switch S19.

Auxiliary function is activated.

The LED in the switch is on.

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

The locking bolts are extended.

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

The locking bolts are retracted.

3.5 Installation and removal of attachment parts 3.5.1 3.5.1.1

Safety Instructions Installation and removal of attachment parts

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). itable lifting devices with sufficient load 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.

3.5.1.2

Removal and installation of attachment pins pulling device to push out the pins on the attachment. held by another person. of the pin and hit the screw only.

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Control, operation Installation and removal of attachment parts

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.

3.5.2

Attachment of grapple to industrial stick

Fig. 3-76

Attaching grapple to industrial stick

Danger!

Risk of injury!

Ensure that the machine operator follows the hand signal instructions of the instructor when moving the equipment.

Two workers are required to attach or remove the grapple.

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Installation and removal of attachment parts

3.5.2.1

Attaching grapple Before attaching a clamshell grab or multiple grab, ensure that the necessary hydraulic lines for grapple operation are mounted on the stick.

The grapple must be in a stable position (grabs fully opened).

Move the attachment in order to position the industrial stick between the bearing points of the grapple suspension 1.

Insert the bolts 2 and secure them with the plate 3.

Caution!

The hydraulic lines are under pressure.

Before connecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick and press the buttons of the "Rotate grapple" function).

Move the safety lever up.

Connect the hydraulic hoses 4 and 5 (for the supply of the grab cylinders) to the pipelines.

For grapples with hydraulic rotator, also connect the hydraulic hoses 6 and 7 to the pipelines for this auxiliary equipment.

Complete all working movements several times without load (opening and closing grapple, moving grapple to the right and left) in order to let any trapped air escape from the hydraulic circuits.

3.5.2.2

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

Caution!

The hydraulic lines are under pressure.

Before disconnecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick and press the buttons of the "Rotate grapple" function).

Move the safety lever up.

Disconnect the hydraulic hoses from the pipelines on the stick.

Immediately seal open lines to prevent dirt from entering the system.

Prop up the grapple to ensure that it cannot topple over.

Unscrew the plate 3 and carefully drive out the bolt 2. To do this, you might have to start the diesel engine and lift the attachment slightly from the ground.

3.5.3

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

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3.5.3.1

Safety information 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.

3.5.3.2

Positioning option

Fig. 3-77

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.).

3.5.3.3

Overview

Fig. 3-78

Industrial stick with hydraulic quick-change adapter

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A Industrial stick 1 Lock pin

3.5.3.4

B Suspension system of working tool 2 Half shell at suspension tackle

Releasing and locking

Fig. 3-79

Control elements, releasing (R)

Fig. 3-80

Control elements, locking (L)

S47 R

Push button / quick-coupling system Push button / release (lock pin is retracted)*

L

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 S47 and then press the button L or R with the other hand (two-hand control).

You can then release the button S47, and continue to operate the lock pin with the buttons L or R (holding function). *

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.

Releasing and locking: The auxiliary function must be activated (switch 19, LED on).

Press and hold the button S47.

The quick-coupling system is activated.

Press and hold the right button R. The buzzer sounds.

The lock pins are retracted.

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

The quick-change adapter is released.

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Press and hold the left button L. The buzzer is off.

The lock pins are extended.

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

The quick-change adapter is locked.

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

3.5.3.5

Attaching working tool 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. 3-81

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.

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Operating manual

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Fig. 3-82

Locking

Lock the quick-change adapter.

Release all buttons.

If in place: Loosen the locking screw 1 (optional equipment) at the suspension (unless the locking screw is loosened, the working tool cannot be moved freely).

Caution!

The hydraulic lines are under pressure.

Before connecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick).

Connect 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.

3.5.3.6

Dismantling working tool The working tool must be in a stable position.

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

Danger!

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.

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Fig. 3-83

Tightening the locking screw, disconnecting the lines and releasing

If in place: Tighten the locking screw 1 (optional equipment) at the suspension (without tightening the screw, the suspension would tilt to the side during removal, so that it would be difficult to take it up at the next attachment).

Caution!

The hydraulic lines are under pressure.

Before disconnecting the hydraulic lines, depressurise them using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick).

Disconnect all hydraulic or electrical lines to the working tool (e.g. for dismantling of grapple).

Release the quick-change adapter.

Release all buttons.

Fig. 3-84

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.

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

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3.5.3.7

Acknowledging buzzer signal (warning signal) After the working tool has been removed, the buzzer (warning signal) sounds as long as the system is not locked.

If the overload warning system is switched on, the warning buzzer can be acknowledged.

If no working tool is to be mounted, it is useful to deactivate the warning signal. This is also recommended to ensure that another buzzer sound (i.e. from the overload warning system) is actually audible.

Press the switch S349.

The buzzer is switched off.

The "quick-change adapter" icon remains displayed.

Note!

The acoustic warning signal is automatically reactivated when the system is locked again.

In order to activate the warning buzzer, lock the system once.

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

The buzzer and warning sound are on at the next release process.

3.5.4

LIKUFIX MH 110 quick-coupling system (optional equipment) The LIKUFIX MH 110 quick-coupling system allows for the fast and efficient exchange of working tools without having to leave the operator's cab. Hydraulic and electrical connections are thereby automatically disconnected and connected.

3.5.4.1

Safety information urself with the functions and operation of the quick-coupling system (without attached working tools). in the working area of the tool. e working tool only at minimum speed, 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 lock 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. stem is equipped with an integrated safety load hook for the safe attachment of lifting tackle, such as cables or chains. To use lifting tackle, you must use a suspension system with a safety load hook. the working tool.

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Operating manual

Control, operation Installation and removal of attachment parts

3.5.4.2

Positioning option

Fig. 3-85

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.).

3.5.4.3

Overview

Fig. 3-86

LIKUFIX MH 110 quick-coupling system

A Top section (at attachment)

B Bottom section (at working tool)

1

Lock pin

2

3

LIKUFIX at working tool

LIKUFIX top section

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Control, operation

Operating manual

Installation and removal of attachment parts

3.5.4.4

Releasing and locking

Fig. 3-87

Control elements, releasing (R)

Fig. 3-88

Control elements, locking (L)

S47

Push button / quick-coupling system

R L

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 pins.

With one hand, press the button S47 and then press the button L or R with the other hand (two-hand control).

You can then release the button S47, and continue to operate the lock pins with the buttons L or R (holding function). *

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.

Releasing and locking: The auxiliary function must be activated (switch 19, LED on).

Press and hold the button S47.

The quick-coupling system is activated.

Press and hold the right button R. The buzzer sounds.

The lock pins are retracted.

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

The quick-coupling system is released.

Press and hold the left button L. The buzzer is off.

The lock pins are extended.

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

The quick-coupling system is locked.

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Operating manual

Control, operation Installation and removal of attachment parts

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

3.5.4.5

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

Switch off the magnet system (if installed).

Position the top section above the working tool and rotate it so that the LIKUFIX couplings are aligned with each other.

Fig. 3-89

Releasing, lowering top section

Release quick-coupling system.

Release all buttons.

Slowly lower the top section until it is located between the guide tabs of the bottom section.

If necessary, adjust the position.

Continue lowering the top section until the locking bolts are aligned with the respective bores.

Fig. 3-90

Locking

Lock quick-coupling system.

Release all buttons.

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Control, operation

Operating manual

Installation and removal of attachment parts

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

3.5.4.6

Dismantling working tool The working tool must be in a stable position.

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

Danger!

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.

Fig. 3-91

Releasing, lifting top section

Release quick-coupling system.

Release all buttons.

Slowly lift the top section.

Attach the other working tool.

- alternatively To switch off the buzzer, lock the quick-coupling system without attaching a working tool.

3.5.4.7

Acknowledging buzzer signal (warning signal) After the working tool has been removed, the buzzer (warning signal) sounds as long as the system is not locked.

If the overload warning system is switched on, the warning buzzer can be acknowledged.

If no working tool is to be mounted, it is useful to deactivate the warning signal. This is also recommended to ensure that another buzzer sound (i.e. from the overload warning system) is actually audible.

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Operating manual

Control, operation General working methods

Press the switch S349.

The buzzer is switched off.

The "quick-change adapter" icon remains displayed.

Note!

The acoustic warning signal is automatically reactivated when the system is locked again.

In order to activate the warning buzzer, lock the system once.

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

The buzzer and warning sound are on at the next release process.

3.6 General working methods 3.6.1

Tips for the proper operation of the machine preventing damage and wear In order to prolong the service life of the machine and to prevent avoidable damage, observe the following instructions: attachment is used to hammer against a hard material to remove it. Repeated impact of the working attachment against hard materials results in damage to the steel structure and the machine components. 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.

Caution!

Incorrect operation of the attachment (e.g. backhoe bucket, concrete crusher, scrap shear, hydraulic hammer, swivelling rotator, stick extension) might result in an excessive load of the attachment.

The load on the attachment is greatest 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.

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Control, operation

Operating manual

General working methods

Fig. 3-92

3.6.2

Permissible working range for hydraulic cylinders

1

Possible swivel range

2

Permissible working range with 10 ° distance to end position

3 5

Limit range Hydraulic cylinder

4

Boom or stick

Preparation

Fig. 3-93

Safe working: observe machine range and danger zones

Danger!

Risk to life and limb when the machine is swivelled.

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

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Operating manual

Control, operation General working methods

Caution!

Risk of injury during work.

Always wear safety footwear. If required by the nature of the work to be carried out, wear hard hat and protective goggles.

Always wear the safety belt.

Before starting work, operate the horn to warn other workers.

Position the transport vehicle and the machine in such a way that the machine operator can properly supervise the transfer of the load.

If possible, position the machine at a higher point than the transport vehicle, in order to avoid unnecessary lifting of the load.

Lock the oscillating axle.

Extend the supports until the wheels are fully lifted from the ground.

3.6.3

Working with grapples Danger!

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.

3.6.4

Loading operation Danger!

Even when properly levelled, the machine can rock and tip over! Sinking of an outrigger below ground level would have devastating consequences!

Therefore always check whether the ground it is firm.

Carry out all movements with increased caution.

Do not travel with suspended loads. Before setting the machine into motion for travel, 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.

