operating manual 9400 Liebherr

en

Operating Operating manual Hydraulic excavator R9400 from serial number 26377

Document Document identification ORIGINAL MANUAL Order number:

11000047

Edition:

06 / 2012

Valid Valid for :

R9400 from serial number 26377

Au th or :

LEC - Technical documentation department

Product identification

2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

Manufacturer:

Liebherr-Mining Equipment Colmar SAS

Type:

R9400

Type no.:

1257

Conformity:

CE

Add A dd r ess es s Liebherr-Mining Equipment Colmar SAS 49 rue Frédéric Hartmann CS 50038, F-68025 Colmar Cedex

Operating manual

Machin Machin e data Please fill in the following data when you receive your machine. This will also be of use to you when ordering replacement parts.

Vehicle Vehicle i dent. number: WLHZ . . . . . ZK . . . . . . Construction year: . . . . First st art-up date: date: . . / . . / . .

2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

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R9400 / 11000047

Operating manual

Machin Machin e data Please fill in the following data when you receive your machine. This will also be of use to you when ordering replacement parts.

Vehicle Vehicle i dent. number: WLHZ . . . . . ZK . . . . . . Construction year: . . . . First st art-up date: date: . . / . . / . .

2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

0-2

MJFCIFSS

R9400 / 11000047

Operating manual

Preface

These operating instructions have been written for the machine operator and and for the maintenance personnel of the machine. They contain: – the technical data. – the safety requirements. – the operating instructions. – the maintenance instructions. The operating instructions are to be read and used carefully by all persons who carry out work with or on the machine before putting the machine into service for t he first t ime and later, at regular intervals.

Work with or on the machine includes, for example: – Operation including setting up and equipping, rectifying malfunctions during the course of work, resolving production dropouts, care, disposal of operating and process materials. – Maintenance, including maintenance, inspection and repair work. – Transportation or loading the machine. The operating instructions allow the machine operator to familiarize himself with the machine more easily and prevent malfunctions occurring due to improper oper ation. The observance of the operating and maintenance instructions by maintenance personnel: – increases reliability in use. – extends the service life of your machine. – reduces repair costs and downtime. The operating operating i nstru ction s belong wit h the machine. Place Place a copy in an easily easily reached position o n the cab storage shelf.

The operating and maintenance instructions must be completed by information on current national regulations for accident prevention and protection. In addition to the operating instructions and legally binding regulations on accident prevention which apply in the user country and at point of use, authorized specialist rules for safe and correct working procedures are also to be observed. These operating and maintenance instructions contain all the information required for operating and maintaining your machine. – Some illustrations in these operating instructions may depict details and working devices which differ to your machine. – In some illustrations, protective devices and covers have been removed in the interests of better presentation. – Improvements, which are always being incorporated into our machines, may result in changes to your machine which are not yet indicated in these operating instructions. However, should you require any further explanations or information, LIEBHERR's technical documentation, sales school and customer service departments are avail-

MJFCIFSS

Operating manual

able for your convenience. You will appreciate that LIEBHERR warranty claims made on the basis of improper operation, unsatisfactory maintenance, use of unauthorized operating materials or non-adherence to safety regulations cannot be recognized. LIEBHERR will annul any and all obligations incurred by LIEBHERR and / or its d ealerships, such as guarantee commitments, service contracts etc. without prior notice in the event that replacement parts other than orig inal LIEBHERR parts or parts purchased from LIEBHERR are used for maintenance or repair work.

Modifications, conditions, copyright We reserve the right to make modifications without prior notice in the course of technical developments. The information and illustrations contained in these operating instructions may neither be copied and distributed, nor used for the purposes of competition. All rights are expressly reserved in accordance with copyright laws. The warranty and liability conditions of LIEBHERR’s general business conditions will not be enlarged upon through the above information.

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Operating manual

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Produ ct descr ipt ion ....... .......... ...... ...... ....... ....... ...... ....... ....... ...... ....... ....... ...... ...... ....... ....... ....... ....... ...... ....... ........ ....... ...... ....... ....... ...... ....... ........ ....... ...... ...... ...... ...... ...... ....... ........ ....... ...... ...... ..... .. 1-1

1.1

1.2 1.3 1.4

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Safety in st ru ct io ns ............. .................... .............. .............. ............. ............. ............. ............. ............. ............. .............. ............. ............. ............. ............. ............ ............ ............. ............. ............. ...... 2-1

2.1 2.2 2.3 2.4

3

Meaning Meaning of the symbols symbols in this this manual..... manual........... ............. ............. ............. .............. ............. ............. ............. ............. .............. .............. ............. ............. ............. ........ 2-1 Use in in accordanc accordance e with with the the regulati regulations ons ............. .................... .............. ............. ............. .............. ............. .............. .............. ............. .............. ............. ............. .......... ... 2-2 Safety Safety Instructions Instructions ............. .................... ............. ............. ............. ............. ............. ............. .............. ............. ............. ............. ............. ............. ............. .............. ............. ............. ........... .... 2-2 Signs on the machine machine ............ ................... .............. .............. .............. .............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............ ............. ........... .... 2-20 2.4.1 Introduction.... Introduction........... ............. ............. ............. ............. ............. ............. ............. ............. .............. ............. ............. ............. ............. ............. ............. ............ ............ ........... .... 2-20 2.4.2 Arrangement Arrangement of signs .............. .................... ............. .............. ............. ............. ............. ............. .............. ............. ............. ............. ............. .............. ............. ......... ... 2-22 2.4.3 Meaning Meaning of the signs ............. .................... ............. ............. .............. .............. .............. .............. ............. ............. ............. ............. .............. ............. ............ .......... .... 2-24

Contr ol and operati on ...... .......... ........ ....... ...... ....... ....... ...... ....... ....... ....... ....... ...... ...... ....... ........ ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ..... .. 3-1

3.1

3.2

3.3

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Assembly Assembly - overview............ overview................... .............. ............. ............. ............. ............. ............. ............. .............. ............. ............. ............. ............. .............. ............. ............ ............. ......... .. 1-1 1.1.1 Machine Machine and construction construction equipment........ equipment............... .............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ....... 1-1 1.1.2 Uppercarriag Uppercarriage......... e................ ............. ............. .............. ............. ............. ............. ............. .............. .............. .............. .............. ............. ............. ............. ............. ............. ........ 1-2 1.1.3 Undercarriag Undercarriage......... e................ ............. ............. .............. ............. ............. ............. ............. .............. .............. .............. .............. ............. ............. ............. ............. ............. ........ 1-3 Vibration Vibration emissions..... emissions........... ............. .............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............ ............ ............. ............. ....... 1-3 EC Declar Declaration ation of Conformi Conformity ty ............. ..................... .............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ........... ............ ............. ........ .. 1-5 Technical Technical data ............. .................... ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............ ............ ............. ............. ............ ...... 1-6 1.4.1 Working Working technical technical data ............. .................... .............. .............. ............. ............. ............. ............. .............. .............. .............. ............. ............. ............. ............ ......... ... 1-6 1.4.2 Technical Technical description..... description............ ............. ............. .............. ............. ............. ............. ............. .............. ............. ............. ............. ............. ............. ............. ............. ........ .. 1-6

3.4

3.5

Operating Operating and control control elemen elements...... ts............. ............. ............. .............. ............. ............. .............. .............. ............. ............. .............. ............. ............. ............. ............ .......... .... 3-1 3.1.1 Overview Overview of of the the control control cab................... cab......................... ............. ............. ............. .............. ............. ............. .............. .............. ............. ............. ............ .......... ..... 3-1 3.1.2 Arrangement Arrangement of joystick joystick...... ............. .............. ............. ............. .............. ............. ............. .............. .............. .............. ............. ............. .............. ............ ............ ......... .. 3-3 3.1.3 Keyboard Keyboard ............. .................... .............. .............. .............. ............. ............. ............. ............. .............. .............. ............. ............. ............. ............. ............. ........... ............ ............ ..... 3-4 3.1.4 Control Control board........... board.................. ............. ............. .............. ............. ............. ............. ............. .............. ............. ............. .............. ............. ............. ............ ........... ............. ......... .. 3-8 3.1.5 Monitoring Monitoring display display .............. ..................... .............. ............. ............. ............. ............. .............. ............. ............. ............. ............. ............. ............. ............. ............ ........ .. 3-10 3.1.6 Main screen screen ............. ................... ............. ............. ............. ............. ............. .............. .............. .............. .............. .............. .............. ............. ............. ............ ............ ............ ..... 3-12 3.1.7 Monitoring Monitoring cameras cameras ............. .................... ............. ............. ............. ............. .............. ............. ............. .............. ............. ............. ............. ............. ............ ............ ......... 3-30 The access access and the outfit outfit of the the cab.............. cab.................... ............. .............. ............. ............. ............. ............. .............. ............. ............. ............. ............ ............. ......... 3-32 3.2.1 Entering Entering or or leaving leaving the cab......... cab................ ............. ............. .............. ............. ............. .............. ............. ............. .............. .............. ............. ............ ............ ...... 3-33 3.2.2 Safety lever .............. ..................... ............. ............. ............. ............. ............. ............. ............. ............. .............. ............. ............. .............. ............. ........... ............ ............. ...... 3-37 3.2.3 Operator’s Operator’s seat................. seat........................ ............. ............. .............. ............. ............. ............. ............. .............. ............. ............. ............. ............. ............ ............ ........... .... 3-38 3.2.4 Adjusting Adjusting of of the auxili auxiliary ary seat......... seat................ ............... .............. ............. ............. ............. .............. ............. ............. .............. ............. ............. ............. ........ 3-41 3.2.5 Sunshade Sunshade ............. ................... ............. .............. .............. .............. .............. ............. ............. ............. ............. .............. .............. .............. ............. ............. .............. ............. ...... 3-42 3.2.6 Emergency Emergency exit........ exit............... ............. ............. ............. ............. .............. .............. .............. .............. ............. ............. ............. ............. .............. ............. ............. ........... .... 3-43 3.2.7 Interior Interior lightings lightings ............. .................... ............. ............. ............. ............. .............. .............. .............. .............. ............. ............. ............. ............. ............ ............ ............. ...... 3-44 3.2.8 Fire extinguishe extinguisherr ............. .................... ............. ............. ............. ............. ............. ............. .............. .............. ............. ............. ............. ............. ............. ............ ............ ...... 3-44 3.2.9 Windscreen Windscreen wiper................ wiper....................... ............. ............. ............. ............. .............. .............. .............. ............. ............. ............. ............. .............. ............ ............ ....... 3-45 3.2.10 Field of view ............. ................... ............. .............. ............. ............. ............. ............. ............. ............. .............. .............. ............. ............. ............. ........... ............ ............. ...... 3-47 3.2.11 Lighting Lighting...... ............. .............. ............. ............. ............. ............. .............. .............. .............. ............. ............. .............. ............. ............. .............. ............. ............ ............. ............ ..... 3-49 3.2.12 Heating/air Heating/air conditioning conditioning system system ............. .................... .............. ............. ............. .............. ............. ............. .............. ............. ............. .............. ............. ...... 3-50 Setting Setting the the machine machine into operation operation ............. .................... ............. ............. .............. ............. ............. .............. ............... ............... .............. ............. ............. .............. ....... 3-54 3.3.1 Bringing Bringing the the machine machine safely safely into service service ............. .................... ............. ............. ............. ............. .............. ............. ............. ............. ............. ......... 3-54 3.3.2 Starting Starting / stopping stopping the the machin machine e .............. ..................... ............. ............. .............. .............. .............. ............. ............. .............. ............. ............. ............. ...... 3-56 3.3.3 Starting Starting aids (optional) (optional) ............. .................... ............. ............. .............. .............. ............. ............. ............. ............. .............. ............. ............. ............. ............ ........ .. 3-63 3.3.4 Jump start procedure procedure .............. ..................... .............. ............. ............. .............. ............. ............. .............. .............. ............. ............. .............. ............. ............ ........ .. 3-67 3.3.5 Emergency Emergency operations operations ............. .................... ............. ............. .............. .............. ............. ............. ............. ............. .............. ............. ............. ............. ............ ........ .. 3-68 3.3.6 Board E52 for safety mode of Diesel engine and servo control control ............. ................... ............. .............. .............. ............ ..... 3-70 3.3.7 Driving Driving ............. ................... ............. ............. ............. .............. ............. ............. ............. ............. ............. ............. .............. .............. .............. ............. ........... ............ .............. ......... 3-73 Working Working with the machine....... machine.............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ........... ........... ............. ....... 3-76 3.4.1 The uppercarriag uppercarriage e swing movements movements ............. .................... ............. ............. .............. ............. ............. ............. ............. .............. .............. ........... .... 3-81 3.4.2 Working Working positi position on...... ............. ............. ............. .............. ............. ............. ............. ............. ............. ............. .............. .............. ............. ............. ............. ............ ............ ...... 3-83 3.4.3 Joystick Joystick functions functions when setting up the machine machine ............. .................... ............. ............ ............. ............. ............. ............. ............. .......... ... 3-83 3.4.4 3.4.4 Lowerin Lowering g the work equipme equipment nt when the engine engine is not running running ....... .......... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ... 3-87 3-87 General General working working methods......... methods................ ............. ............. ............. ............. .............. .............. ............. ............. .............. .............. .............. ............. ............ ............. ............. ........ 3-88 3.5.1 Minimum Minimum impact working working methods for your machine machine ............. .................... .............. ............. ............. .............. ............. ............. ......... 3-88

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Malfu nc ti on s ............. .................... .............. ............. ............. ............. ............. ............. ............. ............. ............. .............. ............. ............. ............. ............. ............ ............ ............. ............. .............. .......... ... 4-1

4.1

4.2

4.3

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3.5.2 Preparatory Preparatory activities activities ............. .................... ............. ............. .............. .............. ............. ............. ............. ............. .............. .............. .............. ............. ............. .......... ... 3-89 3.5.3 Positionin Positioning g of the machine machine ............. .................... .............. ............. ............. .............. ............. ............. .............. ............. ............. .............. ............. ............. ......... 3-90 3.5.4 Working Working with with the backho backhoe e bucket............ bucket................... .............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ....... 3-90 3.5.5 Working Working with the Shovel Shovel bucket .............. .................... ............. ............. ............. .............. ............. ............. ............. ............. .............. ............. ............ ........ 3-93 Transport..... Transport............ .............. .............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. .............. .............. .............. ............ ............ ............. ............. ............ ..... 3-95 3.6.1 Travelling Travelling procedures procedures for mining machine............ machine.................. ............. .............. .............. .............. ............. ............. ............. ............. ............. ...... 3-95 3.6.2 Excavator Excavator lifting lifting and lashing lashing operations operations .............. .................... .............. .............. ............. .............. ............. ............. .............. .............. ............. ...... 3-97

Error code code charts charts ............. ................... ............. .............. ............. ............. .............. ............. ............. ............. ............. .............. ............. ............. ............. ........... ............ .............. ............. ........ 4-2 4.1.1 Sensors Sensors ............. ................... ............. .............. .............. ............. ............. .............. ............. ............. ............. ............. .............. .............. .............. .............. ............ ............ ............. ...... 4-2 4.1.2 Regulating Regulating circuit circuit ............. .................... ............. ............. .............. ............. ............. ............. ............. ............. ............. ............. ............. .............. ............. ............. ............. ...... 4-3 4.1.3 Keyboard Keyboard ............ ................... .............. ............. ............. ............. ............. .............. .............. ............. ............. .............. .............. ............. ............. .............. ............ ........... ............ ...... 4-3 4.1.4 Display Display...... ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. .............. ............. ............. ............ ........... ............. ............ ..... 4-4 4.1.5 Coding Coding error.................. error........................ ............. ............. ............. ............. ............. ............. ............. .............. .............. ............. ............. ............. ............. .............. .............. ......... .. 4-4 4.1.6 Connection Connection box pump transmitters......... transmitters............... ............. ............. ............. .............. .............. ............. ............. .............. .............. .............. ............. ........ .. 4-4 4.1.7 Joysticks Joysticks ............. .................... ............. ............. ............. ............. .............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ........... ............ ............. ........ .. 4-4 4.1.8 Error due to warning warning symbols symbols in in SY field....... field.............. .............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ......... ... 4-5 4.1.9 Heating/air Heating/air conditionin conditioning g system......... system................ ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............ ......... ... 4-7 Faults and remedies remedies ............. ................... ............. ............. ............. ............. ............. .............. .............. .............. ............. ............. ............. ............. ............. ............. .............. ............. ........ 4-8 4.2.1 Diesel Diesel engine engine and fuel system..... system............ ............. ............. ............. ............. .............. ............. ............. .............. .............. ............. ............. ............. ............. ....... 4-8 4.2.2 Hydraulic Hydraulic system ............. .................... ............. ............. .............. ............. ............. ............. ............. ............. ............. .............. ............. ............. ............. ............ ............. ....... 4-9 4.2.3 Transmission Transmission ............. ................... ............. ............. ............. .............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............ ............ ............. ......... 4-9 4.2.4 Electrical Electrical system.......... system................. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............ ............. .......... ... 4-10 4.2.5 Heating/airHeating/air-condi conditionin tioning g system ............. .................... .............. ............. ............. .............. ............. ............. .............. ............. ............. .............. ............ ....... 4-10 4.2.6 Work equipment equipment ............. .................... ............. ............. .............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............ ............ ....... 4-10 Fuses and relays........ relays.............. ............. ............. ............. .............. ............. ............. .............. ............. ............. ............. ............. ............. ............. ............. ............ ............. ............. ........... ..... 4-11 4.3.1 Power electrical electrical box E1003 ............. .................... .............. .............. ............. ............. ............. ............. ............. ............. .............. ............. ............. ............. ........ 4-11 4.3.2 Cabin electrical electrical box E1005........... E1005................. ............. ............. ............. .............. .............. ............. ............. ............. ............. .............. .............. ............. .......... .... 4-13 4.3.3 Heating Heating / air-conditio air-conditioning ning electrical electrical box E1006 ............. .................... ............. ............. ............. ............. .............. ............. ............. ........... .... 4-14

Maint enanc e ............. .................... .............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. .............. ............. ............. ............ ............ ............. ............. .............. .......... ... 5-1

5.1 5.2 5.3

5.4

5.5

Servicing Servicing the the machine machine safely safely ............. ................... ............. .............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............ ............ ............. .......... ... 5-1 Maintenance Maintenance access doors ............. .................... ............. ............. ............. ............. .............. ............. ............. ............. ............. .............. .............. .............. .............. .............. ......... .. 5-7 Lubricants Lubricants and operati operating ng fluids fluids ............. .................... ............. ............. .............. ............. ............. .............. ............. ............. .............. .............. ............. ............ ............. ........... .... 5-9 5.3.1 General General informati information on on changing changing lubrica lubricants nts and operating operating fluids...... fluids............. ............. ............. .............. .............. ............ ..... 5-9 5.3.2 Lubricating Lubricating chart ............. .................... .............. ............. ............. ............. ............. .............. .............. ............. ............. ............. ............. ............. ............ ............. ............ ..... 5-10 5.3.3 Service Service trap ............. .................... ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. .............. ............ ............ .............. ....... 5-11 5.3.4 Lubricant Lubricant chart chart ............. .................... .............. .............. .............. .............. .............. ............. ............. ............. ............. ............. ............. ............. ............. .............. ............. ...... 5-13 5.3.5 Operating Operating material material chart ............. .................... .............. .............. ............. ............. ............. ............. .............. ............. ............. ............. ............. ............. ............ ...... 5-14 5.3.6 Service Service trap ............. .................... ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. .............. ............ ............ .............. ....... 5-14 5.3.7 Location Location of oil oil sample sample points points ............. .................... .............. ............. ............. ............. ............. .............. ............. ............. .............. .............. ............. ........... ..... 5-16 Lubricating Lubricating and operati operating ng material material specificatio specifications ns ............. ................... .............. .............. ............. .............. ............. ............. .............. .............. ............. ...... 5-17 5.4.1 Lubrication Lubrication oil for the diesel engine engine .............. .................... ............. .............. ............. ............. .............. .............. ............. ............. .............. ............. ........ 5-17 5.4.2 Fuel............. Fuel................... ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ........... ........... .............. ......... .. 5-17 5.4.3 Hydraulic Hydraulic oil specificati specifications ons for LIEBHERR LIEBHERR Mining excavators excavators ............. .................... .............. .............. ............. ............. ....... 5-17 5.4.4 Swing and travel gear oils ............. .................... ............. ............. ............. ............. ............. ............. .............. ............. ............. ............. ............. ............ .......... ..... 5-23 5.4.5 Splitterbox Splitterbox oil ............ ................... ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. .............. ............. ............. ............. ............. ............ ..... 5-24 5.4.6 Lube oil for elastic elastic couplin coupling g ............. ................... ............. .............. ............. ............. ............. ............. .............. .............. .............. .............. ............. ............. ....... 5-24 5.4.7 Lubricating Lubricating grease and other lubricants lubricants ............. .................... .............. ............. ............. .............. .............. ............. ............. ............. ............. ......... 5-25 5.4.8 Coolant Coolant .............. ..................... ............. ............. .............. .............. .............. ............. ............. ............. ............. ............. ............. .............. .............. ............. ............ ............ ........... ..... 5-26 5.4.9 Lubricants Lubricants specificati specifications ons for -40°C .............. .................... ............. ............. ............. ............. ............. .............. .............. .............. .............. .............. ......... 5-26 Diesel Diesel engine ............ ................... ............. ............. .............. ............. ............. .............. ............. ............. ............. ............. ............. ............. ............. ............. .............. ............. ............. ........... .... 5-27 5.5.1 Diesel Diesel engine oil level check ............. ................... ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ........ 5-27 5.5.2 Diesel Diesel engine engine oil change change .............. .................... ............. ............. ............. .............. .............. ............. ............. ............. ............. .............. ............. ............. ........... .... 5-28 5.5.3 Engine Engine oil sump sump refilling..... refilling........... ............. ............. ............. ............. ............. ............. ............. ............. ............. .............. ............. ............. ............. ............ .......... .... 5-30 5.5.4 Engine Engine oil sampling sampling ............. .................... ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ............. ......... 5-31

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MJFCIFSS

R9400 / 11000047

2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

Operating manual

5.6

5.7 5.8

5.9

5.10

5.11

5.12

5.13 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

5.14 5.15

5.5.5 Mounting screws .................................................................................................................... 5-32 5.5.6 Elastic bedding ....................................................................................................................... 5-33 5.5.7 Alternator belt ......................................................................................................................... 5-33 Splitterbox............................................................................................................................................ 5-34 5.6.1 Mounting screws .................................................................................................................... 5-34 5.6.2 Elastic bedding ....................................................................................................................... 5-36 5.6.3 Air filter ................................................................................................................................... 5-37 Coupling............................................................................................................................................... 5-38 5.7.1 Geislinger coupling wear check.............................................................................................. 5-38 Cooling system .................................................................................................................................... 5-39 5.8.1 Checking and cleaning the cooling system ............................................................................ 5-39 5.8.2 Checking the coolant level ..................................................................................................... 5-39 5.8.3 Coolant antifreeze and anti-corrosion fluid............................................................................. 5-40 5.8.4 Changing the coolant ............................................................................................................. 5-40 Fuel system ......................................................................................................................................... 5-42 5.9.1 Refuelling ............................................................................................................................... 5-43 5.9.2 Draining the fuel tank ............................................................................................................. 5-44 5.9.3 Emptying and cleaning the fuel tank ...................................................................................... 5-44 5.9.4 Fuel filtering system ............................................................................................................... 5-45 Pressurized air system ........................................................................................................................ 5-48 5.10.1 Pressure regulator and compressor ....................................................................................... 5-48 5.10.2 Air dryer.................................................................................................................................. 5-49 Dry air filter .......................................................................................................................................... 5-51 5.11.1 To change the primary filter element...................................................................................... 5-52 5.11.2 Changing the safety element.................................................................................................. 5-53 5.11.3 To clean the air channels for the precleaner .......................................................................... 5-54 5.11.4 Check the air intake system, hoses, elbows, clamps ............................................................. 5-54 Hydraulic system ................................................................................................................................. 5-55 5.12.1 Preparatory activities.............................................................................................................. 5-55 5.12.2 Checking the oil level in the hydraulic tank ............................................................................ 5-56 5.12.3 Depressurising the hydraulic system...................................................................................... 5-56 5.12.4 Emptying and refilling the hydraulic tank ................................................................................ 5-57 5.12.5 Hydraulic oil sampling ............................................................................................................ 5-59 5.12.6 Hydraulic oil coolers ............................................................................................................... 5-59 5.12.7 Leak oil and return-line filters ................................................................................................. 5-59 5.12.8 Oil filters in PowerPack .......................................................................................................... 5-62 5.12.9 High pressure filters on valve bank ........................................................................................ 5-63 5.12.10 Control circuit ......................................................................................................................... 5-65 5.12.11 Hydraulic pumps bleeding ......................................................... ............................................. 5-66 5.12.12 Bleeding the hydraulic cylinders .......................................................................... ................... 5-67 5.12.13 Hydraulic pumps intake hoses removal............................ ...................................................... 5-68 5.12.14 Oil cooler protection filters (optional) ............................................. ......................................... 5-69 5.12.15 Servicing the hydraulic cylinder ..................................................... ......................................... 5-70 5.12.16 Replacing hydraulic hoses ..................................................................................................... 5-71 5.12.17 Progressive criss-cross tightening procedure................................................................ ......... 5-72 Oil changes on components ................................................................................................................ 5-73 5.13.1 General information................................................................................................................ 5-73 5.13.2 Swing gears – oil change ....................................................................................................... 5-74 5.13.3 Lifetime Travel gear – oil change ........................................................................................... 5-75 5.13.4 Swing gears and travel gears flushing ................................................................................... 5-80 5.13.5 Oil level check on idler (ITT idler only) ................................................................................... 5-81 5.13.6 Splitterbox – oil change .......................................................................................................... 5-82 5.13.7 Coupling – oil change............................................................................................................. 5-83 Rotary connection (from SN 28066) .................................................................................................... 5-85 Track components ............................................................................................................................... 5-86 5.15.1 Track components mountings check ...................................................................................... 5-87 5.15.2 Monitoring the track tension ................................................................................................... 5-89 5.15.3 Track tensioning system......................................................................................................... 5-90