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Control, operation

Operating manual

General working methods

Fig. 3-94

Loading operation

Align the machine in a horizontal position (see chapter "Horizontal alignment of the machine").

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 (open the grapple).

Danger!

Risk to life and limb from suspended loads that become dislodged during loading onto the transport vehicle.

Do not overload the transport vehicle and ensure that the load cannot fall from the platform.

While loading the vehicle, ensure that no persons are in the danger area of the excavator or in the transport vehicle.

Never swivel the equipment over the driver's cab.

3.6.5

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

Danger!

The machine may only be used for lifting operations, if it is equipped with the necessary safety devices and when these devices are in proper working order.

According to the European standard EN 474-5, machines used to lift loads must be equipped with the following safety devices:

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Operating manual

Control, operation General working methods

Lifting tackle that allows for the safe attachment of a load (optional equipment) An example of a safe lifting tackle are lift hooks that are attached to the machine instead of the digging bucket. Load lift hooks may be replaced with safety hooks welded to the digging bucket.

Overload warning system (optional equipment) If the actual load reaches or even exceeds the permissible load according to the load lift chart, the overload warning system must generate a visual and audible alarm signal to the machine operator.

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

– Load lift chart in the operator's cab If one or more of the above requirements is not met, the machine may not be used for load lifting operations.

3.6.6 3.6.6.1

Overload warning system (optional equipment) General 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.

Note!

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

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Control, operation

Operating manual

General working methods

Note!

The overload warning system must be tested prior to the commissioning of the machine and then every year by a specialist technician, in accordance with the testing and setting installations in the service manual.

3.6.6.2

Operating principle 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.

3.6.6.3

Start-up Danger!

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 S18.

The overload warning system is activated.

The LED in the switch is on.

3.6.6.4

Functional test 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.

3.6.7

Hoist cylinder warning system Excessive stress on the working attachment can lead to a situation where the hydraulic pressure in the hoist cylinders rises very quickly to the load limit. This might for example occur if a very heavy load is moved with a large reach.

The control system monitors the load and protects the hoist cylinders against damage from excessive loads. If the maximum permissible hydraulic pressure is reached, the hoist cylinders are automatically depressurised (protective function).

The working attachment is automatically lowered and the machine operator cannot stop this movement.

The hoist cylinder warning system informs the operator in advance if the protective function is about to be activated. The operator is thus made aware of possible uncontrolled movements of the attachment. The warning is given with a visual (screen symbol) and an acoustic (warning buzzer) signal.

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Operating manual

Control, operation Transport and assembly

Symbol: e working attachment might suddenly be lowered. ach of the attachment must be reduced and/or the load must be lowered to the ground without increasing the reach.

Notwithstanding the hoist cylinder warning system, it is the responsibility of the machine operator to ensure that only loads of a known weight that is below the maximum permissible load of the machine are lifted. Also observe the applicable statutory accident prevention regulations.

Danger!

If the signals of the hoist cylinder warning system are ignored, the working attachment might suddenly be lowered. The machine operator might lose control of the load. Risk of accident!

If the hoist cylinder warning system is triggered, never increase the load or the reach of the attachment.

Reduce the reach and lower the load.

The hoist cylinder 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 instructions in the service manual.

3.7 Transport and assembly Due to the machine weight and dimensions, the machine is normally supplied as a disassembled unit for assembly on site. To assemble the machine, follow the instructions in the assembly guidelines of LIEBHERR. 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. Contact the service department for instructions on how to transport, assemble and modify the machine.

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Control, operation

Operating manual

Transport and assembly

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4 Malfunctions Malfunctions are indicated by indicator lights or icons on the monitoring display. In certain cases, an acoustic warning signal is issued. Additional information that facilitates the elimination of the problem is provided by error codes.

Malfunctions are frequently caused by incorrect operation of the machine or improper maintenance.

Each time you encounter a malfunction, read the relevant chapter in the Identify the cause of the malfunction and eliminate it or have it eliminated.

Note!

If you are unable to identify the cause of the malfunction, contact the LIEBHERR service department.

Do not carry out any work for which you are not qualified.

When contacting the LIEBHERR service department, describe the malfunction and all associated circumstances in as much detail as possible.

Quote the machine type, the serial number and the year of manufacture of your equipment.

4.1 Error code list General error codes Error code

Effect

Cause

Measure / remedy

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

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4-1

Malfunctions

Operating manual

Error code list

General error codes Error code

Effect

Cause

Measure / remedy

E 010

Hydraulic oil level not monitored

Hydraulic oil level sensor, short circuit, earth contact or wire break

Check hydraulic oil level, contact LIEBHERR customer service

Hydraulic oil temperature not monitored

Hydraulic oil temperature sensor, short circuit, earth contact or wire break

Check 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 Contact LIEBHERR customer service

E 011 E 012 E 013 E 014 E 015 E 016 E 017 E 018 E 022 E 023

E 042

Slewing gear fine control not working

Cable defect at valve

Monitoring of hydraulic oil cooling does not work

Cable defect at valve

No power reduction at slewing gear

Cable defect at valve

Performance regulation of hydraulic pump not working properly

Cable defect at valve

E 045

Insufficient pressure for attachment

Tool Control, cable defect at pressure control valve

Contact LIEBHERR customer service

E 046

Engine speed cannot be adjusted through the keyboard

Speed-adjustment servo motor faulty

Switch diesel engine to emergency mode, contact LIEBHERR customer service

E 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 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

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Operating manual

Malfunctions Error code list

General error codes Error code

Effect

Cause

Measure / remedy

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.

Error codes combined with symbols / indicator lights Error code

Symbol *

Effect

Cause

Measure / remedy

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

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4-3

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.

4.2 Engine diagnostic system 4.2.1

Engine monitoring 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

Indicator light

Description

Measure

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.

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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

4.2.2

Eliminating fault 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).

4.2.3

Viewing error codes 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 PROTECTION switch is pressed. To proceed to the next error code, actuate the DIAGNOSTIC rotary switch.

Switch off the ignition and switch it on again.

Press the PROTECTION switch.

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

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

Fig. 4-2

Example: Flashing sequence for error code 235

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4-5

Malfunctions

Operating manual

Troubleshooting

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

Turn the DIAGNOSTIC 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 PROTECTION switch again.

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

4.3 Troubleshooting 4.3.1

Diesel engine and fuel system

Error / fault 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

Cause

Remedy

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

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Operating manual

Malfunctions Troubleshooting

Error / fault

Cause

White steam emitted by diesel engine

Blue exhaust fumes

Remedy

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

Damaged bearing

Contact LIEBHERR customer service

Piston ring worn or broken

Contact LIEBHERR customer service

Diesel engine does not reach full speed

Poor engine performance

Diesel engine too hot

Insufficient oil pressure in diesel engine Note!

Immediately switch off the diesel engine

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

4.3.2

Hydraulic system

Error / fault Unusual noises / noise from hydraulic pumps Note!

Immediately switch off the diesel engine

Cause

Remedy

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

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4-7

Malfunctions

Operating manual

Troubleshooting

Error / fault

Cause

Remedy

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

4.3.3

No servo pressure

Contact LIEBHERR customer service

No pump high pressure

Contact LIEBHERR customer service

Travelling

Error / fault

Cause

Remedy

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 S354 (if installed).

Emergency control activated

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

4.3.4

Electrical system

Error / fault

Cause

Remedy

Battery charging indicator light does not go off

V-belt of alternator loose or broken

Tighten or replace V-belt

Alternator defective

Replace alternator

Batteries 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

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R 984 C Litronic High Rise / 11140259

Operating manual

Malfunctions Fuses and relays

Error / fault

Cause

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

Remedy

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

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

4.3.5

Contact LIEBHERR customer service

Heating and air conditioning system

Error / fault

Cause

No warm air escaping from heating system

Remedy

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

4.3.6

Working attachment

Error / fault

Cause

Remedy

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

4.4 Fuses and relays Danger!

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 High Rise / 11140259

4-9

Malfunctions

Operating manual

Fuses and relays

Before exchanging a fuse or relay, set the battery main switch to position 0 (OFF).

4.4.1

Fuse box E50

Fig. 4-3

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.

F19

15 A

Diesel engine

F20

80 A

Main fuse

F22

7.5 A

Reserve

F31

7.5 A

Heating and a/c system terminal 15

F32

15 A

Heating and a/c system terminal 30

F33

15 A

Reserve

F34

15 A

Reserve

F35

15 A

Reserve

F36

15 A

Reserve

F37

15 A

Reserve

F109

50 A

Flywheel

K16

Starter relay

K43

Engine stop relay

K66

Cylinder shut-down relay

K93

Cold start system relay

K103

Diesel engine ON (12 V for operating hours counter) relay

K141

Relay E5

K280

Relay E150

K288

Main relay terminal 15

K360

Headlight relay

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R 984 C Litronic High Rise / 11140259

Operating manual

Malfunctions Fuses and relays

4.4.2

A1010 printed circuit board

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.

F1

15 A

Reserve

F2

15 A

Reserve

F3

15 A

Reserve

F4

15A

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

F5

7.5 A

Windscreen wiper

F6

7.5 A

Emergency speed adjustment

F7

7.5 A

Keyboard and display

F8

15 A

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

F9

15 A

Speed-adjustment motor, excavator control

F10

25 A

Attachment headlight, revolving deck headlight, auxiliary headlight*

F11

15 A

Reserve

F12

15 A

Reserve

F13

7.5 A

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

F14

15 A

Cab lighting, cigarette lighter, horn

F15

15 A

Reserve

K5

Emergency control, engine stop* relay

K6

Horn relay

K7

Cab roof headlight relay

K8

Float position relay

K9

Emergency mode flow reduction relay

* optional equipment

copyright by R 984 C Litronic High Rise / 11140259

4 - 11

Malfunctions

Operating manual

Emergency operation

4.5 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). :

Emergency operation

Application

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

Danger!

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.

4.5.1

Emergency control In the event of a failure of the control electronics, certain machine components might not work properly.

Depending on the type and extent of the malfunction, it might be possible to reestablish proper operating conditions for the machine components.

The emergency control feature includes three functions:

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.

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R 984 C Litronic High Rise / 11140259

Operating manual

Malfunctions Emergency operation

4.5.1.1

Fig. 4-5

Control panel in the right control console

Fig. 4-6

Control panel for emergency control

S71

Emergency control switch / speed R6 adjustment

S73

Emergency control switch / machine control

Speed controller

S84-2 Emergency control switch / central lubrication system

Emergency speed adjustment The emergency speed adjustment caters for the following failures: S86 S228 and S229 If the diesel engine is in emergency mode, the engine speed can be adjusted with the regulator R6.

Set the switch S71 to position 1.

Start the diesel engine with the ignition key.

The indicator light H11 is on.

The symbol n-min/MANU is shown at the display.

The speed adjustment is in emergency mode.

Adjust the speed with the regulator R6.

Turn the regulator clockwise to increase speed.

Turn the regulator counter-clockwise to reduce the speed.

copyright by R 984 C Litronic High Rise / 11140259

4 - 13

Malfunctions

Operating manual

Emergency operation

4.5.1.2

Emergency machine control The emergency machine control caters for the following situations:

Danger!

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 S71 to position 1.

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.

4.5.1.3

Emergency mode for central lubrication system 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 S84-2 briefly to the left or right to initiate a complete lubricating cycle.

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

Set the switch S84-2 to position 1.

A lubricating cycle is completed.

4.5.2

Emergency operation of the hydraulic pump In the event of a failure in the pump control, the performance of the hydraulic pumps is automatically reduced to a minimum.

For such a situation, the excavator is equipped with an emergency operation function for the hydraulic pump. 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.

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R 984 C Litronic High Rise / 11140259

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 1 (Y50).

Remove the cotter pin 2.

Move the lever 3 into a horizontal position (emergency position).

The hydraulic pump is switched to emergency operation.

Start the diesel engine.

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4 - 15

Malfunctions

Operating manual

Emergency operation

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R 984 C Litronic High Rise / 11140259

5 Maintenance 5.1 Safety instructions 5.1.1

General safety instructions 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.

5.1.2

Checking for cracks , 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 High Rise / 11140259

5-1

Maintenance

Operating manual

Safety instructions

keep the machine clean and to clean it regularly. schedule. tions with the machine supported, on firm 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.

5.1.3

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

5.1.4

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

5.1.5

Repair 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.

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5-2

R 984 C Litronic High Rise / 11140259

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.

5.1.6

Electrical system 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.

5.1.7

Pressure accumulator 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 High Rise / 11140259

5-3

Maintenance

Operating manual

Safety instructions

mechanical work on them.

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

5.1.8

Hydraulic hoses and lines 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).

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R 984 C Litronic High Rise / 11140259

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.

5.1.9

Cab protection (FOPS) For certain machine applications LIEBHERR offers optional cab protection systems of various designs. These systems consist of a full length FOPS (falling objects protective structure) or a top guard and front guard to protect the operator's cab and windscreen area from falling objects (for example rocks or debris).

The full length FOPS wraps around the operator's cab, is mounted to the uppercarriage and is a stand-alone system.

The top and front guards are either bolted individually or in combination to the cab structure. In that case the operator's cab is also part of the cab protection system and is subject to the following instructions.

or example welding, cutting or drilling)

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

5.2 Access points for maintenance 5.2.1

Uppercarriage

Fig. 5-1

Access points at uppercarriage

copyright by R 984 C Litronic High Rise / 11140259

5-5

Maintenance

Operating manual

Access points for maintenance

No.

Access point

Access to:

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 filter, 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.

Caution!

Access doors might inadvertently close and cause injury to persons.

After opening the access doors, lock them in position, using the holder.

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.

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Operating manual

Maintenance Access points for maintenance

Fig. 5-3

Locking mechanism for bonnet

Open the locks 1, open the bonnet and fold it up.

Secure the bonnet with the holder 2.

Caution!

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 2.

5.2.2

Bottom side of undercarriage

Fig. 5-4

Access points, bottom side of undercarriage

1

Diesel engine

2

Hydraulic pumps

3

Radiator

4

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.

If necessary remove the cover plates and replace them after completion of the maintenance tasks

copyright by R 984 C Litronic High Rise / 11140259

5-7

Maintenance

Operating manual

Access points for maintenance

5.2.3

Undercarriage

Fig. 5-5

Access points at undercarriage

1

Internal compartment (additional tanks, access ladder to slewing gear)

3

Travel gear

Fig. 5-6

2

Chain tensioner

Internal access ladder with hatch

The hatch is located at the end of the access ladder to the slewing gear. When working at that height below the slewing gear, ensure that the hatch is closed.

5.2.4

Platform service unit

Fig. 5-7

Platform service unit

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Operating manual

Maintenance Access points for maintenance

1 3

Refuelling system control device Compressed air connection

2

Clutch drain hose

The service unit s located to the side of the tower superstructure and is accessible from the platform. Several connections are combined: 1. Refuelling system control device: fuel connection, control unit and electrical connection (see chapter "Refuelling system").

2. Drain hose connection: In the following chapters, a drain hose is referred to, used for the draining of lubricants and other media. We recommend connecting one end of the drain hose to the respective unit and the other to this coupling point.

The line ends in the undercarriage where you should place a collecting vessel of suitable dimensions to collect the drained off substances.

3. Compressed air connection: An external compressed air compressor can be connected at the undercarriage. This line connects the platform to the compressor.

5.2.5 5.2.5.1

Electric slewing crane (special equipment) Operating instructions The slewing crane is designed for the movement of loads during repair and maintenance work on the machine. Any other use, for example the pulling of loads, is deemed improper.

Proper use includes compliance with the instructions in the operating manual and the inspection and maintenance schedules.

5.2.5.2

Commissioning, testing Before commissioning the slewing crane, the operator must have it approved for use according to the applicable statutory regulations. In certain countries, these regulations might require that the crane be inspected and tested at specific intervals, and these regulations must be complied with.

The enclosed crane test log must be properly completed to document the inspections and tests that have been carried out.

5.2.5.3

Power source The power source of the crane (mains power, generator on the platform) must meet the following requirements: lation monitored frame)

copyright by R 984 C Litronic High Rise / 11140259

5-9

Maintenance

Operating manual

Access points for maintenance

5.2.5.4

Operation

Fig. 5-8

Overview, crane in parked position

1 3

Basic boom Crane brake

2 4

Crane trolley Mains switch with padlock

5

Storage box

6

Control unit

Fig. 5-9

Crane trolley released (A); crane trolley secured (B)

1

Crane trolley

2

Chain

3

Load lift hook

4

Endless sling

5

shackles

During machine operation, the slewing crane must be in parking position and the crane trolley must be secured. Do not start the machine while working with the slewing crane.

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R 984 C Litronic High Rise / 11140259

Operating manual

Maintenance Access points for maintenance

Danger!

Incorrect or improper use of the slewing crane can lead to serious injury or even death.

Switch the machine off and tilt the safety lever upwards before operating the slewing crane.

Never allow anyone to remain in the danger zone near and under suspended loads.

Preparing slewing crane for operation: Take the connecting cable from the storage box and connect it to the power source.

Take the control unit from the storage box and position it so that you can see the crane while operating the control unit.

Release the crane brake locking mechanism.

Turn the mains switch to position ON. Release the crane trolley.

Moving the crane to its parking position: Turn the basic boom towards the crane brake.

Engage the locking mechanism of the crane brake.

Secure the crane trolley: Fully retract the crane trolley and secure the load lift hook with the endless sling and the shackle to the crane tower.

Lift the chain and tighten it slightly.

Turn the mains switch to OFF and secure it with the padlock, if necessary.

Switch off the power source and disconnect the power cable.

Stow away the connecting cable and the control unit in the storage box.

Operating slewing crane: Switch

Function A

Emergency-stop

B

Lifting chain (2-stage operation)

C

Lowering chain (2-stage operation)

D

Crane trolley forward

E

Crane trolley back

F

Swivelling right (2-stage operation)

G

Swivelling left (2-stage operation)

For detailed information, refer to the operating manual of the crane manufacturer.

copyright by R 984 C Litronic High Rise / 11140259

5 - 11

Maintenance

Operating manual

Access points for maintenance

5.2.6 5.2.6.1

Mechanical slewing crane (special equipment) Operating instructions The slewing crane is designed for the movement of loads during repair and maintenance work on the machine. Application example: Lifting fuel tank nozzle onto the uppercarriage to refill the fuel tank. Any other use, for example the pulling of loads, is deemed improper.

Proper use includes compliance with the instructions in the operating manual and the inspection and maintenance schedules.

5.2.6.2

Commissioning, testing Before commissioning the slewing crane, the operator must have it approved for use according to the applicable statutory regulations. In certain countries, these regulations might require that the crane be inspected and tested at specific intervals, and these regulations must be complied with.

The enclosed crane test log must be properly completed to document the inspections and tests that have been carried out.

5.2.6.3

Operation

Fig. 5-10

Overview, crane trolley released (A); crane trolley secured (B)

1

Basic boom

2

Cable

3

Load lift hook

4

Hand crank

5

Endless sling

6

Railing

During machine operation, the crane must be secured to the railing. Do not start the machine while working with the slewing crane.

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Operating manual

Maintenance Access points for maintenance

Danger!

Incorrect or improper use of the slewing crane can lead to serious injury or even death.

Switch the machine off and tilt the safety lever upwards before operating the slewing crane.

Never allow anyone to remain in the danger zone near and under suspended loads.

Operating slewing crane: Lift or low the cable by turning the hand crank to lift or lower the cable.

Move the slewing crane by hand to the desired position.

Securing slewing crane: Swivel the slewing crane across the railing.

Attach the load lift hook with the endless sling to the railing.

Lift the cable and tighten it slightly.

Releasing slewing crane: Release the cable.

Remove the load lift hook from the endless sling.

For detailed information, refer to the operating manual of the crane manufacturer.

5.2.7

Attachment points for fall-arrest equipment The machine must always be accessed through the access and climbing aids provided.

For installation, maintenance and cleaning work, persons might need to access parts of the machine that forces them to stand outside the railings and designated access areas.