MJFCIFSS

0-7

Operating manual

5.16

5.17

5.18

5.19 5.20

5.21 5.22

5.15.4 Cleaning the track components .............................................................................................. 5-91 Electrical system.................................................................................................................................. 5-91 5.16.1 Notes on the electrical system................................................................................................ 5-91 5.16.2 Principal batteries switches and ECM connectors.................................................................. 5-92 5.16.3 Battery care ............................................................................................................................ 5-93 5.16.4 Electrical components location ............................................................................................... 5-94 5.16.5 Electrical boxes and cab pressurization ................................................................................. 5-95 Heating/air conditioning system........................................................................................................... 5-95 5.17.1 Heating system....................................................................................................................... 5-96 5.17.2 Air-conditioning system .......................................................................................................... 5-97 5.17.3 Dual air-conditioning system (optional)................................................................................. 5-100 5.17.4 Additional maintenance operations ...................................................................................... 5-100 Check mounting bolts for tightness.................................................................................................... 5-101 5.18.1 Counterweight mounting bolts .............................................................................................. 5-102 5.18.2 Swing ring mounting bolts .................................................................................................... 5-103 5.18.3 Fuel tank mounting bolts ...................................................................................................... 5-104 5.18.4 Hydraulic tank mounting bolts .............................................................................................. 5-105 5.18.5 PowerPack mounting bolts ................................................................................................... 5-106 5.18.6 Swing gears and swing motors mounting bolts .................................................................... 5-107 5.18.7 Hydraulic pumps mounting bolts .......................................................................................... 5-108 5.18.8 Side frames mounting bolts .................................................................................................. 5-109 5.18.9 Cabin elevation mounting bolts ............................................................................................ 5-110 5.18.10 Driver’s cabin mounting bolts ............................................................................................... 5-111 Drive unit brakes and swing gear brakes........................................................................................... 5-111 General maintenance points.............................................................................................................. 5-112 5.20.1 Replacing working parts ....................................................................................................... 5-112 5.20.2 Welding work on the machine .............................................................................................. 5-112 Control and maintenance chart.......................................................................................................... 5-113 Centralized lubrication system........................................................................................................... 5-120

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MJFCIFSS

R9400 / 11000047

1 Product description 1.1 Assembly - overview This section comprises an overview of the machine and descriptions of the components shown.

1.1.1

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Machine and construction equipment

Fig. 1-1

Machine and construction equipment

100

Uppercarriage

320

Hydraulic cylinder

200

Undercarriage

330

Stick

310

Boom

350

Bucket


MJFCIFSS

1-1

Product description

Operating manual

Assembly - overview

1.1.2

Uppercarriage

Fig. 1-2

Uppercarriage

20

Swing gear installation

77

Cab elevation

25

Swing ring installation

80

Covering

40

Service trap

85

Lower covering

50

PowerPack

90

Cab

60

Hydraulic tank installation

95

Catwalk and handrail

65

Oil radiator installation

110

Fuel tank

70

Control valve installation

115

Counterweight installation

75

Rotating deck

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MJFCIFSS

R9400 / 11000047

Operating manual

Product description Vibration emissions

1.1.3

Undercarriage

Fig. 1-3

Undercarriage

208

Idler

1000 Rotary connection

400

Track chain

4500 Travel gear with sprocket

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. 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

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


MJFCIFSS

1-3

Product description

Operating manual

Vibration emissions

table below apply. These values conform to the specifications in the technical report ISO/TR 25398:2006 "Earth-moving machinery – Guidelines for assessment of exposure to whole-body vibration of ride-on machines – Use of harmonized data measured by international institutes, organizations and manufacturers". The method 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 (Lipart) shipped with new machines. For instructions how to reduce whole-body vibration du ring 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 condi tions " 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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MJFCIFSS

R9400 / 11000047

Operating manual

Product description EC Declaration of Conformity

1.3 EC Declaration of Conformity

Fig. 1-4

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


MJFCIFSS

1-5

Product description

Operating manual

Technical data

1.4 Technical data 1.4.1

Working technical data Backhoe

Shovel

Maximum working slope* (22 m3)

4,0° - 7,0%

4,0° - 7,0%

Maximum travelling angle (350 t)

22,1° - 40,6%

22,1° - 40,6%

Maximum tilt angle of diesel engine

30°

30°

Working ambient temperature range

-12°C to +55°C

-12°C to +55°C

78dB(A)

78dB(A)

Noise emission** LpA (inside cab) with: - water and hydraulic oil fans at 70%, - air conditioning fan at 60%. Tab. 1-1

Working technical data

* The maximum working slope has been determined for a hydraulic excavator in standard configuration (with bucket volume as given in the table above) with a material density of 1,8 t/m3. Changing the excavator configuration or the material density has an impact on the maximum working slope. In this case, LEC recommends contacting Customer Service in order to determine specific working conditions and the maximum working slope in particular. The machine stability has been defined relative to a horizontal surface and taking into account a safety factor. Operating the excavator with a different configuration will reduce this safety factor. When working on slopes, it is not permitted to overload the bucket and to work with a material de nsity different from that intended for the bucket provided by LEC. In order to use the excavator in material handling operations, LEC recommends also contacting the Customer Service. ** The sound pressure level (LpA) is determined according to ISO 6396. Th e measurement uncertainty is defined in the above standard.

1.4.2

Technical description This should be taken from the accompanying technical description.

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MJFCIFSS

R9400 / 11000047

Mining Excavator

R 9400

Operating Weight with Backhoe Attachment: 345,500 kg / 760,594 lb Operating Weight with Shovel Attachment: 353,000 kg / 778,230 lb Engine Output: 1,250 kW / 1,675 HP Bucket Capacity: 18.00 – 24.00 m3 / 23.5 – 31.5 yd3 Shovel Capacity: 18.00 – 24.00 m3 / 23.5 – 31.5 yd3

Technical Data Engine 1 Cummins diesel engine Rating per SAE J 1995 ________________ 1,250 kW/1,675 HP at 1,800 rpm Model ________________________ QSK50 (USA/EPA Tier 2) Type __________________________ 16 cylinder turbocharged V-engine after-cooler two separate water cooling circuits common rail Displacement _____________ 50 l/3,067 in3 Bore/Stroke ________________ 159/159 mm / 6.26/6.26 in Engine cooling system ______ fans driven via hydraulic piston motor Air cleaner _______________________ dry-type air cleaner with pre-cleaner, with automatic dust ejector, primary and safety elements Fuel tank _________________________ 6,908 l/1,825 gal Electrical system Voltage ______________________ 24 V Batteries ____________________ 4 (+ 2) x 170 Ah/12 V Alternator ___________________ 24 V/260 Amp Engine idling ____________________ sensor controlled Electronic engine power management __________ engine power and speed sensing over the entire engine rpm range

Electric Motor (optional) 1 electric motor Power output ___________________ 1,350 kW/1,810 HP Type _______________________________ 3 phase AC squirrel cage motor Voltage ____________________________ 6,000 V, other voltage on request Frequency _______________________ 50 Hz (or 60 Hz – dependent on country) Revolutions ______________________ 1,500 rpm or 1,800 rpm Motor cooling __________________ integrated air-to-air heat exchanger Starting method _______________ reduction of inrush current

Hydraulic System Hydraulic pumps for attachment and travel drive _________________ 4 variable flow axial piston pumps Max. flow ___________________ 4 x 751 l/min. / 4 x 198 gpm Max. hydr. pressure ____ 320 bar/4,640 psi Hydraulic pump for swing drive ____________ 2 reversible swash plate pumps, closedloop circuit Max. flow ___________________ 2 x 390 l/min. / 2 x 103 gpm Max. hydr. pressure ____ 350 bar/5,076 psi Pump management __________ electronically controlled pressure and flow management with oil flow optimisation Hydraulic tank capacity _____ 2,200 l/581 gal Hydraulic system capacity __________________________ 4,200 l/1,110 gal Hydraulic oil filter ______________ 1 high pressure safety filter after each high pressure pump + fine filtration of entire return flow Hydraulic oil cooler ___________ 2 separate coolers, 2 temperature controlled fans driven via hydraulic piston motor

Hydraulic Controls Servo circuit

____________________ independant, electric

over hydraulic proportional controls of each function Emergency control ______ via accumulator for all attachment functions with stopped engine Power distribution ____________ via monoblock control valves with integrated primary relief valves and flanged on secondary valves Flow summation _________ to attachment and travel drive Control functions Attachment and swing ________________________ proportional via joystick levers Travel ________________________ proportional via foot pedals or hand levers Bottom dump bucket __ proportional via foot pedals

Electric System Electric isolation _______________ easy accessible battery isolations Working lights __________________ high brightness halogen lights: – 2 on working attachment – 1 on RHS of uppercarriage – 3 on LHS of uppercarriage – 2 on counterweight Xenon lights in option Emergency stop switches __ at ground level, in hydraulic compartment, in engine compartment and in operator cab Electrical wiring ________________ heavy duty execution in IP 65 standard for operating conditions of – 50 °C to 100 °C/ – 58 °F to 212 °F

Swing Drive Hydraulic motor ________________ 2 Liebherr axial piston motors Swing gear ______________________ 2 Liebherr planetary reduction gears Swing ring _______________________ Liebherr, sealed triple roller swing ring, internal teeth Swing speed ____________________ 0 – 3.9 rpm Swing-holding brake _________ hydraulically released, maintenance-free, multi-disc brakes integrated in each swing gear

Uppercarriage Design

____________________________ torque

resistant designed upper frame in box type construction for superior strength and durability Attachment mounting _______ parallel longitudinal main girders in boxsection construction Machine access _______________ 45° access system with handrails on the cab side of the uppercarriage. Full controlled descent in case of emergency stop. Additional emergency ladder fitted near the cab

Service Flap Design

____________________________ hydraulically

Quick couplers on request

2

R 9400

actuated service flap, with lighting easily accessible from ground level to allow: – fuel fast refill – hydraulic oil refill – engine oil quick change – splitterbox oil quick change – swing gearbox oil quick change – swing ring teeth grease barrel refilling via grease filter – attachment/swing ring bearing grease barrel refilling via grease filter – windshield wash water refilling

Technical Data Operator’s Cab Design

____________________________ resiliently

mounted, sound insulated, large windows for all around visibility, integrated falling object protection FOPS Operator’s seat ________________ suspended, body-contoured with shock absorber, adjustable to operator’s weight Cabin windows ________________ 20.5 mm/0.8 in tinted armored glass for front window and right hand side windows, all other windows in tinted safety glass, high pressure windshield-washer system 75 l/20 gal watertank, aluminium sun louvers on all windows Heating system/ Air conditioning ________________ 1 heating system + air conditioning (double unit optionally available) fully automatic Cabin pressurization _________ ventilation with filter Controls __________________________ joystick levers integrated into armrest of seat Monitoring _______________________ via LCD-Display, data memory Rear vision system_ ___________ camera installation on counterweight and right-hand side of the uppercarriage displayed over an additional LCD-display Automatic engine shut off ____________________________ engine self-controlled shut off Destroking of main pumps ____________________________ in case of low hydraulic oil level Safety functions _______________ aditional gauges with constant display for: engine speed, hourmeter, voltmeter, safety mode for engine speed control and pump regulation Noise level (ISO 6396) _______ LpA (inside cab) = 77 dB(A) with oil/water fans at 100 % and AC fan at 65 %

Central Lubrication System Type _______________________________ Lincoln Centromatic lubrication system for the entire attachment/swing ring bearing and teeth Grease pumps _________________ Lincoln Powermaster pump plus separate pump for swing ring teeth Capacity __________________________ 200 l/53 gal bulk container for attachment/ swing ring bearing, separated 80 l/21 gal container for swing ring teeth Refill _______________________________ via the service flap for both containers, fill lines with grease filter

Attachment Design

____________________________ box-type

structure with large steel castings in all high-stress areas Pivots _____________________________ sealed with double side centering with 1 single floating pin per side, all bearings with wear resistant steel bushings, bolts hardened and chrominium-plated Hydraulic cylinder _____________ Liebherr design and made, all cylinders located in well protected areas Hydraulic connections ______ pipes and hoses equipped with SAE splitflange connections Kinematics ______________________ Liebherr parallel face shovel attachment geometry, backhoe bucket pivoting angle 150°, electronic controlled end-cushioning

Undercarriage Design

____________________________ 3-piece undercarriage, box type

structures for center piece and side frames (stress relieved steel work component as a standard) Hydraulic motor ________________ 2 axial piston motors per side frame Travel gear _______________________ Liebherr planetery reduction gear Travel speed ____________________ 0 – 2.7 km/h / 0 – 1.67 mph Parking brake ___________________ spring engaged, hydraulically pressure released external wet multi-disc brakes for each travel motor, maintenance-free Track components ____________ maintenance-free, forged double grouser pad, tractor-type chain, optional maintenance-free dual pin cast link and pad combined Track rollers/ Carrier rollers ___________________ 9/2 Automatic track tensioner _________________________ pressurized hydraulic cylinder with accumulator Transport ________________________ undercarriage side frames are removable

R 9400

3

Dimensions F

E

A2

D

A1 A

OEL

H3 H2

W1 W

C

H1 H

K

P Q N

L U

S Z

B

V

G

X

A A1 A2 C D E F H H1 H2 H3 K L

4

R 9400

mm/ft in 6,405/21’ 7,184/23’ 6” 7,900/25’10” 7,957/26’ 1” 6,400/20’11” 6,665/21’10” 3,100/10’ 2” 5,664/18’ 6” 6,653/21’ 9” 7,227/23’ 8” 8,343/27’ 4” 2,434/ 7’11” 6,645/21’ 9”

P Q S U Z N B G V W W1 X OEL Operator’s Eye Level

mm/ft in 2,494/ 8’ 2” 1,187/ 3’10” 5,516/18’ 1” 8,825/28’11” 10,657/34’11” 1,000/ 3’ 3” 6,516/21’ 4” 6,926/22’ 8” 13,279/43’ 6” 8,421/27’ 7” 9,243/30’ 3” 18,560/60’10” 6,740/22’ 1”

Dimensions F

E

A2

D

A1 A

OEL

H3 H2

W1 W

C

H1 H

K

P Q N

L U

S Z

B G

V X

A A1 A2 C D E F H H1 H2 H3 K L

mm/ft in 6,405/21’ 7,184/23’ 6” 7,900/25’10” 7,957/26’ 1” 6,400/20’11” 6,665/21’10” 3,100/10’ 2” 5,664/18’ 6” 6,653/21’ 9” 7,227/23’ 8” 8,343/27’ 4” 2,434/ 7’11” 6,645/21’ 9”

P Q S U Z N B G V W W1 X OEL Operator’s Eye Level

mm/ft in 2,494/ 8’ 2” 1,187/ 3’10” 5,516/18’ 1” 8,825/28’11” 10,657/34’11” 1,000/ 3’ 3” 6,516/21’ 4” 6,926/22’ 8” 16,400/53’ 9” 6,800/22’ 3” 8,100/26’ 6” 20,600/67’ 6” 6,740/22’ 1”

R 9400

5

Backhoe Attachment with Gooseneck Boom 9.30 m/30’6” ft

m

Digging Envelope

55 16 50

Stick length

45

14

40

12

Max. reach at ground level Max. teeth height Max. dump height Max. digging depth

R 3750

35 10 30 25 20 15

4.20 m/13’ 9” 16.30 m/53’ 5” 15.50 m/50’10” 10.50 m/34’ 5” 9.50 m/31’ 1”

8

Max. digging force (ISO) Max. breakout force (ISO)

6

1000 kN/224,809 lbf 1050 kN/236,049 lbf

4

10 5 0 -5

2

Operating Weight and Ground Pressure

0 -2

-10 -15 -20 -25

The operating weight includes the basic machine with backhoe attachment and a 22.00 m3 /28.78 yd3 bucket.

-4 -6

Pad width Weight Ground pressure

-8

-30

mm/ft in 1,000/3’3” kg/lb 345,500/760,594 kg/cm 2 / psi 2.60/36.98

-10 20

18

16

14

12

10

8

6

4

65 60 55 50 45 40 35 3 0 2 5 2 0 1 5 1 0

2 5

0

m

0

ft

Buckets For materials classe according to VOB, Section C, DIN 18300 Typical operation according to VOB, Section C, DIN 18300 Capacity ISO 7451

m3 yd3 Suitable for material up to a specific weight of t/m3 lb/yd3 Cutting width mm ft in Weight kg lb GP: General purpose bucket HD: Heavy-duty bucket XHD: Heavy-duty rock bucket

6

R 9400

<5

5–6

5–6

5–6

7–8

7–8

GP 24.00 31.39 1.7 2,867 3,900 12’9” 22,000 48,502

HD 18.00 23.54 2.2 3,710 3,400 11’1” 23,000 50,706

HD 22.00 28.78 1.8 3,035 3,700 12’1” 23,000 50,706

HD 24.00 31.39 1.6 2,698 3,900 12’9” 23,800 52,470

XHD 18.00 23.54 2.0 3,373 3,400 11’1” 24,500 54,013

XHD 20.00 26.16 1.8 3,035 3,700 12’1” 25,000 55,116

Shovel Attachment with Shovel Boom 6.75 m/22’1” ft

m

Digging Envelope

18 55

17

Stick length

16 50 45

Max. reach at ground level Max. dump height Max. crowd length Bucket opening width T

14 13

40 35

4.30 m/14’ 1”

15

12 11

T

10 30

Crowd force at ground level (ISO) Max. crowd force (ISO) Max. breakout force (ISO)

9 8

25

7 20

14.00 m/45’11” 11.20 m/36’ 8” 4.50 m/14’ 9” 2.50 m/ 8’ 2” 1195 kN/268,647 lbf 1610 kN/361,942 lbf 1290 kN/290,004 lbf

6 5

15

4 10

2

5

2

0 -5 -10

Operating Weight and Ground Pressure

3

0

The operating weight includes the basic machine with shovel attachment and a 22.00 m3 /28.78 yd3 bucket.

-1 -2 -3

Pad width Weight Ground pressure

-4 -15

-5 16 15 14 13 12 11 10 9 50

45

40

35

30

8

7

25

6 20

5

4 15

3 10

2

1 5

0 m

mm/in 1,000/3’3” kg/lb 353,000/778,230 kg/cm 2 / psi 2.66/37.83

0 ft

Bottom Dump Buckets For materials classe according to VOB, Section C, DIN 18300 Typical operation according to VOB, Section C, DIN 18300 Capacity ISO 7546

m3 yd3 Suitable for material up to a specific weight of t/m3 lb/yd3 Cutting width mm ft in Weight kg lb Wear kit level GP: HD: XHD:

<5

<5

5–6

5–6

7–8

7–8

GP 24.00 31.39 1.6 2,698 4,250 13’11” 36,700 80,910 I

GP 22.00 28.78 1.8 3,035 4,250 13’11” 35,400 78,044 I

HD 18.00 23.54 2.2 3,710 4,250 13’11” 35,400 78,044 II

HD 22.00 28.78 1.8 3,035 4,250 13’11” 35,400 78,044 II

XHD 18.00 23.54 2.1 3,541 4,250 13’11” 37,500 82,673 III

XHD 19.00 24.85 1.9 3,204 4,250 13’11” 38,500 84,878 III

General purpose bucket Heavy-duty bucket Heavy-duty rock bucket

Level I: For non-abrasive materials, such as limestone, without flint inclusion, shot material or easily breakable rock, i.e., deteriorated rock, soft limestone, shale, etc. Level II: For preblasted heavy rock, or deteriorated, cracked material (classification 5 to 6, according to DIN 18300) Level III: For highly-abrasive materials such as rock with a high silica content, sandstone etc.

All illustrations and data may differ from standard equipment. Subject to change without notice. All indicated loads are based in accordance with ISO 9248.

R 9400

7

The Liebherr Group of Companies Wide Product Range The Liebherr Group is one of the largest construction equipment manufacturers in the world. Liebherr’s highvalue products and services enjoy a high reputation in many other fields, too. The wide range includes domestic appliances, aerospace and transportation systems, machine tools and maritime cranes.

Exceptional Customer Benefit Every product line provides a complete range of models in many different versions. With both their technical excellence and acknowledged quality, Liebherr products offer a maximum of customer benefits in practical application.

State-of-the-art Technology To provide consistent, top quality products, Liebherr attaches great importance to each product area, its components and core technologies. Important modules and components are developed and manufactured inhouse, for instance the entire drive and control technology for construction equipment.

Worldwide and Independent Hans Liebherr founded the Liebherr family company in 1949. Since that time, the enterprise has steadily grown to a group of more than 120 companies with nearly 33,000 employees located on all continents. The corporate headquarters of the Group is Liebherr-International AG in Bulle, Switzerland. The Liebherr family is the sole owner of the company.

www.liebherr.com

Printed in Germany by Typodruck RG-BK-RP LEC/SP 11003238-1-07.11_enGB-US

Liebherr-Mining Equipment Colmar SAS 49 rue Frédéric Hartmann, F-68025 Colmar Cedex  +33 369 49 20 00, Fax +33 369 49 23 18 www.liebherr.com, E-Mail: [email protected]

2 Safety instructions Working with the machine holds dangers to which you as the owner, machine operator or maintenance expert could be exposed. If you regularly read and note the safety information, however, you can prevent danger and accidents. This is particularly true for those who are only occasionally in contact with the machine, eg. for maintenance work. The following information comprises safety regulations which, if followed conscientiously, will contribute to your safety and that of other persons, as well as avoiding damage to the machine. Following these precautions does not release you from the responsibility to take note of safety regulations which apply on site or of guidelines given by legal bodies or professional associations. For EU countries, guideline 2009 / 104 / EC contains the minimum required safety information applicable to the owner.

2.1 Meaning of the symbols in this manual Work processes and actions that could cause danger are accompanied by safety informations in these operating instructions. These safety informations describe various dangers which are emphasized by the terms Danger , Caution and Note. These terms are identified by symbols in the operating instructions and have the following meaning: Danger! Warning relating to a danger that carries with it a high risk of death or serious injury if the appropriate preventative measures are not taken.

Caution! Warning relating to dangers that could re sult in physical injury and/or damage to the machine if the appropriate preventative measures are not taken.

Note! This symbol identifies user tips and operating and maintenance procedure s whose use will guarantee a high degree of user-friendliness and longevity to the machine or which will considerably simplify working procedures.

– This symbol identifies a listing. • This symbol identifies a sub-listing.

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 This symbol signifies the following: “The precondition must be fulfilled”.

The machine operator or the maintenance personnel must first fulfil the precondition described, i e. the machine must be brought into a particular work position in order to be able to carry out the actions subsequently described.  This symbol identifies an action.

The machine operator or the maintenance personnel should be active at this location and carry out the action described.  This symbol means “Carry out an activity".


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Safety instructions

Operating manual

Use in accordance with the regulations

If the machine operator or maintenance personnel have carried out the activities described in an action, the result of this action will be described here. Following these notes does not relieve you of responsibility for following additional rules and guidelines!