As there is a danger of falling, persons must always use fall-arrest equipment secured to the attachment points provided.

This also applies to persons that walk on the machine in areas where there is insufficient protection against falling from railings (e.g. cleaning of the operator's cab windscreen and roof).

Abseiling from the machine is only possible with suitable fall-arrest equipment and the necessary skills. Persons who must carry out work that requires abseiling must be trained in the use of fall-arrest equipment.

The attachment points at the machine are clearly identified with signs (see Fig. 5-11).

An attachment point must only be used to secure one person at a time.

If several persons must attach themselves to the machine, they must used different attachment points.

copyright by R 984 C Litronic High Rise / 11140259

5 - 13

Maintenance

Operating manual

Cleaning machine

Fig. 5-11

Attachment point (left) and sign (right)

5.3 Cleaning machine The machine should be cleaned before carrying out any maintenance or repair work.

In particular, the connections and screws should be cleaned of oil, fuel and residue of cleaning agents.

Note!

High-pressure water jet cleaners (steam cleaners) can damage the coating.

Do not use high-pressure water jet cleaners during the first two months after commissioning (or after recoating).

Observe the prescribed safety distances.

Before cleaning the machine: Before cleaning the machine with water or with a steam cleaner (high-pressure water jet cleaner), carry out the following tasks to protect the equipment against penetrating water.

Lubricate all bearing points, bolt connections and the slewing ring; if necessary, use the central lubrication system to do this.

Cover or seal all openings that must be protected against penetrating water for safety reasons (particularly at risk of damage are electric motors, electric components, switch cabinets, plug connections, measuring sensors and air filters).

Cleaning: Use flint-free cleaning cloths.

Do not use aggressive detergents or flammable liquids.

When cleaning the engine compartment, ensure that the temperature sensor of the fire alarm and extinguishing systems (if installed) are not accidentally brought into contact with the hot cleaning solution, After cleaning: Remove all seals and covers.

Check all fuel, engine oil and hydraulic lines for leakage, loose connections, chaffing and damage.

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Operating manual

Maintenance Care for rubber components

Repair any defects without delay.

Lubricate all bearing points, pin connections and the slewing ring to remove any water that might have been penetrated.

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

5.4 Care for rubber components The service life of rubber seals can be prolonged by treating them with a rubber care product.

Clean and regularly treat the rubber seals on doors and panelling elements with a care product. This helps prevent premature wear and protects the rubber seals during the cold season.

Recommended care products: Silicone, talcum powder, deer tallow

5.5 Fuels, lubricants and process chemicals 5.5.1

General information Observe the instructions for lubricants and process chemicals. Lubricate the machine and change the oils at the prescribed intervals. For more information, see lubrication chart and inspection and maintenance schedule.

Keep workplaces for these activities clean. This enhances the service life and reliability of the machine.

All work on the machine must be carried out while it is standing on firm and level ground.

Switch off the diesel engine, remove the ignition key and set the battery main switch to position 0 (OFF).

Clean lubricating nipples before adding grease.

Clean all filling points and the area around them before opening the caps and screws.

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.

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Maintenance

Operating manual

Fuels, lubricants and process chemicals

5.5.2 5.5.2.1

Filling volumes, lubricating chart Recommended lubricants

Designation

Recommended lubricant

Diesel engine

Liebherr Motoroil 10W-40 low ash

Symbol

Volume [litre]* 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 mechanism

Liebherr Gear Basic 90 LS

2 x 20

Pump distributor gear

Liebherr Gear Basic 90 LS

10.5

Central lubrication system, lube points on machine and attachment

Liebherr Universalfett 9900

-

Lubrication system of slewing gear

Liebherr spray paste

-

-

Hinges, joints, locks

Engine oil

-

-

* = guide values

5.5.2.2

Recommended fuels and chemicals

Designation

Recommended fuel

Symbol

Fuel tank

Conventional diesel fuel

1585

Coolant

Anti-corrosion grease 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

-

Volume (litre)*

3.0

* = guide values

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Operating manual

Maintenance Fuels, lubricants and process chemicals

5.5.2.3

Lubricating chart

Fig. 5-12

Lubricating chart

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Maintenance

Operating manual

Lubricants and fuels

Symbol

Description 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

5.6 Lubricants and fuels 5.6.1

Diesel fuels Minimum quality requirement Approved diesel fuels in line with DIN EN 590, ASTM D 975 1-D/2-D

Diesel engine stage III-A or Tier 3

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.

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Operating manual

Maintenance Lubricants and fuels

5.6.2

Engine oils Liebherr recommendation Description 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).

Minimum quality requirement Specification 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.

5.6.2.1

Adverse factor 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.

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Maintenance

Operating manual

Lubricants and fuels

Sulphur content of fuel

LH-00ENG3A

Liebherr Motoroil 5W-30

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

5.6.3 5.6.3.1

Change interval of engine oil

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

5.6.3.2

Corrosion inhibitor Liebherr recommendation Description

Manufacturer

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

5.6.3.3

Liebherr recommendation with 50:50 mixing ratio

Anti-freeze and corrosion protection agent Liebherr recommendation Type

Description

Concentrate

Liebherr Antifreeze OS Concentrate

PremixA)

Liebherr Antifreeze OS Mix

Tab. 5-7

Liebherr recommendation

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Operating manual

Maintenance Lubricants and fuels

Ambient temperature

Mixing ratio

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)

Minimum quality requirement 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.

5.6.4

Hydraulic oils Liebherr recommendation Ambient temperature

Description 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 Liebherr-PAO3) biodegradable

-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

Minimum quality requirement 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.

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Maintenance

Operating manual

Lubricants and fuels

5.6.4.1

Normal application (Oil analysis optional)

Oil analysis

Liebherr mineral oil

Dust intensive application

Normal operation

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

5.6.4.2

Filter replacement Dust intensive application

Normal operation

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.

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Operating manual

Maintenance Lubricants and fuels

5.6.4.3

Oil change

Liebherr mineral oil

Without oil analysis

With oil analysis5)

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)

5.6.5

For eco-friendly applications, oil analysis is mandatory.

Axle oil Note 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.

Liebherr recommendation Ambient temperature

Description

-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

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Maintenance

Operating manual

Lubricants and fuels

Minimum quality requirement Specification 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.

5.6.6

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

Liebherr recommendations Ambient temperature

Description

-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

Minimum quality requirement Specification 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.

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Operating manual

Maintenance Lubricants and fuels

5.6.7

Transmission oils Liebherr recommendation Description Liebherr Motoroil 10W-40 Tab. 5-17 Liebherr recommendation

Minimum quality requirement SAE viscosity class

Specification

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.

5.6.8 5.6.8.1

Pump distributor gear oils Machine without pump distributor gear oil cooler Liebherr recommendation Ambient temperature

Description

-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

Minimum quality requirement Specification 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.

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Maintenance

Operating manual

Lubricants and fuels

5.6.8.2

Machine with pump distributor gear oil cooler Liebherr recommendation Ambient temperature

Description

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

Minimum quality requirement Specification 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.

5.6.9

Energy recuperation cylinder oils Liebherr recommendation Description

Tab. 5-23 Liebherr recommendation

Minimum quality requirement 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.

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Operating manual

Maintenance Lubricants and fuels

5.6.10

Greases Liebherr recommendation Ambient temperature

Description

From -20°C

Liebherr Universalfett 9900

From -55°C

Liebherr Universalfett Arctic

Tab. 5-24 Liebherr recommendation

Minimum quality requirement Thickener

Shelf life

Specification

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

5.6.11

Windscreen washer fluid Liebherr recommendation Liebherr recommends commercially available windscreen washer fluid with antifreeze.

Minimum quality requirement Use mixture of water and denatured alcohol.

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Maintenance

Operating manual

Diesel engine

5.6.12

Lubricants and care products for electrical and mechanical systems Liebherr recommendation Application

Product

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

5.7 Diesel engine Danger!

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.

5.7.1

Checking the oil level

Fig. 5-13

Dip stick

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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 min and max marks.

If necessary, add engine oil until the level reaches the max mark.

5.7.2

Changing engine oil Preparation: 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.

Draining off engine oil:

Fig. 5-14

Filler neck, drain valve

1

Drain valve

2

Drain hose

3

Filler neck

4

Oil filter cartridges (see Fig. 5-15)

protect the V-ribbed belt against escaping engine oil.

Open the filler neck 3.

Remove the cover cap from the drain valve 1 on the oil pan.

Screw the drain hose 2 to the drain valve of the oil pan.

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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.

Replacing oil filter cartridges:

Fig. 5-15

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 4 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 by hand by 1/2 to 3/4 revolutions, using the oil filter strap spanner.

Adding engine oil: Add engine oil through the filler neck 3 until the oil level reaches the upper mark (max) on the dipstick.

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.

5.8 Cooling system Danger!

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.

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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.

5.8.1

Checking and cleaning the cooling system 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.

5.8.2

Checking coolant level

Fig. 5-16

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.

5.8.3

Changing coolant When changing the coolant, observe the following instructions:

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Maintenance

Operating manual

Cooling system

the cooling circuit. contact position.

Fig. 5-17

Radiator drain valves

The drain valves A and B 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).

5.8.4

Coolant 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.

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Operating manual

Maintenance Fuel system

5.8.5

Changing water filter

Fig. 5-18

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.

Note!

The filter cartridge is easily damaged.

Do not use any tools when tightening the filter cartridge.

Tighten the filter cartridge by hand completing 1/2 - 3/4 revolution.

Open the stop valves.

5.9 Fuel system Danger!

Danger of explosion!

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

Do not smoke.

5.9.1

Refuelling Note!

If the fuel tank is emptied while the diesel engine is running, the fuel system must be bled, which is a complicated and time-consuming procedure.

Therefore avoid running the tank empty and refuel the machine on time.

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Maintenance

Operating manual

Fuel system

Note!

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

The indicator P3 indicates the fuel level in the tank.

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

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

5.9.1.1

Direct refuelling

Fig. 5-19

Tank lid

Remove the tank lid 1.

Refill fuel through the strainer.

5.9.1.2

Refuelling unit (optional equipment) By installing auxiliary fuel tanks in the undercarriage, the machine can carry more fuel reserves so that refuelling can be postponed longer. This increases the operating time until the next refuelling stop.