Additional points that should be noted are: – the safety regulations which apply on site, – statutory road traffic regulations, – the guidelines provided by professional associations.

2.2 Use in accordance with the regulations – The hydraulic excavator is a machine with work equipment (eg. hoe type bucket, grab, bucket attachment) designed to detach, lift, transport and shake off earth, stones and other materials, while the transportatio n of the load itself usually takes place without moving the machine. Moving the machine when it is carrying a load must be carried out while observing the appropriate safety measures (see sect ion "Notes for safe working"). – Machines used for hoisting are subject to specific conditions and must be fitted with the stipulated safety devices (see section “Hoisting work”). – Machines used underground (deep mining and tunnel construction) must be equipped with exhaust gas reducing equipment (e.g. diesel particle filter). Always comply with the statutory regulations applicable at the location of operation. – Special tasks require special attachments and possibly also special safety devices. This equipment may only be attached to the machine and used with the explicit consent of and according to the instructions of the ma nufacturer of the basic machine. – Any other use, in particular transporting persons or working in explosive atmospheres or contaminated environments is not deemed to be in accord ance with regulations. The manufacturer is not liable for any damage resulting from this action. The user is solely responsible for the risk incurred. – Observing the operating instructions and the inspection / maintenance instructions is also deemed to be appropriate use in accordance with regulations.

2.3 Safety Instructions General safety inst ruct ions – Please familiarize yourself with the operating instructions before starting up the machine. – Ensure that you have obtained, read and understood any additional instructions relating to special accessories for the machine. – Only specifically authorized persons may operate, maintain or repair the machine. The legal minimum age is to be adhered to. – Only employ trained or appropriately instructed personnel. Clearly establish which personnel are responsible for operating, setting up, maintaining and repairing the machine. Give personnel the power to refuse to carry out unsafe instructions. This also applies in relation to traffic regulations.

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Safety instructions Safety Instructions

– Only permit apprentices and personnel who are in training or who have only general training to operate on the machine unde r the constant supervision of an experienced member of staff. – As far as possible, monitor personnel to ensure that they are adhering to safe working practices, are aware of risks and are observing the operating instructions. – Always wear safe work clothes when you are working on or with the machine. Avoid wearing rings, wrist watches, ties, scarves, open jackets, baggy clothing etc... There is a risk of injury from, for example, getting caught up or being drawn in. – Wear individual protective equipment ( protective goggles, safety helmets, safety shoes and gloves, reflective vests and ear protection etc...). – Ensure that you obtain information on any special safety regulations for the job site from the site foreman. – Always tilt up the safety lever before leaving the operator’s seat. – When getting in and out, do not hold on to the steering column, control panel or joystick. Doing this could cause unintentional movement, which could result in an accident. – Never jump from the machine; use the steps, ladders, gangplanks and supporting straps provided for this purpose. – Face the machine when getting in or out and always use three-point support, i.e. two hands and one foot or two feet and one hand must always be in contact with the access system at the same time. – Familiarize yourself with the location of the emergency exit. – In the absence of any other instructions, proceed as follows for all maintenance and repair work: • park the machine on firm, level ground • align the uppercarriage with the undercarriage so that the sprockets locate at the back-end • anchor the bucket in the ground. • place all operating levers into neutral and tilt the safety lever up. • switch off the engine and remove the start key. – Before touching any parts of the hydraulic circuits, you must also operate all pilot control devices (joystick and pedals) in all directions with the start key in contact position and with the security lever lowered, in order to reduce the actuating and dynamic pressures in the work circuits. You must then reduce the internal tank pressure as described in these operating instructions. – Secure all loose parts on the machine. – Never operate a machine before carrying out a ca reful inspection tour and checking whether any warning signs are missing or illegible. – Respect all danger and safety instructions. – For special applications the machine must be equiped with specific safety equipments. Work only if they are mounted and functional. – Do not carry out any modifications, alterations or conversions to the machine which may affect safety without the express permission of the manufacturer. This also applies for the installation of safety devices and valves and for welding work on load-bearing parts.

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– It is forbiden to repair the structure of the cab. – Not original equipment and component parts or such kind, wich has generaly not been validated by LIEBHERR for installation or extension, has not to be installed or added onto the excavator without previous written agreement of LIEBHERR. Wherefore the necessary technical docume ntations has to be at LIEBHERR’s disposal.


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Safety instructions

Operating manual

Safety Instructions

Av oi dan ce of cru shi ng and bu rn s – Do not work beneath the equipment if it is not safely positioned on the ground or supported. – Do not use any damaged or insufficient load-bearing take-up materials, such as ropes or chains. – Wear adapted work gloves when working with wire cables. – When working on the equipment, never use your fingers to locate bores; use the correct punch for the procedure. – Ensure that no objects enter the fans when the engine is on. The fan will eject or destroy these objects and will itself be damaged. – Near operating temperature, the parts of the engine cooling system, of the exhaust system and of the hydraulic system can reach very high temperatures. Avoid coming into contact with coolant carrying parts, with parts from the exhaust system and with hot oil or oil-bearing parts.There is a risk of sustaining burns. – Only check the coolant when the sealing cap of the expansion container has cooled to a point where it is possible to touch it. Then turn the cap carefully to let off the overpressure. – Wear protective goggles and gloves when working on the battery. Avoid sparks and naked flames. – Never permit the bucket to be guided by hand by auxiliary personnel. – When reaching into the engine compartment, always secure the side doors against unintentional closing by positioning the supports if provided for this purpose. – Never lay under the machine if it is raised with work equipment and has not been correctly and securely supported with appropriate supports.

Av oi dance of fir e and expl os io ns – Switch off the engine when refuelling. – Do not smoke or use a naked flame when refilling tanks and working near or charging the batteries. – Always start the engine in accordance with the operating instructions. – Check the electrical system regularly. – Have all faults, such as loose connections, blown fuses and lamps and clogged or abraded cables rectified by authorized personnel. – Do not transport any combustible liquids anywhere on the machine other than in the tanks provided for this purpose. – Check all lines, hoses and screwed joints regularly for leakage and damage. – Rectify leakages immediately and replace damaged components. – Oil spraying out of leaking areas can easily cause a fire. – Ensure that all holds and shields are correctly installed to guard against vibration, abrasion and heat accumulation. – Do not use cold start materials (ether) in the vicinity of heat sources, naked flames or in inadequately ventilated areas. – Do not use any starting aids containing flammable material to start diesel engines with preheating or flame glow systems. There is a risk of EXPLOSION. – Familiarize yourself with the location and operation of fire extinguishers on the machine and with local fire warning and fire abatement options. – It is possible to install an extinguisher into the driver’s cab.

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– All doors, covers and boxes locks have to be unlocked before operation in order to facilitate firefighting in case of fire. Only electrical boxes from and over 50V must remain locked during operation.

Bring ing the machin e safely into service – Carry out a careful inspection tour around the m achine each time before starting it. – Ensure that no one, except an authorized person, is in the work and movement area of the machine. – Check the machine for loose bolts, cracks, wear, leakage and damage. – Never attempt to operate a damaged machine. – Ensure that any damage is immediately rectified. – Ensure that all hoods and covers are closed, but that locks are unlocked, to facilitate the fight against fire in case of. – Ensure that all warning signs are present. – Keep windows and interior and exterior mirrors clean. Secure doors and windows against unintended movement. – Ensure that no one is working on or under the machine and warn personnel in the vicinity of the machine that it is about to start by sounding the horn.

Safely gettin g up – Proceed with the the same precautions to climb up or down onto the machine, as to install yourself at the operator’s seat. – When getting up or down, position the machine on even, horizontal ground. The upper structure should be positioned with the undercarriage in such a way that the steps and ladders are aligned with each other. – Ensure that steps, ladders and hand-rails (grips) are in good condition. In particular, you should ensure that they are free of dirt, oil, ice and snow. NOTE: To ensure that the doors open properly in all weather conditions, the door seals must be dusted with talc or silicon at least every two months or more often if required. The door hinges and locks should be greased regularly. – Face the machine when getting in or out and always use three-point support, i.e. two hands and one foot or two feet and one hand must always be in contact with the access system at the same time. – If you are able to reach the door handle with your free hand, open the doors before you climb any higher. External influences, such as wind, can make it more difficult to open doors. Because of this, always use your hand for control when opening doors. Ensure that the door is latched open to prevent it slamming open and shut. – In case of bad weather conditions, be particulary vigilant to realise the climbing and descent from the cab with the best safety conditions, and do or give the instuctions to the execution of prior preparat ions to be accomplished, as enunciated above, in order to displace yourself safely.

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– Be particulary vigilant with those prerequisites conditions. – For cab wi th a si de d oo r: • Now continue to climb up, still using the three-point support and sit down in the operator’s seat as soon as you enter the cab. • Fasten the safety belt (if available), unlock the door, using the planned lever, and close it immediately using the door handle, before tilting down the safety lever, and start the machine. • If you wish to work with the door open, it is necessary to fasten your safety belt.


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Safety instructions

Operating manual

Safety Instructions

If unavailable, let it be instaled before working with the door open. – For cab with a rear door: • Now continue to climb up, still using the three-point support and close the door as soon as you enter the cab. • Sit down in the operator’s seat and fasten the safety belt (if available) before tilting down the safety lever, and start the machine.

Ad ju st in g t he o per ato r’s standin g p os it io n – Before starting the machine, adjust the seat, mirrors, armrests and operator’s controls in such a way that you are able to work comfortably and safely. – Acoustic insulation devices on the machine must be set to the insulation position throughout operation.

Protection from vibration - seat adjusting – Keep the seat in good condition and adjust it as follows: • The seat and its damping action should be adjusted depending on the weight and height of the operator. • Check the seat’s damping action and adjustment mechanisms regularly and ensure that these seat characteristics remain as per the seat manufacturer’s instructions.

Utilisation in confined spaces – Only operate combustion engines and fuel-operated heaters in adequately ventilated spaces. Before starting in closed areas, ensure adequate ventilation. Follow the regulations which apply for the particular area of use.

Startin g th e machine safely – Before starting, check all control lamps and instruments for correct function, place all operator’s controls in Neutral and tilt the safety lever up. – Before starting, sound the horn briefly to alert people in the vicinity of the machine. – Only start the machine from the driver’s seat. – In the absence of any other instructions, start the engine in accordance with the regulations given in the operating instructions. – Tilt the safety lever down and then test all display and checking devices. – In enclosed spaces, only allow the engine to run when there is adequate ventilation. If necessary, open doors and windows to ensure sufficient fresh air supplies. – Bring the engine and hydraulic oil to operating temperature. Low oil temperatures make the control unit react sluggishly. – Check that the equipment is operating correctly. – Move the machine carefully to an open area and then check the function of the running and slewing gear brakes, the steering and the signaling and lighting devices.

Stopping the machine safely – Only stop the machine on level, firm ground. – If the machine has to be stopped on an incline, chocks should be used to secure it from rolling away. – Before stopping the machine, each time it is possible, align the uppercarriage with the undercarriage so that the sprockets locate at the back-end. This is the only one position which enables a secured access to every maintenance locations on the uppercarriage.

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– Use the stop bolts to secure the upper structure facing the undercarriage, if available. – Lower the equipment and anchor the grab lightly in the ground. – Position every control lever into neutral position and depress the parking and slewing brakes. – Stop the engine in accordance with the operating instructions and tilt the safety lever up before leaving the cab. – Lock the machine, included hoods and compartments, retire every keys and secure the machine against unpermited use and vandalis.

Safely getting down – Proceed with the the same precautions to climb up or down onto the machine, as to instal yourself. – Stop the machine on level, horizontal ground. The upper structure should be positioned with the undercarriage in such a way that the steps and ladders are aligned with each other. – Open and lock the door. Be sure of it’s locking. Take care of weather conditions ! Unfasten the safety belt. – Position yourself with your face toward the machine when getting out and use three-point support, i.e. two hands and one foot or two feet and one hand must always be in contact with the access system at the same time. Climb down until you can close the doors safely. Always use your hand for control when closing the doors. Lock the door. – Now climb down to the ground.

Working safely with th e machine – Before you start working, acquaint yourself with the special features of the job site and any special precautions and warning signals. Examples of particular work environments would be on-site or traffic obstructions, the load-carrying capacity of the ground and any requirements to make the job site safe from public use. – Always maintain a safe distance from overhangs, edges, slopes and unsafe ground. – Be particularly careful in conditions of reduced visibility and changeable ground conditions. – Familiarize yourself with the location of power lines on the job site and take particular care when working near them. If necessary, inform the responsible authorities. – Maintain a safe distance from electrical aerial lines. Do not allow the equipment to come near cables when working near electrical aerial lines. Risk of fatality! Inform yourself about required safety distances. – The following actions must be carried out in the event of any transfer of electricity: • do not move the machine or its equipment, • do not leave the driver’s cab, • warn any personnel in the vicinity not to come close to the excavator and not to touch i t, • instruct or initiate that someone turns off the voltage. • move the machine, if possible, from the danger zone to a sufficient distance, • Do not leave the machine until you are absolutely sure that voltage in the line, which had been touched or damaged, has been turned off !

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


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Safety instructions

Operating manual

Safety Instructions

– When driving onto public roads, paths and squares, observe current traffic regulations and if necessary, ensure that the machine has been made safe as per regulations beforehand. – Always turn on the lights in conditions of poor visibility or darkness. – Do not permit any passengers in the machine. – Only work when seated properly and with the safety belt securely fastened (if available). – Report all function faults and ensure that all necessary repairs are carried out immediately. – Assure yourself that no one is endangered when you start the machine moving. – Before you start working, test the brake system in accordance with the regulations given in the operating instructions. – Never leave the driver’s seat while the machine is moving. – Never leave the machine unattended while the engine is running. – The machine must be positioned, moved and operated in such a way that it is stable and that there is no danger of overturning. Only known loads may be moved with the equipment; this applies particularly when using the grab. – Position the upper structure in the longitudinal direction when moving and hold the load as close to the ground as possible. EXCEPTION : excavators used for loading and unloading, see the part "Safe use when loading and unloading (particularly when loading and unloading wood)" on page 10. – Adjust your driving speed to suit local conditions. – Avoid any working movements which may tip the machine. Should the machine start to tip or slide sideways, however, turn the upper structure to face downhill and lower the equipment at the same time. – As far as possible, work downhill or uphill and not side on to the slope. – Drive safely on stony, sleepery or inclined ground – Only drive downhill at the permitted speed or you could lose control of the machine. – Always shift down to a lower running step before a slope. When doing this, the diesel engine must run at maximal speed and the speed may only be reduced using the foot pedals. – Load an occupied truck only if all safety requirements are fulfilled, notably in order to protect the truck operator. – For demolition work, digging and crane operations etc., always use protective devices specifically designed for the purpose. – For terrain which is difficult to gain an overview of and whenever necessary, ask for the assistance of a spotter. Only permit one person to give you signals. – Authorize only experienced people to attach load and to give indications to the machine operator. This people must be in the operator’s sight or in radio contact with him. – Depending on the equipment combination, there is a risk of collision between the work tool and the machine (uppercarriage and undercarriage). The greatest degree of care must be taken to avoid damage. – Depending on the equipment combination, there is a risk of collision between the work tool and the cab, the cab protection or the boom cylinders. The greatest degree of care must be taken t o avoid damage when the hoe teeth come within this area. – Depending on the equipment combination, there is a risk of collision between the work tool and the equipment parts. The greatest degree of care must be taken to avoid damage.

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– Depending on the equipment combination, there is a risk of collision between the lift ring of the attachment and the cab or the cab prot ection. Before operating, ensure that there is no risk of collision, especially on excavator with cab elevation. If necessary remove the lift ring. – In case of a thunderstorm : • lower the attachment to the ground and if possible anchor the digging tool into the soil. • leave the cab and move away from the machine before the storm breaks out. Otherwise, you must stop the excavator, turn off the radio and keep inside the closed cab until the end of the storm. – Auxiliary control units can have various functions. Always check their functions when starting up the machine. – Stop the swinging motion of the uppercarriage when lowering the attachment into a ditch without striking the attachment on the ditch walls. – Inspect the machine for damage if the attachment h as been swung into a wall or any other obstacles. – Applications in which the attachment is to be used to strike the material being extracted are not permitted, even when working in a longitudinal direction. – Repeated strikes against an object leads to damage to the steel structures and machine components. – Please refer to your LIEBHERR dealer if special teeth for heavy-duty or special applications are required. – Do not attach too large bucket or bucket with side cutters or that are during operations with rocky material. This would prolong the work cycles and may lead to damage to the bucket as well as further machine components. – With the 2x45° offset articulation, the offset position may only be employed if the working tool or the attachment does not touch the material. – Operation of the offset articulation to drill into the material is not permitted. – Do not lift the machine during operation. Should this happen, lower the machine slowly back to the ground. – Do not let the machine fall heavily on the ground and do not hold it back with the hydraulics. This would damage the machine. – During operation with the attachment it is forbidden to raise the machine with the dozing blade (e.g. carving at the ceiling when tunnelling). – Do not dig under the undercarriage. Take all necessary measures to prevent ground collapse under the machine. – The practice of following working methods is forbidden: • Batter pulling, also known as Scaling or Ripping, • Double benching, also known as Split benching or Double flitching. The practice of these methods will result in increased stresses to steel structures and components of Liebherr Mining Machines. It may significantly reduce the expected life of structures and/or components. 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

Liebherr does not condone and does not approve the operation of Liebherr Mining Machines in this manner.

Safe use wit h a hydr aulic hammer – The hydraulic hammer must be selected with particular care. When using a hydraulic hammer not permitted by LIEBHERR, steel structures or the other machine components can become damaged. – Before beginning breaking tasks, position the machine on firm and level ground.


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Safety instructions

Operating manual

Safety Instructions

– Use a hydraulic hammer designed exclusively for breaking stone, concrete and other breakable materials. – Only operate the hydraulic hammer in the longitudinal direction of the machine and with the windshield closed or with a front protective grid. – Ensure during hammer operation that no cylinder is entirely extended or retracted and that the stick is not in the vertical position. – In order to avoid damages to the machine, try not to break stone or concrete while performing retraction and extension motions of the hydraulic hammer. – Do not apply the hydraulic hammer uninterrupted for more than 15 secs. at a time to the same place. Change the breaking point. Too long uninterrupted operation of the hydraulic hammer leads to an unnecessary overheating of the hydraulic oil. – Do not use the drop force of the hydraulic hammer to break stone or other mate rials. Do not move obstacles with the hydraulic hammer. Misuse of this nature would damage both the hammer and the machine. – Do not use the hydraulic hammer to lift objects

Safe use when loading and unl oading (particularly w hen loading and unloading wood) – According to use, it can be necessary when working with a grab to move with the equipment raised and the load lifted up; this applies, for example, when loading and unloading wood. – Here, the centre of gravity of the machine will be displaced upwards in the vertical direction. The driving characteristics of the machine will thus be influenced persistently, e.g. through reduction of the dynamic stability. The following instructions are therefore to be observed at all times: • Adjust vehicle handling to suit the altered machine characteristics and environmental conditions. • Reduce your speed to prevent the need for sudden braking and steering manoeuvres. • Avoid sudden speed changes, such as braking, accelerating and changing direction. • Only rotate the upper structure when the undercarriage is stationary. • Only rotate the upper structure after you have picked up the load. • Only move the machine when you have picked up and lifted the load and rotated the upper structure to the driving position. • There is a danger of possible swinging movement and dropping of the load when the equipment is raised. • A protective grid (FOPS) in accordance with ISO 10262 must be attached to the cab. • A protective roof (FOPS) in accordance with ISO 10262 must be attached if there is a risk of objects falling from above. • Only the maximum permissible load may be taken up using the grab. – NOTE: The weight of absorbent materials, such as logs, is dependent on length, diameter and specific weight. The influencing variables present in a natural product, such as moisture, must be noted. – Working procedures when using machines with grabs require the machine operator to receive special instruction and training. – Use as part of the work process is only permitted when the machine operator has sufficient training and practical experience.

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Safe use of machin es with tower elevation – Due to the tower elevation, the centre of gravity of the machine will be displaced upwards in the vertical direction. The driving and work characteristics of the machine will thus be influenced persistently, e.g. through reduction of the dynamic stability. – Due to the heightened centre of gravity, the machine must be aligned horizontally before use. In horizontal alignment, the centre of gravity of the upper structure is over the centre of the undercarriage, which reduces the risk of tilting. – The machine can still sway and tilt despite being aligned! The following instructions are therefore to be observed at all times: When moving the machine: • Rotate the upper structure parallel to the undercarriage (transport position). • Draw the equipment as close as possible to the machine. • Only at this point may the support feet be retracted and the machine moved. • Moving with loads is not permitted. • Check the terrain to be covered to ensure that the ground is solid and even. Potholes and uneven surfaces jeopardize the stability of the machine. • Adjust vehicle handling to suit the altered machine characteristics (high centre of gravity) and environmental conditions. • Reduce your speed to prevent the need for sudden braking and steering manoeuvres. • Avoid sudden speed changes, such as braking, accelerating and changing direction. • Ascending gradients and obstacles may only be approached in the longitudinal direction in order to prevent unacceptable banking of the machine. • Special care should be taken when driving through narrow passages - drive slowly! When loading and unloading: • The machine must be supported and aligned horizontally before moving (slewing) the upper structure out of the transport position. • It is imperative that you check the contact surface of the support (load carrying capacity of the substrate). A support subsiding would have disastrous consequences! • Carry out all movements with increased care. • To slew the load, move the equipment as close as possible to the machine (Caution! swinging grab) and hold the load close to the undercarriage and above the substrate. • Avoid braking or accelerating the equipment or upper structure abruptly. • Do not lift any loads which are heavier than those given in the load chart.

Protection from vibration – Vibrational loads on mobile building machinery are mainly the result of the type and method of use. The following parameters in particular are decisive influences: • Terrain conditions: Uneven areas and potholes; • Operational techniques: Speed, steering, brakes, controlling the machine’s control elements when driving and working.

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– To a large extent, the machine operator determines the vibrational loads since he selects the speed, gearbox ratio, working method and route himself. This means that there is a wide range of different vibrational loads for the same machine type.


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Safety instructions

Operating manual

Safety Instructions

Whole-body vibrational load for the machine operator can be reduced if the following recommendations are observed: – Select suitable machines, equipment parts and auxiliary devices for each part of the job. – Use a machine that has a suitable seat (i.e. for earth-moving machinery such as hydraulic excavators, this should be a seat which corresponds with EN ISO 7096). – Keep the seat in good condition and adjust it as follows: • The seat and its damping action should be adjusted depending on the weight and height of the operator. • Check the seat’s damping action and adjustment mechanisms regularly and ensure that these seat characteristics remain as per the seat manufacturer’s instructions. – Check the maintenance status of the machine, particularly with respect to: tyre pressure, brakes, steering, mechanical connections etc. – Do not steer, brake, accelerate, shift gears, move or load the machine’s equipment jerkily. – To reduce vibrational load, adjust the machine speed to suit the route as follows: • Reduce speed when driving on difficult terrain; • Drive around obstacles and avoid driving on very difficult terrain. – Keep the terrain on which the machine is working and driving in good condition: • Remove large stones and obstacles; • Fill in ruts and holes; • Have machines ready to prepare and maintain suitable ground conditions and calculate in sufficient time to carry out any work required. – Drive longer distances (e.g. on public roads) at an appropriate (medium) speed. – Use special auxiliary systems (if available) which reduce vibration for machines that are driven frequently. If such auxiliary systems are not available, regulate speed to avoid "oscillating" the machine.

Towing t he machine safely – Always follow the correct procedure if applicable. – The machine may only be towed in exceptional circumstances, e.g. in order to move the machine away from an area where it is at risk. – Before towing, check all attachments and towing devices for safety and stability. – Towing devices such as bars, cables or ropes must have adequate tensile strength and should be secured around the undercarriage tower or the towing hook provided on the undercarriage. Any damage or accidents which occur while towing the machine are not covered by the manufacturer’s guarantee. – Ensure that there is no one in the vicinity of the towing devices when towing. – Stretch safely and hold the towing devices. Avoid kinks on cables or ropes. – When towing, maintain the correct transport position, permitted speed and route, and avoid lurching. – After towing, return the machine to correct operational status. – When restarting the machine, be sure only to proceed in accordance with the operating instructions.

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At tach ing and remo vin g equ ip ment par ts saf ely – Equipment or attachments made by other manufacturers or those which do not have general approval from LIEBHERR for installation or attachment may not be installed or attached to the machine without LIEBHERR’s prior written consent. – LIEBHERR must be provided with the appropriate technical documentation necessary for this purpose. – Before carrying out any major repair work on the equipment, position the machine on level, firm ground. – Do not work beneath the equipment if it is not safely positioned on the ground or supported with appropriate supports. – Before loosening lines or unscrewing bolts, you must store the equipment, switch off the engine and press the start key to the contact position and both joysticks and the pushbuttons to “Turn grapple” in order to reduce the pressure in the hydraulic system. – Do not attempt to lift heavy parts. Use devices which are suitable for this purpose and which have sufficient load carrying capacity. – Do not use cable which is damaged or does not have sufficient load carrying capacity. Wear work gloves when working with wire cables. – When working on the equipment: switch off the engine and keep the safety lever tilted up. Never use your fingers to locate bores; use the correct punch for the procedure. – During repair work: ensure that the hydraulic lines are secured correctly and that all bolts and connections are tight. – When you have removed and chocked an equipment part, close open areas of the hydraulic circuit to stop dirt entering. Only allow authorized persons in the vicinity of the machine or the lifting device used.

Removin g and installing equipment pin s safely – If possible, always use a hydraulic bolt press to press out the equipment’s bolts. – If you have to remove a bolt using a sledge-hammer, a driving punch and a bore hole conductor held by another person must be used. – To drive in a bolt, screw the drive screws provided in the toolbox if provided int o the bolt's threaded hole and only hammer these screws. – When installing bolts locked by means of castle nuts and cotter pins, first drive the bolt to the stop, then screw the castle nut by hand until contact and then only pull it far enough to push in the cotter pin.

Transpor ting the machine safely – Due to transport restrictions, use only suitable means of transport and lifting devices with sufficient load-carrying capacity. – Park the machine on a flat surface and wedge the crawler or wheels securely. 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

– If required, detach a part of the machine’s working equipment during transportation. – The ramp used to drive the machine up onto the flatbed trailer should not exceed an inclination of the angle value indicated in the "Technical data" section of this manual (machine must be able to walk up unaided) and should have a wooden cover to prevent sliding back. – The undercarriage should be swept clean, i.e. before driving up the ramp, clean any snow, ice and mud from the crawler / wheels of the machine. – Align the machine precisely with the loading ramp.


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Safety instructions

Operating manual

Safety Instructions

– Attach the hand lever for fine-tune driving (crawler excavator) onto the accelerator pedals. – Ensure that a spotter gives the machine operator the required signal. – Prepare the placing block to ensure against rolling back when the machine is driving up onto the flatbed. – Tilt the equipment up and drive up the loading ramp. While doing this, always hold the equipment securely over the loading area, drive very carefully up the ramp and onto the transportation vehicle. – Rotate the upper structure carefully to the rear and lower the equipment. Due to restrictions during transport on hoe equipment, tilt the arm in and dismantle the bucket during transportation. – After loading the machine onto the flatbed trailer, the upper structure must be secured facing the undercarriage using the stop bolts (only A devices). – Secure the undercarriage and the remaining individual parts using chains and blocks to prevent slipping. – Before you leave the machine, reduce pressure on all pressure lines, remove the ignition key and tilt up the safety lever. – Lock all cab and panel doors. – Before transportation, find out all details about the route to be travelled, particularly as they relate to width, height and weight restrictions. – Pay particular attention when driving under electrical lines and bridges and through tunnels. – When unloading the machine, take the same amount of care as was taken when it was loaded. Remove all chains and blocks. Start the engine as per the operating instructions. Drive carefully off the trailer’s loading area and down the ramp. Hold the working equipment as securely as possible over the ground while doing this. Have a spotter guide you.

Servic ing the machine safely General safety inst ruct ions – Maintenance and repair work may only be carried out by specially trained personnel. – Observe statutory timetables or intervals given in the operating instructions for repeat tests / inspections. It is imperative that a suitably equipped workshop is available in order to carry out maintenance work. – The inspection and maintenance schedule given at the end of these operating instructions defines precisely who is required / permitted to carry out what work. Jobs listed as daily / weekly work may be carried out by the machine's driver or maintenance personnel when they have received appropriate instruction. The remaining work may only be carried out by specialist personnel with appropriate training. – Replacement parts must correspond to the technical requirements determined by the manufacturer. Original replacement parts are always guaranteed to me et these criteria. – Always wear safe work clothes when carrying out maintenance work. Avoid the wearing of rings, wrist watches, ties, scarves, open jackets, baggy clothing etc... There is a risk of injury from, for example, getting caught up or being drawn in. Protective goggles, safety helmets, safety shoes and g loves, reflective vests and ear protection etc. are required for specific jobs.

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– Do not remain in direct proximity of the diesel engine while the diesel engine is running. Persons with pacemakers should not approach within 20 cm of the running diesel engine. Do not touch voltage-carrying parts on the electrical connection of the individual solenoid injection pumps (Unit Pumps UP) while the diesel engine is running. – Do not permit unauthorised persons to approach the machine during maintenance work. – Cordon off a wide maintenance area if required. – Inform operational personnel before starting to carry out any special work and repair work. Designate persons in charge of supervision. – In the absence of any other information in the operating instructions, carry out all maintenance work on the machine on level, firm ground with the working equipment set aside and the engine switched off. – For some machines, the only one position which enables a secured access to every maintenance locations on the uppercarriage, is when the uppercarriage is aligned with the undercarriage so that the sprockets locate at the back-end. The ladder situated on the undercarriage only corresponds with the uppercarriage’s access when the excavator is in this configuration. – Pull out the ignition key and shut off the main battery switch. – Always tighten any loose screw connections during maintenance and repair work. – The mounting bolts of the main components, of the hydraulic hoses and of the counterweight must be replaced after every removal. – If safety devices have to be dismantled during set-up, maintenance and repair work, they must be immediately reinstalled and checked at the end of the work. – When carrying out repair work, particularly when working under the machine, hang a “Do not start” warning sign in a clearly visible position on the control panel. Pull out the start key and shut off the main battery switch. – Operate combustion motors and fuel operated heaters only in well ventilated areas. Before operating these units, check ventilation. – In addition, always follow applicable local regulations.

Cleaning – Clean oil, fuel or care products off the machine before starting maintenance or repair work and pay particular attention to connections and screw fittings. Do not use aggressive cleaning products and use lint-free cleaning cloths. – Do not use aggressive cleaning products or steam jet devices to clean the machine for the first two months after initial set-up of the machine (or after repainting). – Do not use combustible liquids to clean the machine. – Before cleaning the machine with water or steam jets (high pressure cleaner) or other cleaning materials: • lubricate all bearing points, bolt connections and the rim bearing to prevent water or steam entering the bearing points. • cover or glue shut all openings into which for safety or functional reasons water or steam may not be permitted to enter. Electric motors, electrical components, control boxes, plug connections and air filters are particularly at risk.

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– Ensure that the fire warning systems and fire extinguishers of the engine compartment’s temperature sensor do not come into contact with hot cleaning products during cleaning work. The fire extinguisher could start.


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Safety instructions

Operating manual

Safety Instructions

– If you use a high pressure cleaner with steam or hot water to clean the machine, observe following recommendations : • the distance between the nozzle and the surface to be cleaned must be no lower than 20 inches • the water temperature should not exceed 60°c (140°F) • limit the water pressure to 80 bar maximum (11500 PSI) • if you employ cleaning fluid, only use neutral cleaning agents such as customary car shampoos diluted to 2 or 3 percent maximum – After cleaning: • remove all covers completely. • check all fuel, engine oil and hydraulic lines for leakage, loosened connections, chafing and damage. • rectify any defects found immediately. • lubricate all bearing points, bolt connections and the rim bearing to displace any water or cleaning products that may have entered.

Field of view – Mirrors and cameras, which were possibly removed for the transport, must be inevitably reinstalled and correctly adjusted before the initial set-up of the machine. – Regularly check that the interior and exterior mirrors as well as the cameras are correctly adjusted. – Control the surroundings, and particularly the nearness area of the machine, during operation or when travelling. – Mirrors are installed on the machine: • on the left to check the left side of the machine. • on the front to check the front side of the machine. • on the right to check the right side of the machine. • above the counterweight to check the rear side of the machine. – On some machines, some mirrors may be replaced with cameras. – At each extension, construction or change on the machine, the sight conditions must be maintained. These conditions must otherwise be checked according to ISO 5006. – Mirrors must be cleaned at least at daily intervals. – Damaged mirrors and cameras must be immediately replaced. – The site has to be organised so that the d angers due to a restricte d field of view are minimized, particularly for machines with an operating weight which is superior to 40 tons.

Crack t esting – Even when the machine is operated carefully, there is a possibility of individual cases of overloading occurring, which could lead to cracks or loose connections. The machine should therefore be checked regularly for cracks, loose connections or other visible damage to maintain operational safety. – In order to be able to check for cracks, it is essential that the machine is kept clean and cleaned regularly. – The tests should be carried out in accordance with the monitoring and maintenance plan: • every 250 operating hours by the machine owner’s maintenance personnel. • every 500 operating hours by authorised specialist personnel. – It is advisable to carry out these tests: supported, on firm, horizontal substrate, with the equipment in longitudinal and cross direction for variable loads. Current accident prevention regulations must be adhered to.

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– Especially check the supporting components, in particular : • framed construction undercarriage with axle and gearbox storage, support outriger, lower slewing ring support with tower and slewing ring. • framed construction uppercarriage with bearing for boom and hoist cylinder, upper slewing ring support, cab suspension, mounting fo r slewing gear and counter weight. • framed construction components of attachments, e.g. boom, stick, quick change adapter, digging tool and grapple. • hydraulic cylinders, axles, steering, pins and pin connections, ascents, ladders and mounting elements. – The crack test should be carried out visually. If a crack is suspected, the dye penetration test should be carried out as a crack test on areas which do not have good visibility, such as the ring bearing support, in order to increase testing safety. – Any damage found must be rectified immediately. Welding work on load -bearing parts of the earth-moving machinery, loading devices and transport devices may only be carried out by trained specialist personnel and only in accordance with the accepted rules of welding engineering. In case of doubt, contact the LIEBHERR customer support service to discuss suitable remedies.

Welding, drilling, firing and grinding work – Any welding on structural parts (as undercarriage, uppercarriage, equipment parts,…) may only be done the manufacturer, or authorized official dealer. If this rule is neglected, the warranty is voided. – Only carry out welding, drilling, firing and grinding work on the machine with express authorization. Clean dust and combustible materials off the machine and its surrounding areas before welding, drilling, firing or grinding. Ensure adequate ventilation. Risk of fire or explosion. – Before welding repairs on other parts, always disconnect the battery. Always remove the negative terminal first and reconnect it last. – Nevertheless if welding repair should be done on components which may contain inflammable gases (welded counterweight, hydraulic tank, fuel tank, …), these components must be previously and sufficiently ventilated with pressurized air to avoid all fire or explosion hazard – Before welding, connect the ground cable as close as possible to the welding point, so the welding current will not run through the swing ring, joints, gears, bushings, rubber parts and seals

Process materials – When working with oils, greases and other chemical substances, observe the appropriate current safety regulations for the product. – Ensure that process materials and replacement parts are disposed of in a safe and environmentally acceptable manner. – Take care when handling hot process materials (Risk of burning and scalding).

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Repair work – Do not attempt to lift heavy parts. Use devices which are suitable for this purpose and which have sufficient load capacity. When replacing single parts and larger subassemblies, carefully secure them on lifting devices them so that they do not present a risk. Only use suitable and correctly functioning lifting de vices and load take-up devices with adequate load capacity. Do not stand or work under swinging loads.


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Safety instructions

Operating manual

Safety Instructions

– Do not use lifting devices which are damaged or do not have sufficient load carrying capacity. Wear work gloves when working with wire cables. – Authorize only experienced people to attach load and to give indications to the crane operator. This people must be in the operator’s sight or in radio contact with him. – When working above body height, use safe climbing devices and working platforms which are appropriate for the job. Do not use machine parts as climbing devices if they are not designed for this purpose. When working at height, wear a harness to prevent falling. Ensure that all grips, steps, rails, platforms and ladders are free of dirt, snow and ice. – Pneumatic cylinders do not have to be used as handles. Open doors and covers carefully, so that pneumatic cylinders do not hit their stops, because this could cause mechanical damages. – Make sure the equipment on which you will operate is securely supported before working (e.g. replacing teeth). Prevent metal touching metal when doing this. – For safety reasons, never open and remove a track chain unless having previously totally released the pretension of the chain tensioning unit. – Never lay under the machine if it is raised with work equipment and has not been securely supported with appropriate supports. – Always jack the machine up in such a way that any weight displacement does not jeopardize stability and prevent metal touching metal while doing this. – Work on the suspension, brake and steering systems may only be carried out by trained specialist personnel. – If the machine has to be repaired on a slope, secure the crawler with chocks and connect the upper structure to the chassis using stop bolts. – Only personnel with special training and experience may work on hydraulic equipment. – When searching for leakage, wear protective gloves. A fine jet of liquid under pressure can penetrate the skin. – Do not unscrew any lines or connections before you have set aside the equipment, switched off the engine and depressurized the hydraulic system. After switching off the engine, with the start key in contact position and with the safety lever down into its lowest position, you must operate all pilot control devices (joystick and pedals) in all directions in order to reduce the actuating and dynamic pressures in the work circuits. You must then reduce the internal tank pressure as described in these operating instructions.

Electri cal system – Check the electrical system regularly. Have all faults, such as loose connections, blown fuses and lamps and clogged or abraded cables rectified by personnel. – Only use original fuses with approved current strength. – For machines with electrical neutral and high tension leads: • switch the machine off immediately in the event of malfunctions in the power supply. – Work on the machine’s electrical equipment may only be carried out by skilled electrical personnel or by trained personnel under the supervision of an electrician in accordance with electrical regulations.

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– When working on live parts, ensure that a second person is available t o operate the emergency-off or the main switch and overvoltage release. Cordon off the working area with a red and white safety chain and a warning sign. Only use insulated tools. – When working on neutral and high tension subassemblies, after releasing the voltage, briefly disconnect the supply cable at earth and electronic devices such as capacitors using an earthing rod. – First test the released parts to make sure that they are off circuit, earth them and then disconnect them briefly. Insulate adjacent live parts. – Disconnect the battery before working on the electrical system or carrying out any electric arc welding on the machine. First disconnect the negative, then the positive pole. When reconnecting, proceed in the reverse order.

Hydraulic accumulator – All work on the hydraulic accumulators must be carried out by trained specialist personnel. – Inexpert assembly and handling of hydraulic accumulators can cause serious accidents. – Do not operate damaged hydraulic accumulators. – Before working on a hydraulic accumulator, you must reduce the pressure in the hydraulic system (hydraulic system including hydraulic tank), as described in th ese operating instructions. – Do not carry out welding or soldering or do any mechanical work on the hydraulic accumulator. The hydraulic accumulator can be damaged by heat penetration and can be made to rupture by mechanical working. RISK OF EXPLOSION! – Only charge the hydraulic accumulator with nitrogen. There is a RISK OF EXPLOSION if oxygen or air is used. – The accumulator body can become hot during operation; there is a risk of burning. – New hydraulic accumulators must be charged with the pressure required for the purpose of use before installation. – The operating data (minimum and maximum pressure) are marked permanently on hydraulic accumulators. Ensure that this marking remains visible.

Hydraulic lin es and hos es. – It is forbidden to carry out repair work on hydraulic lines and hoses! – All lines, hoses and bolt connections must be checked regularly for externally visible damage and any possible damage must be immediately checked for leakage. – Never check for leaks with your bare hands, use a sheet of paper or something else.

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– Any damaged parts must be removed immediately! Spurting oil can lead to injury and burns.


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Operating manual

Signs on the machine

– Even with correct storage and perm itted load, lines and hoses are subject to the natural aging process. This restricts their duration of use. • Incorrect storage, mechanical damage and unauthorized load are the most common causes of failure. • In relation to duration of use, current norms, regulations and guidelines pertaining to lines and hoses at place of use must be adhered to. • Use at the limit range of permissible load can shorten duration of use (e.g. high temperatures, frequent movement cycles, extremely high pulse frequencies, multiple shift usage). – Lines and hoses should be replaced if the following are found during inspection: • Damage to the outer sheath as far as the liner (e.g. chafing, cuts and cracks); • Brittleness of the outer sheath (fracture formation in hose material); • Deformations which do not correspond to the natural form of the line or hose, whether in a unpressurized or pressurized state or on bends e.g. sheath separation, blistering; • Unsealed areas; • Non-adherence to requirements during installation; • Damage or deformations to the hose fittings which reduce the tightness of the fittings or the hose / fitting connection; • Hoses working themselves out of the fittings; • Corrosion of the fittings which reduces function and tightness; – When replacing lines and hoses, use only original replacement parts. – Install and mount lines and hoses correctly. Do not mix up the connections. – The following is to be noted when replacing lines and hoses: • Always ensure that the lines and hoses are installed free of torsion. For highpressure hoses, the screws from the half-clamps or full flange must always be attached to both hose ends and should only be tightened afterwards. • When tightening the flange on high-pressure lines and hoses with bent fittings, the side with the bent fitting must always be tightened first and then the side with the straight fitting tightened afterwards. • Any mounting clamps which are located in the centre of the hose may only be attached and tightened subsequently. • Check daily to ensure that all clamps, covers and protective devices are properly fastened. Doing this will prevent vibration and damage during operation. • Install the lines and hoses in such a way that they cannot chafe on other lines, hoses or parts. • A minimum distance from other parts of approx. half the exterior diameter of the hose is recommended. The distance should not, however, be less than 10 to 15 mm. • When replacing the lines or hoses on moving parts (e.g. from the boom to the stay), check before initial start-up that there are no chafing areas in the entire area of movement.

2.4 Signs on the machine 2.4.1

In tr od uc ti on The excavator comprises several types of signs: – the safety plates provide warnings relating to dangers of accidents which could result in serious injury or death. – the information plates indicate specific points relating to the operation, maintenance and characteristics of the machine.

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Safety instructions Signs on the machine

– the n ameplates are attached to components for which the machine serial number must be provided when ordering spare parts. Danger! Non-observance of safety plates can result in serious injury or death.  Check warning plates regularly to ensure that they are complete and clearly le-

gible.  Replace missing or illegible safety and information plates immediat ely. You will

find the ordering numbers of these plates in the spare parts book of the excavator.

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Operating manual


2.4.2

Arrangement of signs

Fig. 2-1

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Arrangement of signs on uppercarriage

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Fig. 2-2

Arrangement of signs on PowerPack


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Operating manual


2.4.3

1

Typeplate Liebherr France "CE"

65

Crush hazard label

2

Typeplate Liebherr America

70

Maximum charge label

3

Typeplate Liebherr France

75

Ladder manual unlock label

10

Danger signal label

76

Ladder accu. depressurization

15

Banning label

80

Crush hazard label

20

Emergency ladder label

90

Filling volumes label

25

Emergency stop label

91

Lubricating chart label

30

Explosion hazard label

94

Control symbols label (backhoe)

35

Emergency exit label

95

Control symbols label (shovel)

40

Rotation blade hazard label

96

Safety lever label

45

Hydraulic valve position label

97

Safety belt label

50

Hydraulic tank pressure label

98

Hydraulic tank shut-off valve label

55

Oil injection hazard label

99

External starting label

60

Burn hazard label

100

Instruction manual warning label

Meaning of the signs Plate 1: Typeplate LFR (Liebherr France) "CE"

This typeplate displays the following information: – Product identification number – Type – Construction year – Nominal engine power – Max. speed – Operating mass* Plate 2: Nameplate LAM (Liebherr Am erica)

This nameplate displays the following information: – Type – Product identification number Plate 3: Typeplate LFR (Liebherr France)

This typeplate displays the following information: – Product identification number – Type – Construction year 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

– Nominal engine power – Max. speed – Operating mass*

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Plate 10: Danger signal label

Indicates to stay out of the surrounding operating area in order to avoid severe injury.

Plate 15: Bannin g label

Indicates that the concerned element may only be opened when the engine is switched off.

Plate 20: Emergency ladder label

Indicates the emergency ladder.

Plate 25: Emergency st op label

Indicates an emergency stop.

Plate 30: Explosi on hazard label

Indicates explosion risk and gives associated safety instructions.

Plate 35: Emergency exit label

Indicates the direction of an emergency exit.

Plate 40: Rotation blade hazard label

Indicates risks due to rotating blades and gives associated safety instructions. 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L


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Operating manual


Plate 45: Hydraulic valve posi tion l abel

Indicates how to open and close the hydraulic valve.

Plate 50: Hydraulic tank pressure ON/OFF label

Indicates how to switch hydraulic tank pressure on and off.

Plate 55: Oil in jection hazard label

Indicates risks due to oil discharge and gives associated safety instructions.

Plate 60: Burn hazard label

Indicates risks due to hot surfaces and gives associated safety instructions.

Plate 65: Crush hazard label

Indicates risks due to moving railings and gives associated safety instructions.

Plate 70: Maximum charge label

Indicates the maximum allowable charge on the access ladder. 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

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Plate 75: Ladder manual un lock label

Indicates how to manually unlock the access ladder.

Plate 76: Ladder accumulator depressurization

Indicates how to depressurize the acces ladder accumulator.

Plate 80: Crush hazard label

Indicates risks due to belts and gives associated safety instructions.

Plate 90: Filling volum es label

Indicates volume of lubricant and operation fluids to fill via the service trap.

Plate 91: Lubri cating c hart label

Indicates the different fluid change and analysis intervals to observe.

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Plate 94: Control sy mbol s label (backhoe attachment)

Indicates the functions associated with the control units.


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Operating manual


Plate 95: Control sym bols l abel (shovel attachment)

Indicates the functions associated with the control units.

Plate 96: Safety lever label

Indicates precaution to be taken before leaving the driver seat.

Plate 97: Safety belt label

Indicates to always seat belt while operating the excavator.

Plate 98: Hydraulic tank sh ut-off valves label

Indicates precaution to be taken before starting the excavator.

Plate 99: External s tarting label

Indicates precautions to be taken before removing starting cables.

Plate 100: Instru ction manual warning label

Indicates that informations in the operating instructions must be carefully noted.

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Plate 101: Lashing p oint label

Indicates the location of lashing points on the excavator.

Plate 102: Stop-lif t po int label

Indicates the location of stop-lift points on the excavator.

* Estimated mass of the machine in its standard version (without optional eq uipment) according to its configuration: Diesel, electric, backhoe, shovel or pontoon.

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Safety instructions

Operating manual


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3 Control and operation 3.1 Operating and control elements 3.1.1

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Overview of the control cab

Fig. 3-1

Control cab

8

Heater vent

S6

Switch / float position attachment

15

Control board

S7

Safety lever

A2

Radio

S100_1 Emergency stop

E14

Cigarette lighter

U13

E52

Control board for safety operation U15

Display for monitoring cameras Greasing module


MJFCIFSS

3-1

Control and operation

Operating manual

Operating and control elements

H1

Monitoring display

U20

Shovel flap pedal

H9

Buzzer

U21

Left joystick

P5

Hourmeter

U22

Right joystick

S1

Ignition key

U23

Right travel pedal

S2

Control keyboard

U24

Left travel pedal

S5

Switch / horn

U103_1 AC / heater control unit

Fig. 3-2

Standing position from operator’s point of view

E14

Cigarette lighter

S5

Switch / horn

H1

Monitoring screen

S6

Switch / float position attachment

S1

Ignition switch

U21

Left joystick

S2

Control keyboard

U22

Right joystick

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Operating manual

Control and operation Operating and control elements

3.1.2

Arrangement of joystick

Fig. 3-3

Joystick, right (3) and left (4)

Standard control

The left joystick (4) controls the stick and slewing movements. – Direction of movement a and b : Stick is drawn in or out. – Direction of movement c and d : Uppercarriage is rotated to the left or to the right. The right joystick (3) controls the boom or bucket and grab movements. – Direction of movement e and f : Bucket will be tilted up or down, grab will close or open. – Direction of movement g and h : Boom will be raised or lowered. Note ! From delivery, the machine is equipped with the standard control system correponding to the norm ISO. Nevertheless, the machine can be equipped with a commutation circuit allowing the use of a special control system (for example LIEBHERR control system).

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3.1.3

Keyb oar d

Fig. 3-4

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Excavator keyboard

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Operating manual


S10 – Working lig ht / attachment floodlights  Press button.

 Working light on the uppercarriage is activated.  LED 1 in the button illuminates.  Press button again.

 Working light is disabled.  LED 1 in the button goes out.  Attachment floodlights are activated.  LED 2 in the button illuminates.  Press button again.