The auxiliary tanks must be filled first. When the fuel in the standard tank of the uppercarriage is used up, this tank can be refilled by pumping fuel from the auxiliary tanks.

Tank

Capacity

Fuel tank in uppercarriage

1585 l

Additional tank in undercarriage

6000 (2 x 3000) l

Pumping fuel from auxiliary tank to standard tank: The indicator P3 indicates the fuel level in the standard tank.

If the red bars are lit, there is very little fuel left in the tank of the uppercarriage.

Pump fuel from the auxiliary tanks to the standard fuel tank.

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Operating manual

Maintenance Fuel system

Fig. 5-20

Platform service unit

1 Fuel hose/uppercarriage A "Pump ON" switch (green)

2 Plug B "Pump OFF" switch (red)

The fuel tank in the uppercarriage is connected through a hose line with the auxiliary tank.

The fuel line coupling, control unit and electrical connection of the refuelling unit are located on the platform service unit.

Swivel the uppercarriage so that it faces away from the travel direction.

Remove the dust protection cap.

Remove the fuel hose 1 from the holder and connect it to the fuel coupling.

Connect the plug 2 to the power socket.

The tank and the refuelling unit are not connected.

The slewing gear is automatically switched off so that the uppercarriage cannot be swivelled.

Actuate the switch A. The refuelling pump is started.

The standard fuel tank in the uppercarriage is filled.

When the fuel tank in the uppercarriage is full, or when the auxiliary tanks are empty, the refuelling pump is automatically switched off.

Alternatively, actuate the switch B. The refuelling pump is switched off.

Disconnect the plug 2 and the fuel hose 1 and place the fuel hose 1 in the holder.

The tank and the refuelling unit are now disconnected.

The slewing gear is automatically released so that the uppercarriage can be swivelled.

Replace the dust protection cap.

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Maintenance

Operating manual

Fuel system

Refilling auxiliary tank through the hose coupling:

Fig. 5-21

Hose coupling at the undercarriage

The hose coupling for the connection of the fuel hose (type: Wiggins) is located near the access ladder on the undercarriage.

The tank may only be refuelled through this hose coupling, if the refuelling unit is equipped with an automatic shut-off function. This function must stop the refuelling process as soon as the auxiliary tank is full. If this is not possible, use the tank lid, (see Fig. 5-22).

Remove the dust protection cap.

Connect the fuel hose to the hose coupling.

Switch on the fuel pump of the unit.

Wait until the auxiliary tank is full and the refuelling pump is automatically switched off.

Disconnect the fuel hose and replace the dust protection cap.

Refilling auxiliary tank through the tank lid:

Fig. 5-22

Tank lid at the undercarriage

The tank lid of the auxiliary tank is located at the undercarriage.

Remove the tank lid 1.

Refill fuel through the strainer.

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Operating manual

Maintenance Fuel system

5.9.2

Fuel tank maintenance

Fig. 5-23

Fuel tank in uppercarriage

Fig. 5-24

Auxiliary fuel tanks in undercarriage (special equipment)

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

Dewatering fuel tank: 1. nsists of two elements with one water drain valve 1 each located in the tank base.

Place a suitable container under the valve.

Open the water drain valve 1.

Drain off the water until fuel begins to escape.

Close the drain valve 1.

Emptying and cleaning fuel tank: Dewater the fuel tank.

Place a suitable container under the valve.

Remove the tank lid 3 and the water drain valve 1 and drain off the fuel.

Regularly check the fuel tank and the strainer 2 for dirt.

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Maintenance

Operating manual

Dry air filter

If required, replace the strainer 2 and/or rinse out the fuel tank.

5.9.3

Fuel filter

Fig. 5-25 1

Fuel filter

Fuel filter

2

Electronic fuel filter

The fuel filters 1 and 2 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.

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

5.10 Dry air filter

Fig. 5-26

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.

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Operating manual

Maintenance Dry air filter

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

Note!

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.

5.10.1

Checking suction vacuum

Fig. 5-27

Underpressure indicator

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 1, 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 2.

5.10.2

Cleaning pre-filter

Fig. 5-28

Pre-filter

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Maintenance

Operating manual

Dry air filter

1 3

Pre-filter Clamp

2

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 2 and 3.

Remove and clean the pre-filter 1.

Replace the pre-filter and tighten the clamps.

5.10.3

Replacing filter cartridges Note!

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.

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

Fig. 5-29

Changing the filter cartridges

1

Main element

2

Wing screw

3

Safety element

4

Mounting screw

Changing the main element: Switch off the engine, screw off the wing screw 2 and remove the main element 1.

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

Insert the new main element 1, and ensure that it is positioned tightly and firmly in its seat.

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Operating manual

Maintenance Dry air filter

Tighten the wing screw 2 by hand.

Changing the safety element: Remove the main element 1.

Unscrew the mounting screw 4 and remove the safety element 3.

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 3.

Tighten the mounting screw 4 by hand.

Insert the new main element 1 and ensure that it is positioned tightly and firmly in its seat.

Tighten the wing screw 2 by hand.

5.10.4

Checking the clean air lines

Fig. 5-30

Checking the clean air line

The clean air lines can be accessed from the engine compartment. Then connect the components of the suction system: 1 Connection of dry air filter and turbocharger 2 Connection of turbocharger and intercooling air cooler 3 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.

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5 - 41

Maintenance

Operating manual

Hydraulic system

Fig. 5-31 1

Please note that certain clamps may not be retightened.

Clamp

2

Clamp with spring pack

Note!

Clamps with spring packs (2, 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 1.

5.11 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.

Danger!

High-pressure liquid might penetrate the skin and cause damage. At operating temperature, the hydraulic oil is hot and can even be under pressure. Escaping 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.

Do not allow your skin to come into contact with hot oil or components containing hot oil.

Note!

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

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

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Operating manual

Maintenance Hydraulic system

5.11.1

Test position

Fig. 5-32

Test 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 shells and position the stick vertically.

Place the attachment on the ground.

5.11.2

Checking the oil level in the hydraulic tank

Fig. 5-33

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 test position, the level must be close to the centre mark in the sight glass.

The upper mark MAXI indicates the maximum oil level when all cylinders are fully retracted.

The lower mark MINI indicates the minimum oil level when all cylinders are fully extended.

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

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

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5 - 43

Maintenance

Operating manual

Hydraulic system

5.11.3

Releasing the pressure from the hydraulic system

Fig. 5-34

Releasing pressure in the hydraulic system, breather filter

The breather filter 1 can be rotated by hand when the safety pin 2 is inserted. If necessary, use an open end spanner to open the filter.

Lower the working attachment to the ground.

Switch off the diesel engine.

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

Rotate the breather filter 1 by maximum one full revolution.

The hydraulic system is now gradually depressurised.

After completion of the maintenance task, retighten the breather filter 1.

5.11.4

Replacing the breather filter Depressurise the hydraulic system.

Replace the breather filter (see Fig. 5-34) each time you change the hydraulic oil.

Note!

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

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Operating manual

Maintenance Hydraulic system

5.11.5

Emptying and refilling the hydraulic tank

Fig. 5-35

Emptying and refilling hydraulic oil

A Top view

B Rear view

C Front view 2 Return filter lid

1 Breather filter 3/4 Drain valve

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

Draining oil: Depressurise the hydraulic system.

Remove the lid 2 from the return filter.

Screw the drain hose onto the drain valves 4 and 5 at the bottom of the tank and let the oil drain into a suitable container.

Adding hydraulic oil: Depressurise the hydraulic system.

Remove the lid 2 from the return filter.

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

Tighten the breather filter 1.

Replace the lid 2 of the return filter.

Caution!

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

Bleed the hydraulic pumps after each hydraulic oil change.

Draining off the condensate (only for mineral oil): Regularly drain the condensate from the system.

Place a suitable container under the machine.

Connect the drain hose to the drain valves 4 and 5 (see Fig. 5-35) until the oil flowing into the container does not contain any water.

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5 - 45

Maintenance

Operating manual

Hydraulic system

5.11.6

Return filter

Fig. 5-36

Return filter

1

Lid

2

Magnetic rod

3 5

Hex head screw Filter cartridge

4

Seal ring

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

Note!

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

Cleaning magnetic rod, replacing filter cartridge: Depressurise the hydraulic system.

Loosen the screws 3 on the lid 1 and remove the lid 1 together with the magnetic rod 2.

Carefully clean the magnetic rod 2 removing any persistent dirt.

Remove the spent filter cartridge 5 holding it by the bracket.

Insert the new filter cartridge 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.

Insert the new seal ring 4.

Carefully replace and centre the lid 1 in the filter cartridge. Ensure that the seal ring 4 is not damaged.

Note!

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.

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Operating manual

Maintenance Hydraulic system

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

5.11.7

Control oil filter, control circuit

Fig. 5-37

Control oil unit

1

Control oil unit

2

Control oil filter

3

Mounting stud

4

Filter cartridge

5 7

Filter cartridge seal ring Seal of filter pot

6 8

Filter pot Accumulator

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

Note!

The filter cartridge cannot be cleaned.

Replace the cartridge each time you open the filter pot.

Replacing filter cartridge: The control oil filter 2 is an integral part of the control oil unit 1.

Depressurise the hydraulic system.

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

Remove the filter pot 6 of the pressure filter 2 and pull out the filter cartridge 4.

Clean the filter pot 6.

Apply a little hydraulic oil to the threads and sealing faces at the filter pot 6 and at the control oil unit 1 as well as to the sealing rings 5 and 7.

Carefully place the new filter cartridge 4 onto the mounting stud 2.

Screw in the filter pot 6 to the stop and tighten it by hand.

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

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5 - 47

Maintenance

Operating manual

Hydraulic system

5.11.8

Bleeding hydraulic pumps Prior to commissioning the pumps, after repairs and after a replacement of the pump, fill the pump housing through the leak oil connection with hydraulic oil.

After the system has been filled, and after an oil change in the hydraulic system, bleed the hydraulic pumps.

Caution!

Hydraulic pumps that were not bled might be damaged during operation, or might result in a limited functioning of the hydraulic unit.