 Working light and attachment floodlights are activated.  LEDs 1 and 2 in the button illuminate.  Press button again.

 Working light and attachment floodlights are desabled.  LEDs 1 and 2 in the button go out.

S11 – Windshield washer  Press and hold button.

 Washing water will be sprayed onto the windshield through the outlet nozzles.  The windshield washer runs continuously.  Release the button.

 Washing water will be stopped.  Windshield washer will run continuously for approx. another 3 seconds.

S12 – No function

S14 – Windshield wiper  Press button.

 Intermittent setting is activated.  LED I in the button illuminates.  Press button again.

 Continuous operation is activated.  LED C in the button illuminates.  LED I in the button goes out.  Press button again.

 Windshield wiper is switched off.  LED C in the button goes out.

In addition, the break time for the intermittent setting can be adjusted:  Select the intermittent setting and keep the button depressed.

 After a few seconds, LED I in the button will start blinking rapidly.

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 Release the button when the blinking duration has reached the desired break ti-

me. Adjustment is possible between 2 and 9 seconds.


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S17 – Swing brake  Press button.

 Swing brake is engaged.  Uppercarriage is locked.  LED in the button illuminates.  Press button again.

 Swing brake is released.  LED in the button goes out.

S18 – Overload warning device (optional)  Press button.

 Overload warning device is activated.  LED in the button illuminates.  Press button again.

 Overload warning device is disabled.  LED in the button goes out.  No overload warning device is built in.  Press button.

 The symbol for "No overload warning device is present" appears on the moni-

toring screen.

 LED in the button illuminates.  Press button again.

 The symbol for "No overload warning device is present" goes out.  LED in the button goes out.

S19 – No function

S20 – Automatic idling  Press button.

 Automatic idling is activated.  LED in the button illuminates.  Press button again.

 Automatic idling is deactivated.  LED in the button goes out.

S21 – High speed gear  Press button.

 Transfer from normal drive to fast drive is activated.  LED 1 in the button illuminates.

While driving, the machine will automatically transfer from normal drive to fast drive. LED 2 illuminates after transfer to fast drive.  Press button again.

 Transfer from normal drive to fast drive is disabled.  LED 1 in the button goes out.

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Operating manual


S22 – Counterweight f loodlights  Press button.

 Counterweight floodlights are activated.  LED in the button illuminates.  Press button again.

 Counterweight floodlights are disabled.  LED in the button goes out.

S36 – Special function 1 (optional)

Configuration and activation according to kit. S41 – Dome light  Press button.

 The interior lights are activated.  Press button again.

 The interior lights are disabled.

S56 – No function

S86 – Mode selection, speed adjustment

Three different modes can be selected by pressing the switch. The currently active mode will be displayed under the letter on the LED. – L : LIFT mode (speed level 5) – F: not used – E: ECO mode (speed level 8) – P: POWER mode (speed level 10) P4 – Engine RPM display

The speed range of the diesel engine is displayed in 10 levels. S228 – Engine RPM increase  Press button.

 Speed will be increased by one level.  A second LED to the right illuminates in engine RPM display.

S229 – Engin e RPM decrease  Press button.

 Speed will be decreased by one level.  A second LED from the right goes out in engine RPM display.

S354 – Travel b rake 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

 Press button.

 Travel brake is engaged.  Undercarriage is locked.  LED in the button illuminates.  Press button again.

 Travel brake is disabled.  Undercarriage is unlocked.  LED in the button goes out.


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Operating manual


3.1.4

Co nt ro l bo ar d

Fig. 3-5

Control board

Standard functions

Quantum engine monitoring system

S100_1 Emergency stop

H60

S122 Disable ladder or trap control lock H61 H38

Greasing system alarm

H62

Quantum STOP indicator Quantum WARNING indicator Quantum PROTECTION indicator

S82_1 Diagnostic increment H81

Hydraulic valve closed

S82_2 Diagnostic decrement

H91

Power reduced

S85

H92

Fire alarm

H94

Fuel valve closed

S149 Ether control (cold starting aid)

Quantum monitoring ON/OFF

Safety operation engin e S23

Engine safety operation ON Engine RPM adjustment

P4

Engine RPM indicator

R6

P8

Service batteries voltmeter

S178 Engine stop after running

P9

Principal batteries voltmeter

H6

Clock

H93

Safety operation hydraulic pumps

Water in fuel indicator

S73

POWER pump control

S74

FLOW pump control

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Operating manual


S126 Additional cabin lighting Optional functions H103 Preheating indicator S12-1 Side wiper S12-2 Back wiper S26

Dual air conditioning

Disable ladder or trap control lock  For further information about correct use of this function, refer to § "Access lad-

der" in section "Entering or leaving the cab" of this manual.

Quantum engine monitoring system If an indicator H60, H61 or H62 goes on during operation, test switches S82_1 and S82_2 will allow the engine maintenance mechanics to ask system to indicate the registrated default by giving a coded message via the control light.  For further information, see Cummins Quantum Operation Manual.

Safety operation funct ions  For further information about correct use of these functions, refer to section

"Emergency operations" of this manual.

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3.1.5

Monitoring display

Fig. 3-6

Monitoring display

A

Analog indicator

H24

No function

B

Check display

P2

Coolant temperature display

C

Main screen

P2.1 Coolant temperature display red area

D

Menu control, screen

P3

H2

Indicator light, engine oil pressure P3.1 Fuel level display red area

H12

Indicator light, battery

S349 Back button

H19

No function

S350 Down button

H20

No function

S351 Up button

H23

No function

S352 Menu button

Fuel level display

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Operating manual


Ar ea A: Diesel eng in e mon it or in g P2 – D iesel engine coo lant temperature disp lay

The display must be in the green area when operating the machine. In the event of overheating (over 98 ºC = 204°F), the red LEDs P2.1 at the end of indicator P2 will flash. The buzzer in the cab also sounds. When this Indicator light illuminates, the error will be saved as error code E 503.  The red indicator protection H62 on the control board will light up.  The Quantum system will cause an engine shutdown.  Find and rectify the cause of the problem.

P3 – Fuel level display

The LED indicator lights show the fuel level. When the both red light P3.1 light up, about 10% to 20% fuel are left in the tank as reserves.

Ar ea B :Ind ic ator li ght s H2 – I ndicator light, low engine oil pressure

The Indicator light illuminates if the engine oil pressure drops below a given value when the machine is operating. The buzzer in the cab also sounds. When this Indicator light illuminates, the error will be saved as error code E 501.  The red indicator protection H62 on the control board will light up.  The Quantum system will cause an engine shutdown.  Find and rectify the cause of the problem.

H12 – I ndicator light, battery charge

The Indicator light illuminates if the ignition key is placed in the contact position. The Indicator light goes out as soon as the engine is started. When the machine is operating, this Indicator light illuminates if the V-belt alternators or the electrical charging system are defective.  Bring the engine to a low idle immediately.  Allow the engine to idle for approximately 5 seconds.  Switch off the engine.  Rectify the error. 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

H19 – No function

H20 – N o function

H23 – No function


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Operating manual


H24 – No function

Ar ea D: Menu co nt rol for scr een

Fig. 3-7

Screen menu control

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

These buttons can be used to jump from the operator’s menu to the submenus or to move from page to page.

Ar ea C: Sc reen To change the screen contrast:  Press button Menu and arrow button Up (higher contrast) or Down (lower con-

trast) simultaneously.  The value set will be saved. To alter the brigh tness of the main screen:  Press button Back and arrow button Up (brighter) or Down (darker) simulta-

neously.  The value set will be saved. Note! A light sensor built in to the top left of the monitoring screen controls the illumination on the main screen, dependent on the brightness of the environment. Tracking is carried out using the buttons and originating from the basic setting. Illumination will be automatically reduced in conditions of low environmental brightness. To change the brightness and the contrast setting to the works setting:  Turn off the ignition.  Press and hold the Up and Down buttons simultaneously.  Turn on the ignition again.  Release the buttons once the automatic check is completed.

3.1.6

Mai n sc reen The main screen appears when the machine has been switched on and remains on display until the screen is changed over to the menu selection screen using the Menu button.

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Operating manual


Fig. 3-8

Main screen

EC

Cable error display

SY

Symbols

INF

Information

TI

Time

Main screen design SY field The uper field of the monitor shows, on the one hand warnin g and indicator symbols, on the other hand a clock, if no more than 4 warning symbols are shown. Should more than two symbols be shown, so the clock is no more displayed and up to four symbols can be diplayed simultaneously in the field SY. If more than 4 symbols must be displayed, the symbols will be shift to the left by one symbol every 10 seconds (see section "Warning symbols in the SY field" further in this chapter).

EC field The EC window displays the error codes for electrical faults which occur in the excavator's electronics system (line errors, sensor errors etc.). A maximum of 7 error codes are displayed simultaneously. If there are more than these 7 errors present, an arrow which points to where the other error codes are located will be displayed next to the error code window.  Press the Up or Down button.

 The error code window will be shifted in the direction selected in the error code

list.

INF field The INF field displays information temporarily, in both text and graphic form. If more than 3 symbols are to be displayed, the symbols will shift one symbol to the left approx. every 10 seconds.

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The information is displayed in graphic or text form and indicates specific operating states on the machine. (see section "Information symbols in the INF field" further in this chapter).

TI field The machine operating hours and the daily operating hours counter are displayed bottom right in this field. The ® symbol indicates that a quantity limitation is active for the pumps (see section


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Operating manual


"Status of hydraulic pumps and electrical inputs and outputs menu" further in this chapter).

Menu navigation i n the event of an error d ispl ay If an error is recognized as “new” in the SY field, the user is returned to the main screen. The relevant error display is activated. Depending on the error (level of urgency), the buzzer will sound either continuously or in short consecutive bursts. This symbol will be displayed in the INF field. Danger! If the error displayed is not rectified immediately, this could lead to persons sustaining injury or the machine being damaged.  Rectify / have the error rectified immediately.  To switch off the buzzer, press the Back button.

 The error will be acknowledged and stored.

Warning symb ols i n the SY field Each of the symbols which follow will be assigned an error code in the form “X xxx”. Each error which occurs will be stored via the relevant error code. E 495 – Engine start at low coolant temperature

This symbol appears as long as the engine coolant temperature is below a preset value.  Avoid starting the Diesel engine and operating the excavator under these condi-

tions if the excavator doesn’t have an optional preheating system.  If the excavator has an optional preheating system, operate the preheating sys-

tem first until the symbol goes off.  If you start the Diesel engine while the symbol is on, error code E 495 will be

stored. E 501 – Low engine oil pressure

This symbol appears if the engine oil pressure drops below a preset value.  Indicator light H2 lights up and buzzer sounds simultaneously.  The Quantum system will cause an engine shutdown.  Find and rectify the problem.  See also Cummins Operation and Maintenance manual.

E 502 – Coolant low

This symbol appears if the coolant level drops below the minimum level. 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

 The buzzer sounds simultaneously.  Bring the engine to a low idle immediately.  Switch the engine off as quickly as possible.  Localise the leak and carry out repairs.

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Caution!

This monitoring device acts as an increased level of security in case of larger amounts of water loss (eg. hose rupture). It does not relieve the operator or maintenance personnel from the responsibility of regularly checking the coolant level in the equalizing reservoir. 2963 / E 503 – Engine coolant o verheat (low / moderate or high )

This symbol appears simultaneously with the P2 coolant temperature display. E 540 – Engine coolant pressure

This symbol appears simultaneously with the red indicator protection H62 if the coolant pressure is too low.  See Cummins Operation and Maintenance manual.  Locate the reason for the trouble and get it repaired.

E 597 – Manifol d ov erheat

This symbol appears simultaneously with the red indicator protection H62 if the manifold temperature is too high (above 104°C=220°F).  See Cummins Operation Maintenance manual.  Locate the reason for the trouble and get it repaired.

E 506 – Oil in splitterbox is overheating

This symbol appears if the oil temperature in the splitterbox exceeds 85°C (185°F).  Turn the engine off.  Find and correct the problem (splitterbox cooler dirty, ...).

E 562 – Low oil level in splitt erbox

This symbol appears if the oil level drops below the minimum level.  Turn the engine off.  Find and repair a possible leak.  Add oil until the level is correct.

E 564 – High oil level in splitterbox

This symbol appears if the oil level in the splitterbox is above the maximum level.  Turn the engine off.  Find and repair the problem.

It is possible that too much oil has been added, or the oil level might have increased due to hydraulic oil entering via a defective pump shaft seal. E 591 – Splitterbox oil pressure low 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

This symbol appears if the splitterbox oil pressure drops below 0.2 bar.  Stop operation and turn the engine off.  Find and correct the problem.


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Servo pressure low

This symbol appears if the servo pressure drops below 20 bar.  Stop operation and turn the engine off.  Find and correct the problem.

E 504 – Low hydraulic oil level

This symbol appears if the oil level in the hydraulic tank drops below the minimum level. At the same time, the pump are automatically returned to minimum flow.  Turn the engine off.  Find and repair the cause of the oil loss.  Add hydraulic oil via the service flap or via one of the return filters.

Hydraulic oil warm-up procedure on

This symbol appears as long as the warm-up procedure is on, i.e. as long as the hydraulic oil temperature is below a preset value.  During the warm-up procedure, the main pumps displacement is limited to

50% in order to prevent damage to components. E 505 – Hydraulic oil ov erheat

This symbol appears if the hydraulic oil te mperature in the tank exceeds a preset value.  Stop operation.  Continue to let the engine run in high idle and wait until the symbol disappears.

If necessary.  Turn the engine off.  Find and correct the problem (oil cooler dirty, blower or thermostat defective, ...).

Main pumps power reduction on

This symbol appears as long as t he hydraulic oil temperature is in a preset high temperature range.  Main pumps power is reduced progressively as long as the hydraulic oil tem-

perature is in this range.  Main pumps output is set to zero if the hydraulic oil reaches the overheating temperature.  Allow the hydraulic oil to cool down to be able to operate the excavator then cor-

rectly. E 590 – Low hydraulic tank pressure

This symbol appears if the hydraulic tank pressurization drops below 0,15 bar.  Stop operation and turn the engine off.  Find and correct the problem (check the air pressure system).

E 566 - E 567 - E 568 - E 569 – Main pum ps are contaminated

This symbol appears if metallic particles have been deposited on the contamination switch of one of the main pumps (the pump number appears in the top corner of the symbol).  Stop operation and turn the engine off.  Notify the maintenance personnel.

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E 572 - E 573 – Swing pump s are contamin ated

This symbol appears if metallic particles have been deposited on the contamination switch of one of the swing pumps (the pump number appears in the top corner of the symbol).  Stop operation and turn the engine off.  Notify the maintenance personnel.

E 578 - E 579 - E 580 - E 581 – Main pu mps o verheat

This symbol appears if the temperature on one of the main pumps exceeds a preset value (the pump number appears in the top corner of the symbol).  Turn the engine off.  Find and correct the problem.

E 584 - E 585 – Swing pump s overheat

This symbol appears if the temperature on one of the swing pumps exceeds a preset value (the pump number appears in the top corner of the symbol).  Turn the engine off.  Find and correct the problem.

E 592 – Low oi l level in the Centinel System (optional)

This symbol appears if the oil level in the Centinal tank drops below the minimum level.  See Cummins Operation and Maintenance manual.  Fill the Centinel tank as soon as possible.

E 593 – High fuel temperature

This symbol appears simultaneously with the red indicator protection H62 if the fuel temperature is too high (above 104°C=220°F).  See Cummins Operation and Maintenance manual.  Locate the reason for the trouble and get it repaired.

E 594 – High fuel rail pressure

This symbol appears simultaneously with the red indicator protection H62 if the fuel rail pressure exceeds a normal limit.  See Cummins Operation and Maintenance manual.  Locate the reason for the trouble and get it repaired.

E 595 – High blow-by pressure

This symbol appears simultaneously with the red indicator protection H62 if the blowby pressure exceeds a normal limit . 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

 Stop engine.  See Cummins Operation and Maintenance manual.  Locate the reason for the trouble and get it repaired.


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E 596 – Low engine oil level

This symbol appears simultaneously with the red indicator protection H62 if the engine oil level drops below the minimum level.  See Cummins Operation and Maintenance manual.  Full the engine oil tank.

E 598 – Oil change required

This symbol appears simultaneously with the red indicator protection H62 if an engine oil change is required.  Do it as soon as possible.

E 543 – Dual Lifetime sealing oil level low

This symbol appears if the oil level in the Lifetime sealing drops below minimal level.  Stop operation and turn the engine off.  Find and correct the problem.  Add oil until correct level is reached.

E 544 – External swing teeth greasing

This symbol appears if the swing teeth greasing system is defect.  Find and rectify the problem.  See also Lincoln servicing manual.

E 545 – Grease level low

This symbol appears if the grease level drops below minimum level.  The bucket will be blocked.  Stop operation and turn the engine off.  Find and rectify the problem.  Add grease until correct level is reached.  See also Lincoln servicing manual.

D 421 – Engine oil temperature high

This symbol appears if the engine oil reaches high temperature.  The Quantum system will cause engine torque derate.  Stop operation.  Continue to let the engine run in high idle and wait until the symbol disappears.

If necessary.  Turn the engine off. 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

 Find and correct the problem.  See also Cummins Operation and Maintenance manual.

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D 421 – Engine oil overheating

This symbol appears if the engine oil reaches maximum temperature.  The Quantum system will cause engine torque derate.  Stop operation.  Turn the engine off.  Find and correct the problem.  See also Cummins Operation and Maintenance manual.

D 418 – Water in f uel

This symbol appears if what is detected in fuel with moderate quantity.  Turn the engine off.  Drain fuel filters.  See also Cummins Operation and Maintenance manual.

1852 – Water in f uel hi gh l evel

This symbol appears if what is detected in fuel with high quantity.  Turn the engine off.  Drain fuel filters.  Find and correct the problem.  See also Cummins Operation and Maintenance manual.

D 441 – Battery voltage low

This symbol appears if the battery voltage drops below minimum value.  Turn the engine off.  Find and correct the problem.

D 442 – Battery voltage high

This symbol appears if the battery voltage exceeds maximum value.  Turn the engine off.  Find and correct the problem.

D 449 – Rail overpressur e

This symbol appears if the fuel rail pressure exceeds maximum value.  Engine will undergo power and/or speed derate.  Turn the engine off.  Find and correct the problem.  See also Cummins Operation and Maintenance manual.

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1362 – Engine oil f ilter di fferential pressure

This symbol appears if the engine oil filter is defective.  Engine will derate and/or stop.  Turn the engine off.  Find and correct the problem.  See also Cummins Operation and Maintenance manual.


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E 460 – Exhaust gas temperature deviation

This symbol appears if the exhaust gas temperature deviates from normal range.  Turn the engine off.  Find and correct the problem.  See also Cummins Operation and Maintenance manual.

E 464 – Exhaust gas temperature too high

This symbol appears if the exhaust gas exceeds maximum temperature.  Turn the engine off.  Find and correct the problem.  See also Cummins Operation and Maintenance manual.

Error d etected on ECM  See also § "Error code charts".

Information s ymbol s in th e INF field Service due

This symbol appears if a service interval is due.  Switch on the ignition.

 The service interval to be carried out will be displayed for approx. 10 seconds

in place of the overall operating hours. Ac kn ow led ge er ro r

This symbol appears if a machine erro r (E 5x x) has occurred and the buzzer sounds simultaneously.

Gettin g infor mation from t he operator’s menu on the main screen Main sc reen menu selection

Fig. 3-9

Main screen

 To change to the operator’s menu, the main screen must be visible.  Press the Menu button on the main screen.

 The list of accessible menus is displayed.

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Fig. 3-10

Menu selection in the operator’s menu.

To select the operator’s menu:  Press arrow key Down or Up .

 The following or previous operator’s menu will be displayed on screen with a

black background.  The selected menu is displayed with a black backgro und, the Reset daily opera-

ting hours menu is used here as an example.  Press the Menu button again.

 The submenu for the function selected is displayed.  Press the Back button again.

 The submenu will be aborted.

Symbol

Description

Reset daily operating hours counter

Confirm service interval

Select quantity limitation relating to attachments (eg. hammer)

Operating hours and device data

Status of hydraulic pumps and electrical inputs and outputs

Recorded and stored errors

Immobilizer (must be activated by LIEBHERR customer service using a service connector)

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Tab. 3-1 Tab. 3-2

Overview of menu options

Reset daily operating hours count er menu The daily operating hours counter can be reset to 0 using this menu.


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Fig. 3-11

Resetting the daily operating hours counter

To set the daily operating h ours co unter to 0:  Press the Up arrow key.

 The OK which is not crossed out will be displayed with a black background.  Press the Menu* button.

 The operating hours will be reset to 0.  The arrow key symbols Up and Down and the Menu symbol will no longer be

displayed. To exit the menu:  Press the Back button.


Confirm servic e interval menu This menu is used for information on service intervals and to confirm service work which has been carried out.

Fig. 3-12

Service intervals menu

The operating hours of the next service interval (in this example, “500 Hrs”) and the current operating hours (“478 Hrs”) are displayed in the menu. A pending service interval can be confirmed a maximum of 50 operating hours before the service interval is due. When this time period has been reached a query will appear to ask whether the service work has been carried out.  Service work carried out.  Press the Up arrow key.

 The OK which is not crossed out will be displayed with a black background.  Press the Menu button.

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Operating manual


 The current operating hour will be confirmed as the last service interval carr ied

out.  Service work not carried out.  Press the Back button.


Al lo cat io n o f q uanti ty li mi tat io n o pt io ns to ext ern al i nput I1 menu (Kit input; for example, activation of the hammer pedal) Predefined quantity limitations have been assigned in this menu. The arrow opposite the symbol represents the current selection. In the example (see Fig. 3-13), quantity 2 is active if the specified attachment is serviced.

Fig. 3-13

Work equipment quantity limitation menu

 Press the Up or Down arrow key.

 A different, predefined quantity (1-4) can be assigned (e g. when work equip-

ment is changed).  Press the Menu button.

 The selection is confirmed. The arrow displays the current selection.

To exit the menu:  Press the Back button.


Operating hour s menu Pages 1 to 2 provide an overview of the operating hours of individual units, processes and operating types.

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Fig. 3-14

Engine service life menu (example)


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Page 1 provides the service life in hours for: – Diesel engine – Diesel engine in P mode (RPM stage 10) – Diesel engine in E mode (RPM stage 8) – Hydraulic operation – Swing movements – Travel movements – Diesel at low idle

Fig. 3-15

Operating hours menu

 Press the Menu button.

 Page 2 is displayed.

The screen (page 2/3) indicates the operating hours for : – Pontoon operation – Safety operation for pump power control – Safety operation for pump flow control

Fig. 3-16

Technical data

 Press the Menu button again.


The technical data menu, page 3, provides information on : – The excavator type, including type and serial number (type, series) – The design condition of the control which is currently built in (ver) – The current operating voltage (volt)  Press the Menu button again.



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Operating manual



Status of hydraulic pumps and electri cal inputs and outputs menu

Fig. 3-17

Quantum system menu

Page 1 provides information from the Quantum system of the engine.

Fig. 3-18

Quantity limitation menu



This screen gives information about the operating position of the hydraulic pumps. It gives the following indications for each working pumps :  If the flow limitation is activated for the pump. If it occurs, the symbol "R" is dis-

played in the field TI, see main screen. The screen 2/7 shows an example with the flow limitation M1 activated, which limits the pump P2 to 34% of the maximum flow. Should several flow limitations be actuated at the same time, so the one with the smallest flow value has priority.  The graphic bar with electric current value indicates for the pump the amount of

the momentary flow control signal.

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Fig. 3-19

LR magnet menu


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Operating manual




The present LR solenoid current (current value for power control) is showed on screen 3.

Fig. 3-20

Fan speed current values menu



The screen 4 indicates for the fan pumps the amount of the momentary flow control signal.

Fig. 3-21

Electrical inputs

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 Page 5 is displayed.  Press the Menu button again.

 Page 6 is displayed.  Press the Menu button again.


Pages 5, 6 and 7 provide an overview of the status of different electrical inputs.

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Operating manual


A “

” means "Input not active".

A “

”means "Input active".

An “NC” beneath the terminal designation means that the software for the relevant input has been deactivated. The status of the inputs can be changed using the menu "set data" - "set E-code". The screen 5 indicates the status of the inputs for the different movements. The screen 6 indicates the status of the flow limitation. M1, M2, ... correspond to machine specific (internal) oil flow limitations. I1, I2, ... correspond to predefined oil flow limitations (see also menu "set option"). The screen 7 indicates the status other inputs. For the frequency inputs B53 and B12, the signs “ ” means that a significant frequency is recognised by the system B12

Engine RPM sensor

B53

Swing motor sensor

S7

Safety lever servo control

S57

Swing brake



Error menu (operating error s and electri cal system errors)

Fig. 3-22

Recorded errors menu

There are 3 selection options in this menu: – By selecting list Exxx , machine errors recorded by the sensors are listed. – By selecting list E-elec , all main screen cable errors stored when operating are listed. – By selecting list S-Exxx , all errors which appeared when the service connector was connected are listed. To select the desired error type:  Press the Down or Up arrow key.

 The following or preceding error type will be displayed with a black bac-

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kground.  Press the Menu button.

 The submenu on a black background will be displayed.  If more than 6 error codes are present, arrow key Down or Up can be used to

scroll to the next page.


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Machine error li st Exxx:

Fig. 3-23

Error list (Fig. left) and Error occurrence (Fig. right) menu

 Select list Exxx .  Press the Menu button.

 The first page of the submenu appears.

All errors and their error codes are listed on the first page.  Use the Down or Up arrow key to select the error code desired.  Press the Menu button again.

 The second page of the submenu appears.

Operating hours and the duration of the first and last ten occurrences of the error selected will be listed on the second page.  Press the Back button.

 The first page of the submenu appears.  Press the Back button again to select another error type or press the Down or Up

arrow key to select a new error code. s*: Error was indicated by a buzzer and was acknowledged using the Back button. The duration is given in seconds. m*: Error was indicated by a buzzer and was acknowledged using the Back button. The duration is given in minutes. Note! Only operating errors with an error code E 5xx will be displayed in the list Exxx menu. Cable error list E-elec.:

Fig. 3-24

Occurrence of electrical error (Fig. left) and Error statistics (Fig. right)

 Select Cable error list E-elec.:

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Control and operation Operating and control elements  Press the Menu button.

 The submenu appears.

The column "Sum" shows the number of all errors that were ever noted. The column "Test" shows the number of errors occurred since the last deletion of this test error memory listing. The operating hours above the test column show the operating hour when the last test memory was deleted (reset). Press the Back button.  A different error type may be selected.

Other errors list S-Exxx: S-Exxx:

Fig. 3-25

Call up service operation error list menu

Selecting "list S-Exxx" also shows the errors accord ing to the list in pages ( see section "Warning symbols in the SY field" previously in this chapter), but this time only the errors that occurred during "service operation". For each error, an overview can be shown and paged in just like for the "list-Exxx" selection. The column "Sum" shows the number of all errors that were ever noted.

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3.1.7

Monitor onitoring ing came camera ras s

Fig. 3-26

Display for monitoring cameras

1

Field for camera 1 (opposite side)

F1 F1 button (full screen camera 1)

2

Field for camera 2 (counterweight)

F2 F2 button (full screen camera 2) F8 F8 button (return)

System description Monitoring cameras are installed on the excavator as follows in order to extend the operator’s field of view with the operating environment: – camera 1: on the opposite side of the cab, – camera 2: on the counterweight.

Display The inputs from the different cameras are transmitted to the display located on the front right of the cab and divided on the screen as described above (see Fig. 3-26).

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Operating manual


Full screen

Fig. 3-27

Full screen display

The input from one camera can be switched to full screen (with the input from the other camera remaining simultaneously displayed with normal size). To switch a camera camera to full screen:  Press F1.

 Camera 1 is switched to full screen while camera 2 remains displayed with

normal size.  Press F2.

 Camera 2 is switched to full screen while camera 1 remains displayed with

normal size. To switch back to standard display:  Press F8.

 Screen turns back to standard display.

Note! Additional cameras can be installed as optional feature. In this case, the additional inputs will be displayed on the screen on the remaining free fields and full screen display will be possible via corresponding Fx button.

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Operating manual

The access and the outfit of the cab

3.2 The access ccess and and the outfit outfit of the cab cab Safely Safely getting up – Proceed with the the same precautions to climb up or down onto the machine, as to install yourself at the operator’s seat. – When getting up or down, position the machine on even, horizontal ground. The upper structure should be positioned with the undercarriage in such a way that the steps and ladders are aligned with each other. – Ensure that steps, ladders and hand-rails (grips) are in good condition. In particular, you should ensure that they are free of dirt, oil, ice and snow. NOTE: To ensure that the doors open properly in all weather conditions, the door seals must be dusted with talc or silicon at least every two months or more often if required. The door hinges and locks should be greased regularly. – Face the machine when getting in or out and always use three-point support, i.e. two hands and one foot or two feet and one hand must always be in contact with the access system at the same time. – If you are able to reach the door handle with your fr ee hand, open the doors before you climb any higher. External influences, such as wind, can make it more difficult to open doors. Because of this, always use your hand for control when opening doors. Ensure that the door is latched open to prevent it slamming open and shut. – In case of bad weather conditions, be particulary vigilant to realise the climbing and descent from the cab with the best safety conditions, and do or give the instuctions to the execution of prior preparations to be accomplished, as enunciated above, in order to displace yourself safely. – Be particulary vigilant with those prerequisites conditions. – For cab wi th a si de d oo r: • Now continue continue to climb up, still still using using the three-point three-point support support and sit down in the operator’s seat as soon as you enter the cab. • Fasten the safety safety belt (if available), available), unlock the door, door, using the planned lever, lever, and close it immediately using the door handle, before tilting down the safety lever, and start the machine. • If you wish to work work with the door open, open, it is necessary necessary to fasten fasten your safety safety belt. If unavailable, let it be instaled before working with the door open.

– For cab with a rear door: • Now continue continue to climb up, still still using the three-point three-point support support and close the door as soon as you enter the cab. • Sit down in the operator’s operator’s seat and fasten fasten the safety belt (if available) available) before before tilting down the safety lever, and start the machine.

Safely Safely getting d own – Proceed with the the same precautions to climb up or down onto the machine, as to instal yourself. – Stop the machine on level, horizontal ground. The upper structure should be positioned with the undercarriage in such a way that the steps and ladders are aligned with each other. – Open and lock the door. Be Be sure of it’s locking. Take care of weather conditions ! Unfasten the safety belt.

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Operating manual

Control and operation The access and the outfit of the cab

– Position yourself with your face toward the machine when getting out and use three-point support, i.e. two hands and one foot or two feet and one hand must always be in contact with the access system at the same time. Climb down until you can close the doors safely. Always use your hand for control when closing the doors. Lock the door. – Now climb down to the ground.

3.2.1

Entering ntering or lea leaving the cab cab Climbing up Caution! Entering or leaving the cab incorrectly could lead to injury.  Proceed with the same attention on exit or entry of the cab, as while climbing the

machine.  Ensure that the safety lever is always in its highest position when entering or lea-

ving the cab.  Always use the handholds provided for the purpose when when entering or leaving the

machine.  Face the machine when getting in or out and always use three-point support, i.e.

two hands and one foot or two feet and one hand must always be in contact with the access system at the same time.  Never use the control elements as handles.  Never jump from the machine.

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Fig. 3-28 Access ladder

Getting Getting in If the access ladder is in its lowest position and the excavator isn’t running, you can climb up on the machine.  Climb in with the access ladders and with your face towards the ladders and use

the provided handholds.  On the cabin catwalk, open the door.  Go in the cabin and sit in the operator’s seat  Adjust the seat if necessary.

Gettin Gettin g out  Switch off the machine and push the safety lever up.

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Operating manual

Control and operation The access and the outfit of the cab  Open the door fully.  Go out of the cabin on the cabin catwalk.  Close the door.  Go down with your face towards the ladders, and use t he appropriate handholds.

Ac ces s lad der

Fig. 3-29

E1022-1 Access ladder control box

H67

Control light red / ladder not up

S155 Push-button / access ladder up

H68

Not used

S156 Not used

S125 Switch / lighting of cab access

S157 Not used

S141 Switch / lighting of main ladder

S158 Push-button / access ladder down

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Operating manual


Fi g. 3-30

S122 on control board

The access ladder can be brought either to lower position to permit access to the uppercarriage or to upper position during operation. Before operating the machine, the ladder must be fully raised to the uppercarriage and locked in place. The ladder can be extended and retracted from the uppercarriage via the co ntrol box E1022-1, which is installed on the catwalk next to upper ladder section leading to the cab. Danger! Never actuate the ladder if you or a third person are on or in immediate proximity of the ladder. To bring the ladder into l ower position:  Push the switch S158 to swing the ladder until it has reached t he lowest position.

To bring the ladder into upper position (working position):  Push the switch S155 until the ladder has reached its top position.

 When the top position is reached, the ladder is locked and control light H67

goes out. Caution! For safety reason, the excavator can only be operated if the ladder is locked in its top position. Otherwise, the red indicator light goes on. This means that the swing and travel movements remain locked.

This safety measure can be momentarily by-passed by pushing and holding the button S122 on the control board. Note! The ladder can only be swung up with the Diesel engine running.

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Operating manual


To bring the ladder into lower posit ion in case of emergency:

In case of defect (service batteries out of order, defective solenoid valve or wiring...) avoiding the regular lowering procedure of the ladder,  Open valves V1 and V2 to lower the ladder.

3.2.2

Safety lever

Fig. 3-31

Safety lever

For safety purposes, the left control panel is provided with a safety lever. Caution! The safety lever must always be pushed up into its highest position (see arrow) when entering or exiting the cab.

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When the safety lever is pushed up, the pilot control circuit is disconnected. This means that: – No work movements can be carried out when pilot control devices, e g. the joystick or foot pedals, are operated. – The slewing gear brake is locked (LED in switch S17 illuminates). – It is not possible to release the slewing gear brake using switch S17. When the safety lever is pushed (push up / push down) to its lowest position, the slewing gear brake and the LED in switch S17 will return to their original states and


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Operating manual


the pilot control devices will be active.  Before the operator starts working, he must push the safety lever down into its

lowest position while seated in the operator’s seat.

3.2.3

Operator’s seat

Fig. 3-32

Standard operator’ seat

1

Set horizontal, upper

4a Set seat inclination, front

7

Set lumbar support

2

Set horizontal, lower

4b Set seat inclination, rear

8

Seat heating

3 Adjust armrests

6

Set lumbar support

10 Set backrest

The operator’s seat should be set up before starting the machine; this means that: – The diesel engine may not be started. – The safety lever must be pushed up. This will avoid unexpected movement of the machine.

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Settin g t he armrests

Fig. 3-33

Setting the armrests

 Turn the knurled head screw 3 on the armrest in direction a.

 The armrests incline upwards.  Turn the knurled head screw 3 on the armrest in direction b .

 The armrests incline downwards.

Settin g t he seat and backrest

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Fig. 3-34

Setting the seat and backrest

 Rear seat inclination: Pull lever 4a up, set the inclination and release the lever.  Front seat inclination: Pull lever 4b up, set the inclination and release the lever.  Backrest: Pull lever 10 up, set the inclination and release the lever.


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Operating manual


Settin g the horizontal seat posi tion

Fig. 3-35

Setting the horizontal

 Pull up the lever 1 to push the operator's seat in the horizontal direction.  Pull up the lever 2 to push the operator's seat and control panels in the horizontal

direction.

Settin g the vibr ation damping and lumbar suppor t, switchin g on the seat heating (air-cushio ned operator’s seat, option al extras)

Fig. 3-36

Switch bar on the air-cushioned operator’s seat

To set the vibration damping:  Press button 5 (+ or -) and set the vibration system according to body weight.

To set the lumbar support:  Press button 6 (+ or -) to inflate or deflate the lower lumbar chamber.  Press button 7 (+ or -) to inflate or deflate the upper lumbar chamber.

To set the seat heating:  Use switch 8 to switch the seat heating on or off.

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

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Operating manual


Putting o n / releasing the safety belt

Fig. 3-37

Safety belt

The safety belt is automatic. It is not necessary to adjust the length of the belt.  Pull the belt and buckle 2 out of the roller mount 1.

 If pulled out of the roller mount sharply, the belt may lock.  Push the buckle into the belt lock 3 until it fastens.

Danger! The safety belt is designed to protect the operator.  Before starting the machine, always fasten the safety belt.  Ensure that the safety belt is not twisted when it is fastened.  To ensure your safety, check the condition, function and fastening of the belt re-

gularly and replace any damaged parts without delay.  To open lock 4, push down on the belt lock using your thumbs.

 The safety belt will slide automatically back into the roller mount 1.

3.2.4

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Adjusting of the auxiliary seat

Fig. 3-38 Auxiliary seat

The lever 1 serves to lock the auxiliary seat into position either beside t he operator’s seat or against the cab’s wall. To rotate the seat,  Pull the lever 1.


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Operating manual


To seat,  Pull down the seating.

Note When there is no one on this auxiliary seat, the seating must be pulled up and the seat in position lock against the cab’s wall.

3.2.5

Suns had e

Fig. 3-39

Windscreen and side windows sunshade

The cab is provided with three sunshades, located on the windscreen and on the two side windows. Windscreen  Pull the sunshade down using the cross strut on the sunshade 1.

 The sunshade can be set for individual use.  Pull out on the string 2.

 The sunshade rolls itself up.

Side windows 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

 Pull the sunshade down using the cross strut on the sunshade 1.

 The sunshade can be set for individual use.  Pull out on the string 2.

 The sunshade rolls itself up.

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3.2.6

Emergency exit rear do or

Fig. 3-40

Emergency exit – rear door

By pulling the handle 1 on the interior of the inferior window of the cabin door, the rubber weatherstrip can be released and removed.  In case of emergency, pull the rubber weatherstrip out of the entire area of the

window and push out the window.

Side wind ow The rear left window is equipped with the same system as the rear door.  By pulling the handle on the interior of the rear left window, the rubber weathers-

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trip can be released and removed.  In case of emergency, pull the rubber weatherstrip out of the entire area of the

window and push out the window.


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3.2.7

Interior lightings

Fig. 3-41

Interior lightings

The interior lightings are switched on using the switch S41 on the Keypad.  Press the switch S41.

 The lights E7 are switched on.  Press the switch S41 again.

 Interior lighting E7 are switched off.

3.2.8

Fire extinguisher The interior of the cab is fitted with fixing points allowing the mounting of a fire extinguisher. These fixing points are on the right side wall of the cab, on the frame between the two windows.

Fig. 3-42

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Fire extinguisher fixing location

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Note! It is the responsibility of the owner of the machine to decide if it must be fitted with a fire extinguisher or not, considering the operating conditions and the regulations which apply in the country and at the point of use of the machine.

Caution! If your machine is fitted with a fire extinguisher:  Always comply with the operating guide on the body of the extinguisher,  Make sure, all the inspections of the fire extinguisher which are prescribed by

the regulations applicable to the operating place of the machine are accomplished.

3.2.9

Windscreen wiper Windscreen wiper When the ignition is switched on, pressing switch S14 will activate the windscreen wiper.  Press switch.

 Intermittent switching  LED I in the switch illuminates.  Press switch again.

 Continuous operation.  LED C in the switch illuminates.  LED I in the switch goes out.  Press switch again.

 Windscreen wiper is switched off.  LED C in the switch goes out.

Setting the interval time for the intermittent switching

The interval time can be set when the ignition is on by pressing switch S14.  Press the switch until the windscreen wiper is switched off (LED I in switch goes

out)  Press and hold switch.

 LED I in the switch flashes.  Release the switch when the desired interval time has been reached.

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

Windshield washer installation 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

When the ignition is switched on, pressing button S11 will activate the electric windscreen washer installation.  Press and hold button.

 Washing water will be sprayed onto the windscreen through the outlet nozzles.  The windshield washer runs continuously.  Release the button.

 Washing water will be stopped.  Windshield washer will run continuously for approx. another 3 seconds.


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Operating manual


Windscreen washing f luid con tainer

Fig. 3-43

Windscreen washing fluid container

The container for the windscreen washing fluid is located under the cabin in the cab elevation. The container can be refilled via the service trap with ordinary windscreen washing fluid. Volume: see lubricant chart

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3.2.10

Field of view

Fig. 3-44 1

Field of view

Camera 1: opposite side of the cab

2

Camera 2: counterweight

Monitoring cameras are installed on the excavator as follows in order to extend the operator’s field of view with the operating environment:

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– camera 1: on the opposite side of the cab, – camera 2: on the counterweight. The combination of the cameras and the outside mirrors allows to see a person standing out of the hatched area illustrated on the fig. above.


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Danger! Before using the excavator, make sure that the camer as and the outside mirrors are correctly adjusted.  Regularly check mirrors for condition and correct adjustment.  Regularly check cameras for condition and correct adjustment. If necessary,

clean using a soft, dry tissue.  Replace damaged mirrors and cameras immediately.

To cover the co rrect area:  Set the cameras and adjust the outside mirrors so as to be able to see a person

standing out of the hatched area definied by the four checkpoints given on the fig. above.

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3.2.11

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Lig hti ng

Fig. 3-45 Arrangement of floodlights


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Operating manual


E1_1Fuel tank floodlight E1_2Fuel tank floodlight (optional, not represented)

E8_1Counterweight floodlight (optional, not represented) E8_2Counterweight floodlight (optional, not represented)

E2 Attachment floodlight

E18_1Counterweight floodlight

E3 Attachment floodlight

E18_2Counterweight floodlight

E4 Attachment floodlight (optional, not represented)

E23_1Counterweight floodlight (optional, not represented)

E5 Attachment floodlight (optional, not represented)

E23_2Counterweight floodlight (optional, not represented)

E6_1Hydraulic tank floodlight

E58_1Top of cabin floodlight

E6_2Hydraulic tank floodlight (optional, not represented)

E58_2Top of cabin floodlight

Working light and attachment f loodlights Floodlights E1_1, E2, E3, E6_1, E58_1 and E58_2 as well as optional floodlights E1_2, E4, E5 and E6_2 can be activated using button S10 on the control keyboard. E1_1, E1_2, E6_1, E6_2, E58_1 and E58_2 constitute working light. E2, E3, E4 and E5 are attachment floodlights.  Press button.

 Working light is activated.  LED 1 in the button illuminates.  Press button again.

 Working light is deactivated.  LED 1 in the button goes out.  Attachment floodlights are activated.  LED 2 in the button illuminates.  Press button again.

 Working light and attachment floodlights are switched on.  LEDs 1 and 2 in the button illuminate.  Press button again.

 Working light and attachment floodlights are switched off.  LEDs 1 and 2 in the button go out.

Counterweight floodlights Floodlights E18_1 and E18_2 as well as optional floodlights E23_1, E23_2, E8_1 and E8_2 can be activated using button S22 on the control keyboard.  Press button.

 Counterweight floodlights are switched on.  LED in button illuminates.

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 Press button again.

 Counterweight floodlights are switched off.  LED in the button goes out.

3.2.12

Heating/air conditioning system A heater and an air conditioner are installed in the cab as standard equipment.

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The heater is installed on the cab floor. The evaporator for the air conditioning system is integrated in the roof of the cab, and the condenser is installed on the Diesel engine radiator.

Control unit f ront panel

Fig. 3-46

Front panel of the heating/air conditioning control unit

Control keys

Indication on the LCD Display

1 Air conditioning ON/OFF

9

Recirculated air mode indicator

Increase cabin temperature

10 Reheat mode indicator

Manual setting "upwards"

11 Air conditioning mode indicator

Decrease cabin temperature

12 Automatic mode indicator

Manuel setting "downwards"

13 Blower manual speed bar

4

Control unit ON/OFF

14 Manual blower mode indicator

5

Evaporator blower speed manu/auto 15 Heating mode indicator

6

Reheat ON/OFF

16 Drivers cabin indicator

7

Heating ON/OFF

17 Temperature set value / error code

8

Fresh air / recirculated air mode

18 Temperature unit

2 3

19 LCD Display

Note! If the control unit recognizes a system error in the heating / air conditioning circuit, a flashing error code number F0-F5 is displayed. Refer to the section "Error code charts" further in this manual.

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Operating the heating/air-condit ionin g contro l unit Switching on the control unit  Press button 4.

 The control unit runs a self-test for approximately 5 seconds (software version

and equipment function are displayed on field 17).  Then the operating hours are displayed on field 17.  And then the last stored temperature adjustment is indicated on field 17.  By default, control unit is in automatic mode and symbol 12 appears on display 19.

Temperature setti ng  Press button 2 to increase the temperature.  Press button 3 to decrease the temperature.

 The selected temperature is displayed on field 17.  The new set value is stored 5 seconds after last button pressure.

Switching ON/OFF the air conditi oning u nit  Press button 1.

 Air conditioning mode is activated.  Symbol 11 appears on display 19.  Press button 1 again.

 Air conditioning mode is deactivated.  Symbol 11 disappears from display 19.

Note! In case of high outside temperature, and especially if the cab has been heated up by the sun, decrease the temperature inside the cab as far as possible before turning on the air conditioner.  Open the windows for a few minutes and adjust blower speed to maximum

speed via buttons 5 and 2.

Switching ON/OFF the reheat mode In order to achieve a quick dehumification of the cab when setting the machine into operation, it may be advisable to briefly turn on the air conditioning operation when the heater is already operative.  Press button 6.

 Reheat mode is activated.  Symbol 10 appears on display 19.  The blower speed is raised to 100%. If necessary the control unit switches the

heating on, to hold ambient temperature at the desired value.  Press button 6 again.

 Reheat mode is deactivated.  Symbol 10 disappears from display 19.

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Note! To avoid overloading the starter motor and the batteries, turn on the air conditioning mode and the reheat mode only after the diesel engine is running.

Reheat mode is automatically limited on 10 minutes.  If the machine is used for a longer period of time without using the air conditio-

ner, press the reheat button 6 about every 2 weeks so to turn on the compressor.

Settin g the evaporator blo wer speed manually  Press button 5.

 Blower speed manual setting is activated.  Indication bar 13 appears on display 19 and indicates currently set blower

speed.  Automatic mode symbol 12 disappears from display 19.  Manual blower mode symbol 14 blinks on display 19 for 5 seconds.  During these 5 seconds, evaporator blower speed can be increased with button 2

or decreased with button 3 in steps of 10%.  Press button 5 twice.

 Manual mode is deactivated.  Symbols 13 and 14 disappear from display 19.  Automatic mode is reactivated.  Symbol 12 reappear on display 19.

Note! Lowest possible evaporator blower speed is 30% (3 bars are indicated on symbol 13).

Switching ON/OFF the heating mode  Press button 7.

 Heating mode is activated.  Symbol 15 appears on display 19.  Press button 7 again.

 Heating mode is deactivated.  Symbol 15 disappear from display 19.

Fresh air / recircu lated air mo de  Press button 8.

 Control unit switches from fresh air to recirculated air mode.  Fresh air flap is closed.  Symbol 9 appears on display 19.

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 Press button 8 again.

 Control unit switches from circulated air to fresh air mode.  Fresh air flap is open.  Symbol 9 disappear from display 19.


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Setting the machine into operation

Switching the temperature unit from °Celcius to °Fahrenheit  Press and hold button 8.  Press button 3 additionally.

 Temperature unit indication 18 switches over into °Fahrenheit.  Repeat same procedure to switch back temperature unit indication to °Celcius.

Dual air condit ioning (opti onal equipment) When you switch the excavator on, the automatic dual air conditioning system is activated by default. The two air conditioning units are working alternately every 6 hours.

Fi g. 3-47


 Press "Dual air conditioning" button S26 on control board (see § "Control board").

 Automatic air conditioning mode is deactivated.  First air conditioning unit is activated.  Second air conditioning unit is deactivated.  Press button again.

 First air conditioning unit is deactivated.  Second air conditioning unit is activated.  Press button again.

 Automatic air conditioning mode is reactivated.

3.3 Setting the machine into operation 3.3.1

Bringing the machine safely into service – Carry out a careful inspection tour around the machin e each time before starting it.

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Control and operation Setting the machine into operation

– Ensure that no one, except an authorized person, is in the work and movement area of the machine. – Check the machine for loose bolts, cracks, wear, leakage and damage. – Never attempt to operate a damaged machine. – Ensure that any damage is immediately rectified. – Ensure that all hoods and covers are closed, but that locks are unlocked, to facilitate the fight against fire in case of. – Ensure that all warning signs are present. – Keep windows and interior and exterior mirrors clean. Secure doors and windows against unintended movement. – Ensure that no one is working on or under the machine and warn personnel in the vicinity of the machine that it is about to start by sounding the horn.

Ad jus ti ng the o perat or ’s standi ng po sit io n – Before starting the machine, adjust the seat, mirrors, armrests and operator’s controls in such a way that you are able to work comfortably and safely. – Acoustic insulation devices on the machine must be set to the insulation position throughout operation.