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

Fig. 5-38

Hydraulic pumps

1

Hydraulic pump P3

2

Hydraulic pump P2

3

Hydraulic pump P1

4

Hydraulic pump of fan drive

5

Hydraulic pump of slewing gear Depressurise the hydraulic system.

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, open one screw plug (see arrows).

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Operating manual

Maintenance Hydraulic system

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.

5.11.9

Removing the suction hose

Fig. 5-39

Suction hose, shut-off valve

The shut-off valve of the suction hose has two positions: A open B closed Depressurise the hydraulic system.

If the suction hose is to be disconnected at the pump or at the hydraulic tank, close the shut-off valve B. Place a suitable container to collect the hydraulic oil under the bleed point.

Drain the hydraulic oil from the pump and suction hose.

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

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5 - 49

Maintenance

Operating manual

Hydraulic system

5.11.10

Replacing the feed line filter

Fig. 5-40

Feed line filter of the slewing gear circuit

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

Depressurise the hydraulic system.

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

Remove the filter pot.

Take out the filter cartridge and insert a new one.

Reinstall the filter pot.

5.11.11

High-pressure filter

Fig. 5-41

High-pressure filter

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

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Operating manual

Maintenance Hydraulic system

Fig. 5-42

High-pressure filter details

1 3

Head section Seal ring

5

Seal ring

2 4

Filter pot Filter cartridge

Cleaning or replacing filter cartridge: Depressurise the hydraulic system.

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

Remove the filter pot 2.

Remove the filter cartridge 4.

Wash the filter cartridge 4 with petrol or replace it.

Clean the filter pot 2 and the head section 1.

Mount the filter pot 2 with the filter cartridge 4.

Leakage check: 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.

5.11.12

Bypass oil filter (optional equipment) 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.

Note!

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. 5-43).

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Maintenance

Operating manual

Hydraulic system

Fig. 5-43

Location of installation of bypass oil filter

Fig. 5-44

Bypass oil filter

1

Screw

2

Washer

3 5

Lid Filter cartridge

4 6

O-ring Filter housing

Changing filter cartridge: Switch off the engine.

Release the pressure from the hydraulic system.

Remove the screw 1 and the lid 3.

Remove the spent filter cartridge 5 by turning it at the carrying straps in clockwise direction while lifting it slightly.

Wait until the oil has been drained off, then remove the filter cartridge 5 and collect dripping oil in a suitable container.

Check the inlet and outlet of the filter housing 6 for dirt deposits and clean it, if necessary.

Remove the new filter cartridge 5 from the packaging while leaving the cardboard mantle attached to the cartridge.

Note!

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.

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Operating manual

Maintenance Hydraulic system

Insert the new filter cartridge 5.

Fill the filter housing 6 with the same hydraulic oil as is used in the machine.

Clean the lid 3 and insert a new O-ring 4.

Replace the lid 3 and secure it with the screw 1. Tighten the screw with a torque of 50 Nm. Start the machine and check the bypass oil filter for leakage.

5.11.13 5.11.13.1

Maintenance of hydraulic cylinders Checking piston rod bearing

Fig. 5-45

Piston rod bearing

Note If there is a leak at the piston rod bearing of a hydraulic cylinder (arrow), we recommend having the seal kit replaced by a LIEBHERR technician.

5.11.13.2

Preservation of piston rods Prior to standstills of more than 4 weeks, and in particular prior to any sea transport of the machine, carry out the following tasks: If possible, position and transport the machine in such a way that the piston rods are fully retracted into the cylinders.

Exposed piston rods must be protected with a thick layer of acid-free corrosion protection grease.

Before loading the machine, check the piston rods again for proper preservation.

Also apply corrosion protection grease to the piston rods, if the respective cylinder is rarely operated during work. Piston rods that are not frequently retracted and extended are not properly lubricated with hydraulic oil.

Regularly check the preservation of rarely operated hydraulic cylinders.

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5 - 53

Maintenance

Operating manual

Hydraulic system

5.11.14

Replacing hydraulic hoses Danger!

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). :

Tightening torque [Nm] Split flange

Full flange

Full flange, cone-shaped

Screw

8.8

10.9

M8

22

31

M10

44

62

M12

76

108

M14

122

172

M16

187

264

M20

-

350

Screw (10.9)

Tightening torque [Nm]

M10

45

M12

70

M14

120

M16

170

M20

250

Screw (10.9)

Tightening torque [Nm]

M10

65

M12

110

M14

180

M16

250

M20

450

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Operating manual

Maintenance Oil change in components

5.12 Oil change in components 5.12.1

General instructions 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.

5.12.2

Slewing gear mechanism – oil change

Fig. 5-46

Oil change in slewing gear mechanism

Fig. 5-47

Oil tank

1

Oil tank

3

Drain valve

2

Lid

The drain valve 3 is accessible through an opening at the front of the revolving deck.

The oil level can be checked at the oil tank 1 located behind the operator's cab. At this point, the tank can also be refilled with oil.

Draining oil: Remove the lid 2.

Lift the cover in front of the drain valve 3.

Connect the drain hose to the drain valve 3 and let the oil drain into a suitable container.

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5 - 55

Maintenance

Operating manual

Oil change in components

Disconnect the drain hose.

Adding oil: Add oil directly into the oil tank 1 until the level reaches the MAX mark.

Replace the lid 2.

5.12.3

Pump distributor gear

Fig. 5-48

Oil change in the pump distributor gear

1

Oil filler neck

3

Drain valve

2

Dip stick

Checking the oil level: Switch off the diesel engine.

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

Pull out the dip stick 2 and clean with a clean cloth.

Insert the dip stick 2 to the stop.

Pull out the dip stick 2 again and check the oil level.

The oil level must be between the min and max marks.

If necessary, add gear oil until the level reaches the max mark.

Draining oil: Remove the screw cap at the drain valve 3.

Connect the drain hose to the drain valve 3 and let the oil drain into a suitable container.

Disconnect the drain hose.

Replace the screw cap at the drain valve 3.

Adding oil: Add oil through the filler neck 1 until it reaches the max mark on the dipstick.

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Operating manual

Maintenance Travel gear

Refilling oil: 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.

5.12.4

Travel gear

Fig. 5-49

Travel gear - changing oil

Before the oil change, ensure that the machine is at operating temperature: Draining oil: To drain off oil or to add oil, position the chassis in such a way that the screw plugs 1, 2 and 3 are in the positions indicated in the drawing.

Place a suitable collecting vessel under the screw plug 3.

Remove the screw plug 3.

Remove the screw plug 1 or 2.

Collect the escaping oil in the vessel.

Adding oil: Close the screw plug 3.

Add oil through the opening 1 until the oil level reaches the opening.

Insert and tighten the screw plugs 1 and 2.

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

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Maintenance

Operating manual

Travel gear

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.

5.13.1

Cleaning drive gear 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.

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.

Note!

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.

5.13.2

Checking fixtures of components

Fig. 5-50

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 A. Check the tightening torques (see table).

No.

Mounting

Tightening torque [Nm]

1

Base plates

2300

2

Travel drive

2100

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Operating manual

Maintenance Travel gear

5.13.3

No.

Mounting

Tightening torque [Nm]

3

Tumbler wheel

2100

4

Hydraulic motor

960

Checking chain tension

Fig. 5-51

Checking chain tension

Under normal operating conditions, the dip between the two support rollers should be between 25 to 30 mm.

Release the chain by moving the machine forward and back.

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

Measure the distance A between the measuring rod lower edge and the base plate.

If necessary, tension the chain.

5.13.4

Tensioning chain

Fig. 5-52

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 3 from the longitudinal member of the undercarriage.

Screw the high pressure hose 1 to the hand grease gun.

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Maintenance

Operating manual

Travel gear

Open the high pressure hose 1 to connect it with the lubrication nipple 2 of the grease tensioner.

Add grease until the chain is sufficiently tensioned.

Check chain tension.

5.13.5

Releasing chain

Fig. 5-53

Releasing chain

Danger!

Risk of injury from slackening chain or expelled grease.

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

The lubrication nipple 1 may not be loosened.

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

When loosening the lubrication nipple extension 2 keep your hands away from the lubricating nipple. To loosen the lubrication nipple extension, always use suitable tools.

Clean the chain and remove any jammed objects.

Park the machine on level ground.

Turn lubrication nipple extension 2 by a few revolutions until grease escapes from the longitudinal groove 3 of the lubrication nipple extension.

As soon as the desired chain tension is reached, tighten the lubrication nipple extension 2.

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

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Operating manual

Maintenance Electrical system

5.13.6

Changing lubrication nipple Release the chain as described in section "Releasing chain".

As soon as no grease escapes from the longitudinal groove 3 of the lubrication nipple extension 2,(see Fig. 5-53): Fully unscrew the lubrication nipple extension.

Fully screw in and tighten the preassembled unit (lubrication nipple extension 2 and lubrication nipple 1).

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

5.14 Electrical system 5.14.1

Notes regarding the electrical system Regularly inspect the electrical system of the machine for defects.

Defects such as loose connections, chaffed cables or poorly fixed clamps must be 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.

5.14.2

Battery main switch Caution!

The auxiliary heater (optional equipment) remains on for a little while after the ignition has been switched off. It might be damaged, if it is suddenly switched off with the battery main switch during this afterrun time.

Only switch off the battery main switch after the afterrun time of the auxiliary heater has lapsed.

Fig. 5-54

Battery main switch

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5 - 61

Maintenance

Operating manual

Electrical system

Before carrying out any work on the electrical system or performing welding work on the machine, set the battery main switch to position 0 (off).

Note!

The battery might discharge itself during prolonged standstills.

Prior to prolonged standstills, switch the battery main switch to position 0 (off).

5.14.3

Battery care Danger!

Battery acid is highly corrosive.

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

Danger!

Risk of explosion from hydrogen gas and sparks.

Check the vent hoses for damage, especially after installation of the battery.

The negative pole (-) must be disconnected first and reconnected last.

Avoid sparks and naked flames when charging batteries or working on them.

Charge the batteries only in well ventilated rooms.