Protection from vibration - seat adjusting – Keep the seat in good condition and adjust it as follows: • The seat and its damping action should be adjusted depending on the weight and height of the operator. • Check the seat’s damping action and adjustment mechanisms regularly and ensure that these seat characteristics remain as per the seat manufacturer’s instructions.

Utilisation in conf ined spaces – Only operate combustion engines and fuel-operated heaters in adequately ventilated spaces. Before starting in closed areas, ensure adequate ventilation. Follow the regulations which apply for the particular area of use.

Startin g th e machine safely – Before starting, check all control lamps and instruments for correct function, place all operator’s controls in Neutral and tilt the safety lever up. – Before starting, sound the horn briefly to alert people in the vicinity of the machine. – Only start the machine from the driver’s seat. – In the absence of any other instructions, start the engine in accordance with the regulations given in the operating instructions. – Tilt the safety lever down and then test all display and checking devices. – In enclosed spaces, only allow the engine to run when there is adequate ventilation. If necessary, open doors and windows to ensu re sufficient fresh air supplies.

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– Bring the engine and hydraulic oil to operating temperature. Low oil temperatures make the control unit react sluggishly. – Check that the equipment is operating correctly. – Move the machine carefully to an open area and then check the function of the running and slewing gear brakes, the steering and the signaling and lighting devices.


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Stopping the machine safely – Only stop the machine on level, firm ground. – If the machine has to be stopped on an incline, chocks should be used to secure it from rolling away. – Before stopping the machine, each time it is possible, align the uppercarriage with the undercarriage so that the sprockets locate at the back-end. This is the only one position which enables a secured access to every maintenance locations on the uppercarriage. – Use the stop bolts to secure the upper structure facing the undercarriage, if available. – Lower the equipment and anchor the grab lightly in the ground. – Position every control lever into neutral position and depress the parking and slewing brakes. – Stop the engine in accordance with the operating instructions and tilt the safety lever up before leaving the cab. – Lock the machine, included hoods and compartments, retire every keys and secure the machine against unpermited use and vandalis.

3.3.2

Starting / stopping the machine General info rmation Note! When using the machine at a specific height above sea level and in connection with certain outside temperatures, the performance and se rvice life of the turbocharged diesel engine may be decisively affected. Under these conditions, there is also an increased risk of overheating of the coolant circuit and of the oil.

To avoid damaging CUMMINS diesel engines, the engine power must be reduced when operating in the following environmental conditions (sea level and exterior temperature):  Refer to the CUMMINS Operation and Maintenance Manual.

Ac tiv it ies b efor e start ing Caution! It is only possible to extinguish a source of fire when this one is accessible.  Before starting, unlock all locks on the panelling of the hydraulic excavator.

 In the event of fire, doors can be opened immediately and the fire extin-

guished.  For locks arrangement, see maintenance chapter

Caution! The activities referred below involve scald or burn hazards due to the high temperature of the coolant or of the oil when the machine is at operating temperature.  Please read first the maintenance chapter in order to get informations about

carrying out these activities.

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Control and operation Setting the machine into operation  Before starting the machine, the following activities should be carried out on a

daily basis: – Check air filters for contamination*. – Check the oil level in the engine*. – Check the coolant level in the diesel engine*. – Check fuel system and fuel level. – Check the oil in the hydraulic system. – Check that the cameras and the outside mirrors are correctly adjusted. – If required, remove any ice and snow from the engine hood in the area of the cooling and combustion air intake. * Refer to the maintenance chapter for further informations about the procedure to follow.

Turning on t he electrical sys tem Ignition key switching positions

Fig. 3-48

Ignition key S1

P

Parking position

2

Not used

0

Off

3

Start position

1

Contact position

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Switching o n the electrical syst em

Fig. 3-49

Batteries switches

 The batteries switches S9_1 and S9_2 must be in position "on". These are instal-

led in an electrical box located on the top of the catwalk above access ladder.  Turn the ignition key S1 to contact position 1.

 Immediately after turning the system on, the display and the control unit will

run through a selft test.  Make sure all indicators function properly after turning the electrical system on,

i.e. the light emitting diodes (indicator lights and gauges) turn on for a short time then the complete field of the LCD scr een 200 turns momentarily black (the matrix indicator is energised completely for a short time).  Only the LED in button S22 doesn’t turn on on that time.

Fi g. 3-50

S22 on control keyboard

Note! If no automatic check of the keyboard and monitoring display is carried out when the ignition key is in the contact p osition, check that the main batteries are switched on.

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Service in terval display

Fig. 3-51

Service interval request

After the automatic check, any service interval that may be due will be indicated by a graphic symbol. In place of the operating hours information, the number of hours relating to the service interval required will now be displayed. The service interval request will go out after approx. 8 seconds.

Startin g the engine Note!  Only operate the starter motor when the diesel engine is off.  Operate the starter motor continuously for no longer than 10 seconds.  If the engine does not start, turn the ignition key back to contact position 0,

before restarting the engine.  And repeat the starting procedure at 20 seconds intervals to allow the starter

motor to cool off.

Starting procedure when the exterior temperature is above 0 °C (32 °F) During the starting procedure of the engine, a starter first drives an engine oil pump to establish the correct lub oil pressure in the engine, before it is being started ("PRELUBE" procedure). Depending on engine oil temperature, a prelub time of up to 15 seconds might be necessary to obtain the correct pressure. Then the prelubrication pump stops and after another 3 seconds the principal starter starts the Diesel engine. If the engine and batteries are in good condition, the engine can be started without preheating. To start the engine :  Make sure that the electrical system is switched on.

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 Turn the ignition key to start position 3.  Maintain the key on this position during the prelub time.  As soon as the engine is running, release the key.


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Cold start aid for exterior temperature below 0 °C (32 °F) (option al)

Fi g. 3-52


A cold start system can be installed on the engine, which makes it easier to start at low temperatures. To actuate the cold start syst em:  Press the cold starting aid button S149 on the control board.  If the engine will not start, or at the beginning of a starting procedure.

 Push this button for a few seconds to spray starter fluid into the intake

manifold.  As soon as the engine turns over, release the button (once the engine is turning,

the button is automatically locked). Note! Do not preheat an engine which is at operating temperature.

Starting proc edure when the exterior t emperature is below -18 °C (0.4°F) For starting at temperatures below -18 °C, it is recommended to equip the machine with a preheating system in accordance with LIEBHERR.

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Engine speed adjust ment and mode functio ns

Fig. 3-53

Speed adjustment and mode functions

The previously selected engine speed will be displayed on the LED chain P4. It is divided into 10 speed levels.  To adjust the engine speed, press arrow keys S228 or S229.

- or Press the mode selection button S86.

Speed select ion w ith arrow k eys S228 and S229 To incr ease the speed:  Press switch S228.

 Speed will be increased by one level.  A second LED to the right illuminates in the P4 display.

To reduce the sp eed:  Press switch S229.

 Speed will be decreased by one level.  A second LED from the right goes out in display P4.

Speed selection with mode selection but ton S86 Three different modes can be selected by pressing switch S86. Depressing hte button causes to change from a pre-selected mode to the next, in t he following order: L , E, P, L and so on (mode F unavailable). – L : LIFT mode (speed level 1 – sensitive lifting of loads) 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

– F: not used – E: ECO mode (speed level 8 – economical work) – P: POWER mode (speed level 10)  Press the mode switch S86.

 The mode selected will be used, with the corresponding speed and power.  The appropriate LED will illuminate permanently.

The currently active mode will be displayed under the letter on the LED. The mode selected will be saved when the engine is switched off and will be displayed by a


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flashing LED above switch S86 the next time the engine is started. If the engine speed is changed via the arrow keys to the engine speed for mode L , E or P, then it jumps automatically to the corresponding mode. If the engine speed does not correspond to the preselected mode (either because the engine speed has been changed via the arrow keys or lowered via the low idle automatic), the LED blinks to indicate the mode selected before.

Warm-up phase for diesel engine and hy draulic c ircui t When engines are running, indicator lights H2 (engine oil pressure) and H12 (charge) on the display must turn off.

Fi g. 3-54

H2 ,H12 and P2 on display

 Let the engine idle at approximately 1000 RPM during the first 3 to 5 minut es, but

at least until warning symbols for low hydraulic tank pressurization and for low servo pressure turn off on the LCD screen.  Slowly increase the engine load until the coolant temperature reaches 40°C, i.e.

second green lighting diode goes on on the temperature gauge P2. Note! Idling for an extended period of time damages the engine.  Switch off the diesel engine if the machine is not being used.

As long as the hydraulic oil temperature is below a preset value, the warm-up symbol is displayed on the SY field of the main screen. During the warm-up procedure, the main pumps displacement is limited to 50% in order to prevent damage to components.

Notes after startin g the engine Danger! Danger of suffocation.  When operating in enclosed spaces, only run the engine in a reas with sufficient

ventilation.  Open doors and windows to ensure sufficient supplies of fresh air.

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Caution!  Bring the engine and hydraulic oil up to operating temperature. The controls

operate sluggishly at low oil temperatures.  Move the machine carefully in an open space to test the function of the travel

and swing brakes.  Check that the equipment is operating perfectly.

Switching off the diesel engine Caution! The engine could be damaged.  Do not switch the engine off suddenly from full throttle.

 Reduce engine RPM to low idle via the arrow key S229 and let the engine run for

3 to 5 minutes so as to lower the temperature.  Then turn the ignition key to position 0 in order to switch off the engine.  Remove the ignition key.

3.3.3

Starting aids (optional) Functional description The excavator can be fitted with an optional preheating kit (required according to the ambient temperature of the work environment) supplied by an external electric power supply. Preheating devices are installed on different components of the excavator. These devices are supplied by 2 electric modules (see § "Preheating components"). These 2 modules are installed in an additional electric cabinet in the cabin elevation. In order to be supplied externally, this cabin elevation has a socket for a generator set (Gen-Set). 

The Gen-Set must provide at least 21kVA, 400V, 50Hz.

When the Get-Set is connected, the 2 modules are supplied one after the other (see § "Preheating procedure"). Caution! The Diesel engine can be started during the preheating but travel and swing movements are not allowed. 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

The preheaters are monitored and a warning light H104 on the control board will come up if a default is detected. A warning symbol on the Display stays on during the preheating cycle until the Diesel engine can be started.


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Preheating compo nents -30°C (-22°F) low temperature kit  This kit must be activated every time the excavator is standing with external tem-

perature between -30°C and 0°C (-22°F and 32°F) and weekend or service and maintenance day. Module 1 supplies following components: – engine cooling water equipment, – engine oil immersion heaters, – hydraulic oil immersion heaters in suction pipe, – splitterbox immersion heaters, – battery heating blankets, – electrical box preheater. Module 2 supplies following components: – hydraulic oil immersion heaters in hydraulic tank.

-40°C (-40°F) low temperature kit  This kit must be activated every time the excavator is standing with external tem-

perature between -40°C and 0°C (-40°F and 32°F) and weekend or service and maintenance day. Additionally to the -30°C kit devices, module 2 supplies the following added components: – windshield defrosting unit, – electric cabin heater.

Optional components Following devices can be installed in addition to the previous kits: – grease tank heating blanket (supplied by module 1), – fuel heater, – ether start aid, – thermal insulation kit (including louvers, lower covering, insulated PowerPack doors and fire protection sheets), – preheating pedal plate and footrests, – connections for external heating air hose, – snow protection for air filter (see description below).

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Snow protection for air filt er (optional)

Fig. 3-55

Snow protection for air filters

A

Summer setting

25 Cover

B

Winter setting

26 Screw

To set summer position A  Set cover 25 on bottom position.

 Fresh air comes exclusively from outside.

To set winter position B  Before starting the engine at ambient temperature below 0°C, the air inlet of the

engine air filter must be switched in winter position B.  Unscrew the screws 26.  Move up cover 25 and install screws 26 on top position.

 The air is a mixture between outside air and PowerPack compartmen t air (war-

med up).

Preheating proc edure Note! If the excavator is turned off but the ambient air temperature won’t be lower than 10°C (14°F), or if the excavator is turned off less than one hour and the ambient air temperature is lower than -10°C (14°F) (for daily maintenance for example):

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 Follow standard procedure to park the excavator (no need to connect the Gen-

Set, i.e. to use the preheating kit).  Then, start the excavator by following the standard start procedure.


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Measures to be taken after engine stop or pr ior t o start p reheating (in any case)

Fig. 3-56

Backhoe (left) and shovel (right) attachments position during preheating

 Lay down the attachment on the ground, so that a maximum quantity of oil is in

the hydraulic tank: stick and bucket cylinders fully raisin in, bucket on the ground.  Shut louvers for hydraulic oil coolers and engine coolers as well as PowerPack

insulation doors (if installed).  Use the snow protection for air filter as described in § "Snow protection for air fil-

ter" previously in this section. To preheat the excavator  Plug Gen-Set into socket for module 1 and 2 on the cabin elevation:

 Power supply indicator light comes on on the electric cabinet.  Preheating cycle for module 1 starts.  Indicator light for module 1 comes on on the electric cabinet.  When preheating cycle for module 1 is completed:  Indicator light for module 1 goes off.  Preheating cycle for module 2 starts.  Indicator light for module 2 comes on on the electric cabinet.  When preheating cycle for module 2 is completed:  Indicator light for module 2 goes off.  Preheating cycle for module 1 starts again.  Indicator light for module 1 comes on on the electric cabinet.  etc...

To operate the excavator  Make sure that the warning symbol for low coolant temperature is no longer dis-

played.  Start the Diesel engine.

 At this step, no travel or swing movement are possible. Attachment move-

ments are limited.  Turn on the windshield defrosting unit and the electric cabin heater (if installed).

 Make sure that the hydraulic oil temperature has reached at least +10°C (+50°F).  Open louvers (if installed).  Operate all attachment movements at reduced speed:

– Lift up the boom very slowly and bring it down very slowly, repeat these operations 5 times. – Do the same operations for each cylinder of the attachment by repeating them 5 times.

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Note!  If the attachment is equipped with bypass valves and if the ambient temperature

is below -30°C (-22°F):  Open these valves to bypass the cylinders in order to heat up oil in the attach-

ment pipes and hoses  Operate all attachment as described above.

 As the bypass valves are open, there is no movement of the attachment.  After these operations, close all bypass valves.

 The excavator can now be operated.

To stop the preheating  Unplug Gen-Set from socket on electric cabinet for module 1 and 2.

 Power supply indicator light on the electric cabinet goes off.

3.3.4

Jump Jump start start proce procedu dure re Danger! When connecting to exterior batteries, old batteries can be subject to increased gas formation.  Wear protective goggles and gloves whenever jump starting, avoid naked flame

and creating any sparks in the vicinity of the flat vehicle battery. RISK OF EXPLOSION!  Only use jump starting cables with a sufficient cross section. Always follow the

established jump starting procedure.

Connecting t he batteries batteries  First connect the cable to the positive terminal (+) of the flat battery and then to

the positive terminal (+) of the exterior battery.  Connect the second cable to the negative terminal (-) of the flat battery and then

to the negative terminal (-) of the exterior battery.  Start the engine as described above.

Caution!  Before removing the jump start cable, be sure to place the diesel engine of the

jump started machine into low idle.  For safety reasons, switch on large consumers such as work headlights, upper

carriage lighting etc. to avoid overvoltage. The electronics could otherwise be damaged.

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Disconnectin g the batteries  First remove the cable from the negative terminal (-) of the exterior battery and

then from the negative terminal (-) of the flat battery.  Remove the second cable from the positive terminal (+) of the exterior battery and

then from the positive terminal (+) of the flat battery.


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 Check the electrical function of the machine.

For battery care and maintenance, see the chapter “Battery care”.

3.3.5

Emerg merge ency opera operatio tions ns Emergency shutdown

Fig. 3-57

S100-1 on control board

To execute an emergency shutdown:  Turn the starter key to the "0" position or push one of the emerg ency stop buttons

S100_1, S100_2, S100_3, S100_4 or S100_5.  This action will shut down the diesel engine and disconnect the electrical system.

Caution! Only use this shutdown method in case of emergency. After an emergency shutdown, it is very important to let the engine run again for a short time at low idle on next restart.

Using the emergency stop buttons will cause the hydraulic tank to be depressurized quickly.  After a shutdown via an emergency stop button, the button must be unlocked be-

fore attempting to restart. Caution! You must wait at least 10 minutes after an emergency shutdown before attempting to restart.

Emergency Emergency op erations erations of t he diesel diesel engine If the engine cannot be started, monitored or operated safely due to a function problem in the control electronic of the excavator, diesel engines operation can be continued via the emergency control function.

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Fig. 3-58

Emergency operation on control board

Starting the diesel engine  Press button S23 to turn on the emergency control circuit for Diesel engine.

 Indicator light in the button illuminates.  Turn the speed control rotary knob R6 fully counterclockwise to low idle RPM.  The starting procedure is the same as during the normal starting procedure (see

§ "Starting the engine" in this manual).  Release the ignition key as soon as the engine starts.

Caution!  Operate the starter motor continuously for no longer than 10 seconds.  Wait 20 seconds before trying the starting procedure again to allow the starter

motor to cool off.

Ad ju st in g t he d iesel ies el engi en gi ne s peed To adjust engine speed with emergency control:  Turn the speed control rotary knob R6 counterclockwise to reduce engine speed.  Turn the speed control rotary knob R6 clockwise to increase engine speed.

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Note! When the emergency control circuit is turned on, the engine control buttons S20, S228, S229 and S86 of the keyboard are not functioning. All remaining buttons on the control panel remains fully functional, if they are not affected by the existing problem.


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Monitorin g the engine speed speed In emergency function, the speed dial indicator P4 remains fully functional and must be monitored regularly and carefully, because all remaining indicators and warning symbols may no longer be reliable or fully functional (depending on the problem).

Turning t he diesel diesel engine off Caution! Do not suddenly turn the engine off when it’s running at high idle.

To turn off the engine with emergency control:  Reduce the engine speed via the speed control rotary knob R6 to low idle.  Continue to run the engine at low idle for 3-5 minutes to lower the temperature.  Turn the ignition key to position 0 to turn the engine off and remove the key.

Emergency Emergency control of the hydraulic pumps During normal operation of the excavator, the electronic horsepower control continuously adjusts the pump flow to the pressure level of the working circuits. If a trouble occurs in the circuit of the regulator, the pumps are swivelled back to minimal flow. However it remains possible in this case to carry on the working with the machine (with somewhat reduced power) by pushing the button S73.

3.3. 3.3.6 6

Board E52 for safety safety mode of Diese Diesell engine engine and servo control Thanks to this printed board, the excavator can, in case of a failure in the main electronic circuit, be maintained operating temporarily and with some restrictions.

Fig. 3-59 E52

Control board for safety operation E52

Printed board for safety operation S71

Switch / engine start in safety mode

H11

Warning light / Diesel engine in safety mode

S72

Switch / RPM selection in safety mode

H60

Warning light / operating error on Diesel engine with safety mode turned on

S73

Switch / servo pressure circuit in safety mode

Startin Startin g th e Diesel Diesel engine engine in safety mode In normal operation, the engine is started via the main electronic circuit when the ig-

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nition key is turned to start position. In case the engine can no longer be started or kept running due to troubles in the control electronics, it can be started in safety operation via the starting switch S71.  Turn the ignition key in start position and at the same time push the safety start

switch S71 to the right.  Keep the switch pushed to the right until the engine starts

 The warning light H11 turns on.  The symbol S71a is displayed on the screen.  The engine is now operating in safety mode.

Safety Safety o peration peration of the Diesel Diesel engine The engine can also be switched into safety operation automatica lly, lly, as an example consecutively to a communication default in the control system. In safety operation, the engine works with reduced output in comparison with the normal operation. In safety operation the stop of the Diesel engine is achieved just like in normal operation, while turning back the ignition key to the "off" position. It is not possible to return to normal operation when the engine is running, the rocker switch S71 must be tilted back from safety ope ration into normal operation (position "AUTO") only when the excavator is turned off. Note! In safety operation, the communication between the electronic control box of the engine and the main circuit of the excavator may be no longer possible. The engine operating error codes are in this case no longer displayed on the screen.

The occurence of an operating error of the engine is then indicated as follows: • the red warni warning ng ligh lightt H60 lights on, • a buzzer buzzer in the cab beginns to sound. sound. • the error code code E525 appears appears on the monitoring monitoring display. display. Caution! In case the warning light H60 lights up, the operator must shut the engine down as soon as possible and recognize which error has occurred. It's the operator's own responsibility to decide if the machine can be maintained operating or not!

In safety operation the following functionss remain available: • the automatic automatic engine power power reduction in case of overheating overheating of the engine engine coolant or of the charge air. • the memorization memorization of the occurring occurring engine faults faults into the inner error memory memory of the control box of the engine.

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At the opposite, the following functions are no longer operative: • the automatic automatic engine shutdow shutdown n in case of low lube lube oil pressure. pressure. • the automatic automatic engine shutdown shutdown when the maximum maximum permitted permitted coolant or charging air temperature has been exceeded.

Diesel Diesel engine RPM RPM adjustment i n s afety afety mode In normal operation, the desired value f or the engine RPM is entered via the buttons


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S86, S228 and S229, and the engine speed is controlled in consequence by the electronic system of the machine.

If the engine has been started in safety mode via the rocker switch S71 so it can be operated only with two different RPM values. T he commutation between the two values is achieved via the switch S72.

Fig. 3-60

Emergency control of the engine RPM

 Manually choose one of the values:

• with with the the swi switc tch h S72 tilted to the left, the engine runs at the lower safety RPM. • with with the the swi switc tch h S72 tilted to the right, the engine runs at the upper safety RPM.. Note! When the engine is switched automatically into safety operation, th e current engine speed is maintained as long as the engine is not shutdown.

Safety Safety operation operation of t he servo servo con trol c ircui ts During normal operation, the servo pressure supply to the swing brake and to the joysticks and pedals is controlled over the electronic circuit of the machine. While tilting the switch S73 in safety position, this servo pressure supply can be enforced, and is maintained even in case of a trouble in the normal control circuit.

Fig. 3-61

Safety mode of servo circuits - Safety switch and symbols at the display

 Tilt the safety lever down.  Commute the switch S73 into safety position (tilt to the right).

 the three indicator symbols S73a, S73b and S73c appear on the display.  the joysticks and pedals are supplied with servo pressure.  the swing brake is released.

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

In safety mode, the swing brake will be released as soon as the ignition key is turned to contact position, and the normal brake control is out of function.  Inform all personnel involved in the operation or maintenance of the machine

that the safety mode has been turned on and that, by the fact, the control of the swing brake is modified.  Locate the trouble which makes the operation in safety mode necessary and get

it repaired as quickly as possible.

Note!  Even with the switch S73 in safety position, the servo pressure supplying the

joysticks and pedals is interrupted when tilting up the safety lever .

3.3.7

Driving Driving straight ahead

Fig. 3-62

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Driving straight ahead

1

Idler

5a / 5b Pedal for left drive unit

2

Sprocket wheel

6a / 6b Pedal for right drive unit

Caution! When driving, the upper carriage must be rotated to the chassis in such a way that when driving forwards, the sprocket wheel 1 is in front and the idler 2 is at the rear. Driving forwards:  Push both pedals forward (5a and 6a).


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Reversing: Caution! Before reversing, ensure that the area behind you can be safely entered.

 Push both pedals down (5b and 6b ).

Turning on the spot

Fig. 3-63

Turning on the spot

Turning left (A):  Push the left pedal down (5b ).  Push the right pedal forwards at the same time (6a).

Turning right (B):  Push the right pedal down (6b ).  Push the left pedal forwards at the same time (5a).

Turning wi th a crawler

Fig. 3-64

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Turning with a crawler

Turning to the left (A):

Push the right pedal forwards (6a). Turning to the righ t (B):

Push the left pedal forwards (5a).

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Note! If possible, avoid turning backwards in order to preserve the running gear parts.

Controlli ng the speed The driving speed is influenced by button S21. The travel motors can be operated in two different positions: – Normal drive (position 1): Maximum tensile force of both drive units at moderate speed. – Fast drive (position 2): Reduced tensile force of both drive units at maximum speed.  Press switch S21.

 Transfer from normal drive to fast drive is activated.  LED 1 in the button illuminates.

While driving, the machine will automatically switch from n ormal drive to fast drive as the ground conditions permit. After transferring to fast drive, LED 2 illuminates. If the ground conditions become more difficult again, the system will automatically switch from fast drive to normal drive. LED 1 illuminates.  Press button S21.