Fig. 5-55

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 B to the outside of the building. Ensure that the rubber hoses are not kinked or damaged, as this could lead to hydrogen gas collecting in the battery box.

Lay the vent hoses B in such a way that there are not kinks or blocked sections in the hoses.

Always replace damaged vent hoses.

Regularly clean the pole heads and cable terminals A and apply a thick layer of acid-proof grease.

From time to time, check the acid density using a battery tester C.

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Operating manual

Maintenance Electrical system

If the battery is fully charged, the density is 1.28 kg/l (31.5° Bé).

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

5.14.4

Slip ring body

Fig. 5-56

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 2.

Remove the housing 1.

Remove any oxidation from the slip ring body (use a cleaning spray, if necessary).

Replace damaged (corroded) fork terminals.

Apply Cramolin contact spray to all slip ring elements.

Mount the housing 1.

Tighten the lock nuts 2 with a uniform torque.

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Maintenance

Operating manual

Heating and air-conditioning system

5.15 Heating and air-conditioning system 5.15.1

Recirculated and ambient air filter

Fig. 5-57

Recirculated air filter

Fig. 5-58

Ambient air filter

If the ambient air filters are dirty, the air flow is reduced. This in turn affects its performance and can result in frequent icing or shut-down of the a/c system.

Never operate the machine without filters, even for short periods, as this might result in blockage of the heat exchanger.

The filters must be cleaned or replaced every 500 operating hours (shorten interval, if the machine is operated in a particularly dusty environment).

Cleaning or replacing the recirculated and ambient air filters: To remove the recirculated air filter 1, tilt the backrest of the operator seat forward.

Open the quick fasteners 2 by turning them by 90 degrees.

Remove the recirculated air filter 1.

Remove the deflector 4.

Remove the ambient air filter 3.

Note!

Incorrect cleaning of the filters might damage them.

Never clean the filters with hot water or steam!

If the ambient air filter is damaged or in poor state, replace it.

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Operating manual

Maintenance Heating and air-conditioning system

To clean the filter elements 1 / 3, blow them out with compressed air or wash them in cold or lukewarm water.

5.15.2

Heating system Every year at the start of the heating period, have the following maintenance routine completed by a qualified specialist.

Check the entire coolant circuit for leakage.

Retighten the connections in the coolant circuit, the hose connections at the heat exchanger, the seals of the stop valves and the hose clamps.

If necessary, bleed the heating system.

Clean the solenoid valve.

Check the heat exchanger and clean it, if necessary.

The system may only be operated with coolant containing a suitable corrosion inhibitor and antifreeze agent.

5.15.3

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

Inspection of the condenser:

Fig. 5-59 1

A/c condensers

A/c condenser

2

Cooler

During the operating period, check the condenser every 500 operating hours: Inspect the condenser 1 for dirt.

If necessary, clean the condenser: 1: loosen the securing screws and tilt the upper part slightly out. Clean it with compressed air, blowing it from the inside (blower side) out.

Ensure that the condenser fins are clean.

Dirt on the condenser might lead to excessive pressure in the coolant circuit, so that the air-conditioning system is automatically switched off.

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Maintenance

Operating manual

Compressed-air system

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

e dryer-collector unit. every 1000 operating hours:

of excess pressure switch Annually: For this purpose, the a/c system must be drained, inspected for leakage and refilled. Check the hose lines for chaffing and replace them, if necessary. If required, retighten the hose connections. aps and the defrost thermostat.

5.16 Compressed-air system 5.16.1

Compressed air accumulator and antifreeze pump

Fig. 5-60 1 3

Compressed air accumulator and antifreeze pump

Pressure accumulator Water drain valve

2 4

Pressure gauge Antifreeze pump

Checking pressure: During operation, the pressure gauge 2 must show the following pressure value: 6.2 to 7.2 bar (90 - 105 PSI).

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Operating manual

Maintenance Compressed-air system

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

Draining off water: Condensate tends to collect in the compressed air system. The pressure accumulator 1 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 3 and allow the water to drain off.

Release the pin when the escaping air is dry.

Adding antifreeze agent to the pump: 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 4 and add antifreeze agent, if required.

5.16.2

Compressed air unit of central lubrication system

Fig. 5-61 1

Compressed air unit of central lubrication system

Oil mist lubricator

2

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.

Draining off water: Remove the screw at the bottom of the oil mist lubricator 1 and turn the air filter 2 a few times. Let the condensate drain off into a suitable container.

Adding oil: Remove the filler neck at the oil mist lubricator 1 and add oil, if necessary.

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

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Maintenance

Operating manual

Automatic lubrication of the machine

5.17 Automatic lubrication of the machine 5.17.1

Semi-automatic lubrication system of slewing gear 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.

Starting lubrication cycle: To start a cycle, press the button S84. 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 S84 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.

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

Adding grease to the grease tank:

Fig. 5-62

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.

5.17.2

Automatic central lubrication system 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. 5-67). 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.

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Operating manual

Maintenance Automatic lubrication of the machine

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

5.17.2.1

Operation

Fig. 5-63

Control console

1

Display

2 3

Timer key Double function button "additional lubrication / reset"

Setting lubricating interval:

Fig. 5-64

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 2 and 3.

Press and hold the button 2.

Simultaneously press and hold the button 3.

The interval is shown on the display 1, 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.

Displaying interval: Press the button 2 briefly twice. The set interval time (PP) and the time remaining to the next lubricating cycle (rP) are displayed.

Releasing additional lubricating cycle: Press the button 3 to release a lubricating cycle before the set interval has lapsed.

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Maintenance

Operating manual

Automatic lubrication of the machine

Press and hold the button 3 for at least two seconds.

The machine is being lubricated.

Monitoring central lubrication system:

Fig. 5-65

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 LL (low level) - the grease tank is empty and must be refilled. The text disappears when the grease tank is filled.

HL (high level) - the grease tank is full Er (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 3 to acknowledge the warning signal.

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).

5.17.2.2

Filling grease tank Adding grease to the grease tank:

Fig. 5-66

Adding grease to the grease tank

1 3

Cover of lubrication box Wing nut

2 4

Pump unit Pressure plate

5

Grease tank

6

25 kg grease bucket

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Operating manual

Maintenance Automatic lubrication of the machine

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

Open and lock the cover of the lubrication box 1.

Open the wing nuts 3.

Remove the pump unit 2 and the pressure plate 4.

Remove the empty grease bucket.

Open the new grease bucket 6 and place it in the box.

Insert the pressure plate 4 and place the pump unit 2 in its place.

Tighten the wing nuts 3.

Filling the grease tank with the filling pump (optional equipment):

Fig. 5-67

External filling of the central lubrication system

1

Cover of lubrication box

2

Hose coupling

3

Overflow

4

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 1.

Remove the dust protection cap from the hose coupling 2.

Connect the filling hose and switch on the filling pump.

Observe the red check pin 4 in the lubrication box.

The grease tank is full when the check pin 4 begins to move upwards or when grease exits through the overflow 3.

Note!

Overfilling can damage the grease tank.

When the red check pin 4 begins to move upwards, immediately switch off the filling pump.

Do not block the overflow 3.

Disconnect the filling hose and replace the dust protection cap.

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Maintenance

Operating manual

Manual lubrication of the machine

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

Note!

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

5.18.1

Attachments (optional equipment)

Fig. 5-68

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.

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Operating manual

Maintenance Manual lubrication of the machine

5.18.2

Industrial stick with hydraulic quick-change adapter

Fig. 5-69

Lubricating the hydraulic quick-change adapter

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

Note!

If the quick-change adapter is lubricated while the bolts are extended, the cavity between the locking bolts is filled with grease, so that they cannot be retracted.

Therefore lubricate the system only, if the locking bolts are retracted.

5.18.3

LIKUFIX MH 110 quick-coupling system

Fig. 5-70 1

Lubricating the quick-change adapter

Lubrication nipple / locking bolt

2

Lubrication nipple / rotator

Lubricate the locking bolts via the lubricating nipple 1, using a grease gun.* Lubricate the rotator via the lubricating nipple 2, using a grease gun.* * apply approx. 2 lubricating strokes Note!

If the quick-change adapter is lubricated while the bolts are extended, the cavity between the locking bolts is filled with grease, so that they cannot be retracted.

Therefore lubricate the system only, if the locking bolts are retracted.

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Maintenance

Operating manual

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

5.19 Couplings of the quick-change adapter systems (optional equipment) 5.19.1

Hydraulic coupling

Fig. 5-71

Hydraulic coupling plug

The LIKUFIX hydraulic coupling system and the multi-coupling system are equipped with hydraulic coupling plugs (see arrows).

The coupling plugs are maintenance-free. We recommend cleaning the system regularly. This prevents caking of dirt and icing up in winter. With regular cleaning, the seals of the system have a long service life.

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

Changing seal ring:

Fig. 5-72

Changing seal ring

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Operating manual

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

Caution!

The hydraulic lines are under pressure.

Before changing the seal ring, depressurise the system using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick).

In the event of leakage at the coupling plugs (A), change the seal rings.

Hold down the seal washer of the coupling plug with a screwdriver and lever out the defective seal ring using a pointed tool (B).

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

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

Let the seal ring expand into the groove (E).

Remove the screwdriver (F).

The seal washer must move upwards.

If this is not the case, push the seal ring into the groove until the seal washer can move.

5.19.2

LIKUFIX electric coupling The LIKUFIX hydraulic coupling system is equipped with an additional electric coupling (e.g. for the operation of a magnet system). This coupling must be regularly inspected and cleaned.

Fig. 5-73 1

Electric couplings

Electric coupling top section

2

Electric coupling bottom section

Switch off the magnet system (if installed).

Remove the working tool, if required.

Switch off the diesel engine.

Check the contacts for corrosion and wear (e.g. burn marks).

Clean the contacts of the electric couplings 1 and 2 with a dry cloth and apply contact spray (Cramolin), if necessary.

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

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Maintenance

Operating manual

Travel and swing brakes

Check the contacts of the top section 1 for play: it must be possible to push in the contacts against the spring force.

Check whether the seals at the contacts of the electric couplings (see arrows) are properly installed and undamaged.

Repair any damage and replace defective parts.

5.20 Travel and swing brakes 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.

5.21 General maintenance tasks 5.21.1

Replacing wear parts Apart from maintenance and care tasks that must be carried out at prescribed intervals, the following minor repairs can be made by the machine operator or a maintenance technician: and hose lines and at connections of the hydraulic units (with the exception of the pressure-relief valves, which are factorysealed). draulic lines and screw connections of the hydraulic unit.

Only use original LIEBHERR spare parts. This applies in particular to hoses and hydraulic lines that must be factory-mounted.

All other repairs, and in particular the removal of the counter weight, must be carried out by authorised specialist technicians.

5.21.2

Replacing teeth on digging tool If the teeth are heavily worn, excess force is required to move the digging tool into the material to be excavated. This can lead to damage to the tooth adapters.

Therefore replace worn teeth in due course.

Do not work with the machine, if there are teeth missing on the digging tool or if they are heavily worn.

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Operating manual

Maintenance General maintenance tasks

U system:

Fig. 5-74

U system – replacing teeth on digging tool

Drive out the roll pin 2 using a hammer and mandrel 1 (A).

Remove the old tooth.

Place the new tooth on the adapter (B).

Drive in the roll pin 2 using a hammer (C).

Z system:

Fig. 5-75

Removing teeth from digging tool - Z system

1

Plug

2

Locking bolt

3 5

Square spanner Tooth adapter

4 6

Tooth Locking piece

Remove the plug 1 from the square recess of the locking bolt 2 (A).

Turn the locking bolt with the square spanner 3 counter-clockwise (a - turn by approx. 30°).

Drive out the locking bolt from the opposite side (B).

Take off the tooth 4 from the tooth adapter 5 and remove the locking piece 6 (C).

Note!

Before mounting a new tooth, check the state of the locking bolt and locking piece.

Replace any deformed or corroded parts.

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Maintenance

Operating manual

General maintenance tasks

Fig. 5-76

Mounting teeth on digging tool - Z system

Insert the locking piece 6 into the recess of the tooth adapter 5 so that the flat locking piece side touches the tooth adapter (D).

Insert the new tooth into the tooth adapter.

Insert the locking bolt to the stop (E).

Turn the locking bolt with the square spanner -clockwise (b - turn by approx. 30°) (F).

The nose 2a of the locking bolt slides across the protruding part 6a of the locking piece and engages.

Insert the plug into the square recess of the locking bolt.

5.21.3

Welded parts on the machine All welding work on all main power-transmitting components (e.g. undercarriage frame, revolving deck, attachment parts, etc.) must be executed by the manufacturer or an authorised specialist workshop.

Before carrying out any arc welding work, disconnect the machine from the battery.

The negative pole (-) must be disconnected first and reconnected last.

Also switch off the battery main switch!

Caution!

Bearings or sealing elements might be damaged (scorched) by high electric currents!

When carrying out welding work, connect the earth cable as close as possible to the welding point so that the welding current does not travel through machine parts such as the slewing ring, joints, bearings, bushes, rubber elements or seals.

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Operating manual

Maintenance Inspection and maintenance schedule

5.22 Inspection and maintenance schedule Note!

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

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

Note!

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

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

Maintenance/inspection at operating hours

TASKS TO BE CARRIED OUT - DIESEL ENGINE by maintenance personnel (machine owner)

together with authorised specialist technicians

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

Initial and single interval Repeat interval

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

Change diesel engine oil: Standard: every 250 operating hours with Centriguard engine oil auxiliary filter: every 500 operating hours Change oil filter (at each oil change) Change water filter Check crankcase bleeding valve; clean if necessary Change fuel filter Check cable connections Check V-belt tension and state Replace gear oil in pump distributor gear Check throttle control; adjust, if necessary

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Maintenance

Operating manual

Inspection and maintenance schedule

Maintenance/inspection at operating hours

TASKS TO BE CARRIED OUT - DIESEL ENGINE by maintenance personnel (machine owner)

together with authorised specialist technicians

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

Initial and single interval Repeat interval

Check intake and exhaust systems for general condition, fixture and leakage Check mounting bolts of engine brackets, oil pan and distributor gear 1500

Complete 1500-hour service according to Cummins operating manual

6000

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

Maintenance/inspection at operating hours

TASKS TO BE CARRIED OUT - MACHINE by maintenance personnel (machine owner) Initial and single interval Repeat interval Annually, at the start of the cold season When required

together with authorised specialist technicians Initial and single interval Repeat interval

RADIATOR Check coolant level Check cooling and heating system for damage 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 AIR FILTER Check underpressure indicator of the air filter Clean pre-filter Change main element of the dry air filter (according to maintenance indication / annually) Change safety element of the dry air filter (at every third main element change / annually) - do not clean or reuse!

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Operating manual

Maintenance Inspection and maintenance schedule

Maintenance/inspection at operating hours

TASKS TO BE CARRIED OUT - MACHINE by maintenance personnel (machine owner)

together with authorised specialist technicians

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

Initial and single interval Repeat interval

COMPRESSED-AIR SYSTEM Check fill level of antifreeze pump Dewater pressure accumulator (daily during winter months, weekly during summer months) Compressed air unit of central lubrication system: Dewater, check oil mist lubricator; add oil, if necessary Check compressor HYDRAULIC SYSTEM 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 (special equipment) (in machines used for dust intensive applications: every 250 operating hours)

2)

Replace filter cartridge in return filter Replace filter cartridge in control oil unit Replace feed oil filter on slewing gear pump Check components for proper fixture Check hydraulic oil cooler for dirt; clean, if necessary Dewater hydraulic tank (max. permissible water content for environmentally friendly fluids: 0.1 %; use bypass filter, take oil sample) Check hydraulic system for leakage; completing 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 ELECTRICAL SYSTEM Check indicator lights and indicating devices upon start-up Check lighting system Check acid density and level, wire terminals and terminal ports of the batteries

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Maintenance

Operating manual

Inspection and maintenance schedule

Maintenance/inspection at operating hours

TASKS TO BE CARRIED OUT - MACHINE by maintenance personnel (machine owner)

together with authorised specialist technicians

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

Initial and single interval Repeat interval

Spray slip rings of the slewing gear connection with Cramolin contact spray Carry out functional tests of entire unit and all components SLEWING GEAR MECHANISM Check oil level; check system for leakage Perform functional test of slewing gear brake Check gearbox and oil motor for proper mounting Change gear oil SLEWING GEAR Start lubrication system of slewing gear Check fill level in grease tank of lubrication system; add grease, if required Clean collecting channels at the bottom of the slewing gear; remove excess grease Check mounting bolts for press fit; check slewing gear pinion meshing TRAVEL GEAR Check oil level; check system for leakage Functional test of travel brake Check gearbox and oil motor for proper mounting Change gear oil TRAVEL GEAR 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

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Operating manual

Maintenance Inspection and maintenance schedule

Maintenance/inspection at operating hours

TASKS TO BE CARRIED OUT - MACHINE by maintenance personnel (machine owner)

together with authorised specialist technicians

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

Initial and single interval Repeat interval

CENTRAL LUBRICATION SYSTEM Perform functional test Change or refill grease tank Service entire system; check pumps and control system (at least once annually) OPERATOR'S CAB + HEATING Check / add detergent solution in windscreen washer system tank Perform functional test of heating Check heating system for leakage Check door hinges, window hinges and locks Treat rubber seals of operator's cab with silicone or talcum powder Treat rubber seals of access doors in uppercarriage with silicone or talcum powder Check water inlet valve for dirt, and clean, if necessary; carry out functional test of valve AIR-CONDITIONING SYSTEM Regularly switch on air-conditioning system (at least 1x every 14 days) Check condenser for dirt; blow clean, if necessary Clean recirculated 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 (moisture, fill level, damage); replace, if necessary Check evaporator unit; clean, if necessary Check electrical lines for chafe marks; check plug connections Perform functional test of excess pressure switch Check cooling performance Replace dryer-collector unit every 12 months; also check cooling circuit for leakage and change refrigerant and refrigeration oil

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Maintenance

Operating manual

Inspection and maintenance schedule

Maintenance/inspection at operating hours

TASKS TO BE CARRIED OUT - MACHINE by maintenance personnel (machine owner) Initial and single interval Repeat interval Annually, at the start of the cold season When required

together with authorised specialist technicians 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 UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENTS Lubricate bearings, using the semi-automatic central lubrication system Exception: machines with fully automatic central lubrication system (special equipment) Check grease level in the central lubrication system tank; add grease, if required Lubricate bearings (undercarriage and attachments); depending on the use and for multi-shift operation, lubricate daily Inspect teeth for wear Check railings, climbing aids and catwalks for proper fixture and damage 250

Check parts for cracks Check counterweight and tank for proper fixture Check lines and screwed connections for proper fixture Attachment points for fall-arrest equipment: Check bolts for press fit; carry out visual inspection; replace deformed or corroded parts Check panelling hinges, quick fasteners and gas pressure springs of hoods Instruct operators in the proper use of the machine Instruct the operator on how the machine must be lubricated according to the lubricating chart and make him/her aware of potential operator errors and their consequences HYDRAULIC QUICK-CHANGE ADAPTERS Perform functional check of the visual and acoustic warning systems Carry out visual inspection of extended lock bolts Check hydraulic hoses and the wire harness for damage Lubricate lock bolts

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Operating manual

Maintenance Inspection and maintenance schedule

Maintenance/inspection at operating hours

TASKS TO BE CARRIED OUT - MACHINE by maintenance personnel (machine owner) Initial and single interval Repeat interval Annually, at the start of the cold season When required

together with authorised specialist technicians Initial and single interval Repeat interval

Clean screen filter GENERAL Check entire machine to ensure that it is properly maintained and in safe working order Explain the machine documentation (in particular the operating manual and safety instructions) to the operating personnel 1

Replace engine oil more often, if temperatures and the quality of the fuel and oil make this seem advisable.

2 3

In the case of applications with excessive dust generation, shorten the maintenance intervals.

For environmentally friendly hydraulic fluids, adjust the maintenance interval on the basis of regular analyses.

The maintenance intervals might have to be shortened, depending on the operating conditions (e.g. generation of dust, barrel fuelling).

4

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