 Transfer from normal drive to fast drive is deactivated.  LED 1 in the button goes out.

When button S21 is switched off, the travel motors remain continually in position 1.

Braking the machine The hydrostatic travelling mechanism of th e machine also functions as a service brake.  Disengage the pedals for the drive units.

 The pedals will return to the neutral position.  The travelling mechanism will be stopped.  The machine will be braked.

When the pedals for the drive units are in the neutral position, the hydrostatic drive prevents the machine from rolling off. In the neutral position, the parking brake will be applied automatically after a few seconds. The work equipment can, however, still be moved. Actuating a travel pedal again will disable the travel brake. Caution! Disengaging the pedals quickly causes the machine to halt abruptly.  Before starting the machine, always fasten the safety belt. 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

The travel brake can also be directly actuated by using button S354.  Press button.

 Travel brake is engaged.  Undercarriage is locked.  LED in the button illuminates.  Press button again.

 Travel brake is disabled.  Undercarriage is unlocked.


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Working with the machine

 LED in the button goes out.

Note! If the travel brake has been activated by using the button S354, the only way to disabled the travel brake is to pressure S354 again. I.e. actuating the travel pedals won’t have any effect.

3.4 Working with the machine Working safely with th e machine – Before you start working, acquaint yourself with the special features of the job site and any special precautions and warning signals. Examples of particular work environments would be on-site or traffic obstructions, the load-carrying capacity of the ground and any requirements to make the job site safe from public use. – Always maintain a safe distance from overhangs, edges, slopes and unsafe ground. – Be particularly careful in conditions of reduced visibility and changeable ground conditions. – Familiarize yourself with the location of power lines on the job site and take particular care when working near them. If necessary, inform the responsible authorities. – Maintain a safe distance from electrical aerial lines. Do not allow the equipment to come near cables when working near electrical aerial lines. Risk of fatality! Inform yourself about required safety distances. – The following actions must be carried out in the event of any transfer of electricity: • do not move the machine or its equipment, • do not leave the driver’s cab, • warn any personnel in the vicinity not to co me close to the excavator and not to touch it, • instruct or initiate that someone turns off the voltage. • move the machine, if possible, from the danger zone to a sufficient distance, • Do not leave the machine until you are absolutely sure that voltage in the line, which had been touched or damaged, has been turned off ! – Before moving the machine, always ensure that any attachments are safely secured. – When driving onto public roads, paths and squares, observe current traffic regulations and if necessary, ensure that the machine has been made safe as per regulations beforehand. – Always turn on the lights in conditions of poor visibility or darkness. – Do not permit any passengers in the machine. – Only work when seated properly and with the safety belt securely fastened (if available). – Report all function faults and ensure that all necessary repairs are carried out immediately. – Assure yourself that no one is endangered when you start the machine moving. – Before you start working, test the brake system in accordance with the regulations given in the operating instructions. – Never leave the driver’s seat while the machine is moving. – Never leave the machine unattended while the engine is running.

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Control and operation Working with the machine

– The machine must be positioned, moved and operated in such a way that it is stable and that there is no danger of overturning. Only known loads may be moved with the equipment; this applies particularly when using the grab. – Position the upper structure in the longitudinal direction when moving and hold the load as close to the ground as possible. EXCEPTION : excavators used for loading and unloading, see the part "Safe use when loading and unloading (particularly when loading and unloading wood)" on page 79. – Adjust your driving speed to suit local conditions. – Avoid any working movements which may tip the machine. Should the machine start to tip or slide sideways, however, turn the upper structure to face downhill and lower the equipment at the same time. – As far as possible, work downhill or uphill and not side on to the slope. – Drive safely on stony, sleepery or inclined ground – Only drive downhill at the permitted speed or you could lose control of the machine. – Always shift down to a lower running step before a slope. When doing this, the diesel engine must run at maximal speed and the speed may only be reduced using the foot pedals. – Load an occupied truck only if all safety requirements are fulfilled, notably in order to protect the truck operator. – For demolition work, digging and crane operations etc., always use protective devices specifically designed for the purpose. – For terrain which is difficult to gain an overview of and whenever necessary, ask for the assistance of a spotter. Only permit one person to give you signals. – Authorize only experienced people to attach load and to give indications to the machine operator. This people must be in the operator’s sight or in radio contact with him. – Depending on the equipment combination, there is a risk of collision between the work tool and the machine (uppercarriage and undercarriage). The greatest degree of care must be taken to avoid damage. – Depending on the equipment combination, there is a risk of collision between the work tool and the cab, the cab prot ection or the boom cylinders. The greatest degree of care must be taken to avoid damage when the hoe teeth come within this area. – Depending on the equipment combination, there is a risk of collision between the work tool and the equipment parts. The greatest degree of care must be taken to avoid damage. – Depending on the equipment combination, there is a risk of collision between the lift ring of the attachment and the cab or the cab prot ection. Before operating, ensure that there is no risk of collision, especially on excavator with cab elevation. If necessary remove the lift ring. – In case of a thunderstorm : • lower the attachment to the ground and if possible anchor the digging tool into the soil. • leave the cab and move away from the machine before the storm breaks out. Otherwise, you must stop the excavator, turn off the radio and keep inside the closed cab until the end of the storm.

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– Auxiliary control units can have various functions. Always check their functions when starting up the machine. – Stop the swinging motion of the uppercarriage when lowering the attachment into a ditch without striking the attachment on the ditch walls.


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– Inspect the machine for damage if the attachment has been swung into a wall or any other obstacles. – Applications in which the attachment is to be used to strike the material being extracted are not permitted, even when working in a longitudinal direction. – Repeated strikes against an object leads to damage to the steel structures and machine components. – Please refer to your LIEBHERR dealer if special teeth for heavy-duty or special applications are required. – Do not attach too large bucket or bucket with side cutters or that are during operations with rocky material. This would prolong the work cycles and may lead to damage to the bucket as well as further machine components. – With the 2x45° offset articulation, the offset position may only be employed if the working tool or the attachment does not touch the material. – Operation of the offset articulation to drill into the material is not permitted. – Do not lift the machine during operation. Should this happen, lower the machine slowly back to the ground. – Do not let the machine fall heavily on the ground and do not hold it back with the hydraulics. This would damage the machine. – During operation with the attachment it is forbidden to raise the machine with the dozing blade (e.g. carving at the ceiling when tunnelling). – Do not dig under the undercarriage. Take all necessary measures to prevent ground collapse under the machine. – The practice of following working methods is forbidden: • Batter pulling, also known as Scaling or Ripping, • Double benching, also known as Split benching or Double flitching. The practice of these methods will result in increased stresses to steel structures and components of Liebherr Mining Machines. It may significantly reduce the expected life of structures and/or components. Liebherr does not condone and does not approve the operation of Liebherr Mining Machines in this manner.

Safe use wit h a hydr aulic hammer – The hydraulic hammer must be selected with particular care. When using a hydraulic hammer not permitted by LIEBHERR, steel structures or the other machine components can become damaged. – Before beginning breaking tasks, position the machine on firm and level ground. – Use a hydraulic hammer designed exclusively for breaking stone, concrete and other breakable materials. – Only operate the hydraulic hammer in the longitudinal direction of the machine and with the windshield closed or with a front protective grid. – Ensure during hammer operation that no cylinder is entirely extended or retracted and that the stick is not in the vertical position. – In order to avoid damages to the machine, try not to break stone or concrete while performing retraction and extension motions of the hydraulic hammer. – Do not apply the hydraulic hammer uninterrupted for more than 15 secs. at a time to the same place. Change the breaking point. Too long uninterrupted operation of the hydraulic hammer leads to an unnecessary overheating of the hydraulic oil. – Do not use the drop force of the hydraulic hammer to break stone or other mate rials. Do not move obstacles with the hydraulic hammer. Misuse of this nature would damage both the hammer and the machine.

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– Do not use the hydraulic hammer to lift objects

Safe use when loading and un loading (particul arly when loading and unloading wood) – According to use, it can be necessary when working with a grab to move with the equipment raised and the load lifted up; this applies, for example, when loading and unloading wood. – Here, the centre of gravity of the machine will be displaced upwards in the vertical direction. The driving characteristics of the machine will thus be influenced persistently, e.g. through reduction of the dynamic stability. The following instructions are therefore to be observed at all times: • Adjust vehicle handling to suit the altered machine characteristics and environmental conditions. • Reduce your speed to prevent the need for sudden braking and steering manoeuvres. • Avoid sudden speed changes, such as braking, accelerating and changing direction. • Only rotate the upper structure when the undercarriage is stationary. • Only rotate the upper structure after you have picked up the load. • Only move the machine when you have picked up and lifted the load and rotated the upper structure to the driving position. • There is a danger of possible swinging movement and dropping of the load when the equipment is raised. • A protective grid (FOPS) in accordance with ISO 10262 must be attached to the cab. • A protective roof (FOPS) in accordance with ISO 10262 must be attached if there is a risk of objects falling from above. • Only the maximum permissible load may be taken up using the grab. – NOTE: The weight of absorbent materials, such as logs, is dependent on length, diameter and specific weight. The influencing variables present in a natural product, such as moisture, must be noted. – Working procedures when using machines with grabs require the machine operator to receive special instruction and training. – Use as part of the work process is only permitted when the machine operator has sufficient training and practical experience.

Safe use of machin es with tower elevation – Due to the tower elevation, the centre of gravity of the machine will be displaced upwards in the vertical direction. The driving and work characteristics of the machine will thus be influenced persistently, e.g. through reduction of the dynamic stability. – Due to the heightened centre of gravity, the machine must be aligned horizontally before use. In horizontal alignment, the centre of gravity of the upper structure is over the centre of the undercarriage, which reduces the risk of tilting.

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– The machine can still sway and tilt despite being aligned! The following instructions are therefore to be observed at all times:


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When moving the machine: • Rotate the upper structure parallel to the undercarriage (transport position). • Draw the equipment as close as possible to the machine. • Only at this point may the support feet be retracted and the machine moved. • Moving with loads is not permitted. • Check the terrain to be covered to ensure that the ground is solid and even. Potholes and uneven surfaces jeopardize the stability of the machine. • Adjust vehicle handling to suit the altered machine characteristics (high centre of gravity) and environmental conditions. • Reduce your speed to prevent the need for sudden braking and steering manoeuvres. • Avoid sudden speed changes, such as braking, accelerating and changing direction. • Ascending gradients and obstacles may only be approached in the longitudinal direction in order to prevent unacceptable banking of the machine. • Special care should be taken when driving through narrow passages - drive slowly! When loading and unloading: • The machine must be supported and aligned horizontally before moving (slewing) the upper structure out of the transport position. • It is imperative that you check the contact surface of the support (load carrying capacity of the substrate). A support subsiding would have disastrous consequences! • Carry out all movements with increased care. • To slew the load, move the equipment as close as possible to the machine (Caution! swinging grab) and hold the load close to the undercarriage and above the substrate. • Avoid braking or accelerating the equipment or upper structure abruptly. • Do not lift any loads which are heavier than those given in the load chart.

Protection from vibration – Vibrational loads on mobile building machinery are mainly the result of the type and method of use. The following parameters in particular are decisive influences: • Terrain conditions: Uneven areas and potholes; • Operational techniques: Speed, steering, brakes, controlling the machine’s control elements when driving and working. – To a large extent, the machine operator determines the vibrational loads since he selects the speed, gearbox ratio, working method and route himself. This means that there is a wide range of different vibrational loads for the same machine type. Whole-body vibrational load for the machine operator can be reduced if the following recommendations are observed: – Select suitable machines, equipment parts and auxiliary devices for each part of the job. – Use a machine that has a suitable seat (i.e. for earth-moving machinery such as hydraulic excavators, this should be a seat which corresponds with EN ISO 7096). – Keep the seat in good condition and adjust it as follows: • The seat and its damping action should be adjusted depending on the weight and height of the operator. • Check the seat’s damping action and adjustment mechanisms regularly and ensure that these seat characteristics remain as per the seat manufacturer’s instructions.

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– Check the maintenance status of the machine, particularly with respect to: tyre pressure, brakes, steering, mechanical connections etc. – Do not steer, brake, accelerate, shift gears, move or load the machine’s equipment jerkily. – To reduce vibrational load, adjust the machine speed to suit the route as follows: • Reduce speed when driving on difficult terrain; • Drive around obstacles and avoid driving on very difficult terrain. – Keep the terrain on which the machine is working and driving in good condition: • Remove large stones and obstacles; • Fill in ruts and holes; • Have machines ready to prepare and maintain suitable ground conditions and calculate in sufficient time to carry out any work required. – Drive longer distances (e.g. on public roads) at an appropriate (medium) speed. – Use special auxiliary systems (if available) which reduce vibration for machines that are driven frequently. If such auxiliary systems are not available, regulate speed to avoid "oscillating" the machine.

3.4.1

The uppercarriage swing movements The swing movements of the uppercarriage are controlled by the left joystick.

Fig. 3-65

Rotating the uppercarriage

Caution! The joystick functions described below refer to the normal control, fitting out the machine at delivery and accordin g to ISO-standards . On machines equiped in addition with a special control system, and if this special control system is activated by the operator, the joystick functions correspond to the information on the label which is sticked on the side window of the cab and is specific to the installed special control system.

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 Push the left joystick to the left c :

 The uppercarriage rotates to the left.  Push the joystick to the right d :

 The uppercarriage rotates to the right.

Braking the uppercarriage The machine is equipped as well with an hydraulic as with a mechanical swing brake.


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The hydraulic swing brake  Let the left joystick move back to neutral position.

 The hydraulically swing braking of the uppercarriage takes place. In normal

working conditions, the braking efficiency is sufficient to bring the uppercarriage to a standstill rapidly.  Move the left joystick in the opposite direction.

 The maximum hydraulic braking action of the uppercarriage is achieved.

The mechanical swing brake

The mechanical brake is a negatively acting multidisc brake which is integrated in the swing gear. It allows to stop the uppercarriage in any desired position (for parking, when working on a slope, ...)  Press button "Swing brake" button S17.

 Swing brake is applied.  LED in the button illuminates.  Press button again.

 Swing brake is released.  LED in the button goes out.

Semi-automatic swing brake control (optional equipment)  Press button S17 to release the swing brake.

 LED in the button goes out.  The swing gear brake is in mode semi-automatic and can now be controlled

as follows by the rocker switch S57:  Tilt down the rocker switch S57 on the joystick handle.

 The brake is applied when the uppercarriage is at standstill, respectively it ap-

plies as soon as the uppercarriage speed gets lower than a limit value.  Tilt up the rocker switch S57.

 The brake remains released permanently.

Note! The red LED beside the button S17 is lighting in any case when the brake is applied. If this light does not go out when the rocker switch S57 is tilted up, the button S17 must first be pushed to pre-select the semi-automatic mode.

Caution! The brake only applies when the uppercarriage is near standstill and if no swing motion is actuated via the joystick! In order to stop the uppercarriage when working on a slope, tilt the switch S57 down and reduce the uppercarriage speed by braking with joystick. Move the joystick back to «0» position only after the brake has applied.

Emergency stop o f the uppercarriage swing mo tion The swing brake can be applied independently of the uppercarriage RPM by switching the "Swing brake" button S17 to position "applied". Caution Perform this braking via "Swing brake" button S17 only exceptionaly, i. e. in emergency cases, since it causes fast abrasion of the brake discs.

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To check th e mechanical swi ng gear brake:  When the uppercarriage is stationary.  Press button S17 to apply the mechanical swing brake.  Push the left joystick to the right and then to the left as far as the stop.

 If the swing brake function is OK, the uppercarriage does not start swinging.

3.4.2

Working position

Fig. 3-66

Working position – machine

 Work with the machine is generally to be carried out over the idler.

Note  Drive backwards when you are working lengthwise with the backhoe bucket.

3.4.3

Joystick functions when setting up the machine Caution! The machine is dispatched as standard with normal control . On request, the machine can be equipped with a control system that deviates from the norm (eg. with LIEBHERR control). The additional operating instructions for this control system apply in this case.

The joystick functions described here refer exclusively to normal control .

Operating the stick c ylind er

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The stick cylinder is operated using the left joystick 4.


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Fig. 3-67

Operating the stick cylinder

 Push the joystick back a.

 Stick will be drawn in.  Push the joystick forwards b .

 Stick will be extended.

Operating the boom c ylind er The boom cylinder is operated using the right joystick 3.

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Fig. 3-68

Operating the boom cylinder

 Push the joystick back g .

 Equipment will be raised.  Push the joystick forwards h .

 Equipment will be lowered.

Operating t he bucket The bucket cylinder is operated using the right joystick 3.

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Fig. 3-69

Operating the bucket cylinder

 Push the joystick to the left e.

 Bucket will be tilted inwards.  Push the joystick to the right f .

 Bucket will be tilted outwards.

Operating the bottom du mp shov el bucket

Fig. 3-70

Operating the bottom dump shovel bucket

The bottom dump shovel bucket is moved via two pedals, 7a and 7b .  Push pedal 7a.

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 Shovel bucket will be closed.  Push pedal 7b .

 Shovel bucket will be opened.

Float posi tion of boom cyl inder for buck et operation (optional equipment)

Fig. 3-71

Float position

To turn on the float position for the lift cylinders,  Move the right joystick 3 forward,  Push the button S5 or S6 on top of the handle at the same time.

Now the bucket can be used for grabing work while moving the joystick 4 forward to extend the crowd cylinders. The attachment can then move freely up or down depending on grade and the bucket will automatically follow the ground contour.

Combined movements Moving a joystick diagonally results in the work functions concerned being combined. This allows different equipment movements to be activated at the same time. The operator can do the following movements without any additional manipulations. When the swing movement is actuated, all working functions / movements are possible without affecting the swing movement. During travel, every attachment movement is possible, but the swing movement has priority. In this case, the travel movement is reduced.

3.4.4

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Lowering the work equipment when the engine is not running In an emergency, the equipment can be lowered when the diesel engine is not running.


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General working methods

Fig. 3-72

Lowering the equipment when engine is not running

 Turn the ignition key to contact position 1.  Operate the joystick or the foot pedals until the equipment has lowered.

Note The equipment can be lowered because of the control oil unit’s pressure reserve. This reserve is limited and is only sufficient for small movements of the pilot control devices.  Only operate the joystick in the directions for lowering the equipment.

3.5 General working methods 3.5.1

Minimum impact working methods for your machine To increase the service life of the machine and avoid unnecessary damage and the resulting repairs, please note the following points: – Do not stop the rotary motion of the upper carriage when slewing into a ditch by stopping the equipment on the walls of the ditch. – Using the machine for applications where the equipment is knocked against the material to be removed, in the longitudinal direction too, is not permitted. Repeatedly hitting the work equipment against rock or other hard material will damage steel parts and machine components. – With specific combinations of boom, stick and work tool, the work tool could hit or break through into the cab. This could damage the cab and injure the machine’s operator. – Do not attach buckets which are too big or side cutters when using the machine in rocky material. This will extend the work cycles and could result in damage to the bucket and other machine components. – Please contact your LIEBHERR contractual partner if special teeth are required for heavy or special applications. – Operating the drag bearing to bore into material is not permitted. – Do not raise the machine when working. If this should occur, slowly lower the machine to the ground. Do not permit the machine to lower quickly and do not intercept the falling movement using the hydraulics, since this could result in damage to the machine.

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MJFCIFSS

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2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

Operating manual

Control and operation General working methods

3.5.2

Preparatory activities Danger! Risk of fatal injury and damage to the machine when working.  Observe the safety information “Notes for safe working” at the start of these ope-

rating instructions.

Fig. 3-73

Working position – machine

 Position the machine so that the load material can be taken up above the idler.

Danger! Insufficient support and machine damage.

Fig. 3-74

Hazard area

Danger! Risk of fatal injury due to rotating the machine.

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 Ensure that nobody stands within the hazard area r of the machine.


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Caution! Risk of injury when working.  Always wear safety shoes and, particularly when leaving the cab when demoli-

tion work is going on, a protective helmet and safety glasses.  Always wear the seat belt.  Use the horn to give a short warning signal before starting work.

3.5.3

Positioning of the machine Setting up properly is a pre-requisite to safe efficient loading, and helps maintain stability, power and bench levels. It will also reduce operator fatigue. Position the excavator as close to the working face as safety permits. Caution! Always ensure there is sufficient clearance between the counterweight and the face, including allowing for any rocks or material that may fall down.

Fig. 3-75

Recommended digging

The recommended digging range is about a 90° arc in front of the machine (A). Note! Avoid digging at right angles to the tracks.

3.5.4

Working with the backhoe bucket Danger! Risk of fatal injury and damage to the machine when moving the backhoe bucket.  Ensure that the backhoe bucket is not slewed too close to the cab.

 The backhoe bucket could damage the cab and injure the machine’s opera-

tor.  Ensure that nobody is standing within the hazard area of the backhoe bucket.

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Operating manual


Digging

Fig. 3-76

Optimal angle for digging

Fig. 3-77

30° forward to the vertical.

 Align the shovel arm in such a way that its underside is at an angle of approx. 30°

forward to the vertical.  Align the backhoe bucket in such a way that its underside can enter the ground

at an angle with the axle of the shovel arm between 10° and 20°.

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Fig. 3-78

Taking up grab material

 To lift out the grab material, slowly and evenly slew in the shovel arm.

Fig. 3-79

45° backward to the vertical

 As soon as the shovel arm is at an angle of approx. 45° backward to the vertical,

raise the boom slowly and evenly in addition to slewing in the shovel arm and the backhoe bucket. Stopping suddenly will result in impact loads and vibrations.  When the backhoe bucket is full or the shovel arm can no longer be slewed in,

raise the boom and backhoe bucket until the filled surface is parallel to the ground. Note! For a efficient digging, the depth of the excavated face shouldn’t exceed the length of the shovel arm.

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Operating manual


Loading the transport vehicle Danger! Risk of fatal injury due to falling grab material.  Do not load the transport vehicle so high that the grab material could drop out

over the walls of the vehicle.  Ensure that nobody is standing in the danger.  Load an occupied truck only if all safety requirements are fulfilled, notably in or-

der to protect the truck operator.  Do not slew the equipment over the driver’s cab.

Fig. 3-80

Emptying grab material

 If possible, the machine should stand higher than the transport vehicle to avoid

having to lift the grab material unnecessarily.  Stop the transport vehicle in a position that allows it to be loaded from the rear or

the side.  Slew the machine's equipment above the loading area of the transport vehicle.  Distribute the grab material evenly over the loading area of the transport vehicle

by slewing the backhoe bucket and shovel arm out, slewing the upper carriage and possibly also moving the boom.  If the backhoe bucket is not sufficiently emptied or there is still grab material in the

backhoe bucket, slew the backhoe bucket in and out several times to loosen the grab material.

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3.5.5

Working with the Shovel bucket Digging To maximise machine power and breakout, maintain grade and fill the bucket, correct digging angles and technique should be used.


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Fig. 3-81

Digging

 Most digging should be started with the bucket almost fully crowded back (50mm

off stops or end of cylinders).  When cleaning up or digging at floor level, angle the teeth aggressively to break

out any toe that may be encountered.  Keeping the heel of the bucket off the ground th erefore creating a void under the

rear of the bucket.  Operate with the teeth and bucket lip doing all the work.

Note! Avoid digging at right angles to the tracks.

Caution!  Each time the stick is crowded back to commence a cut, extreme caution must

be taken not to hit the tracks.  The clam must always be closed when digging, although don’t slam it shut.

Avoid working on the cylinder limits and bucket stops during the digging cycle. Continual use of these practises will lead to premature failure of seals and Orings and can cause stress fractures to the clam, stick and bucket and damage to the boom and superstructure.  Crowd the bucket in (down) while closing the clam. This practise makes use of

gravity to help minimise shock loading on the bucket cylinders.  Never dig, or attempt to bring d own any material overhang, with the bucket while

the clam is open or partly open.  Do not attempt to dig or clean the floor or face with the clam open. These prac-

tises can cause considerable damage to the clam cylinders.

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Operating manual

Control and operation Transport

Unload the buck et

Fig. 3-82

Unloading of the bucket

When dumping the load, tip the bucket for ward slightly as the clam opens. This helps direct the material to fall centrally into the tray and avoids spillage. The position of the bucket backboard when the clam opens, directly affe cts the position of the load in the tray. Bucket in ideal position resulting in material falling straight down. Loading centre of the haul truck.

3.6 Trans port 3.6.1

Travelling procedures for mining machine The life expectancy of undercarriage components is based on standard working conditions with a maximum travel ratio of 5% per service meter unit. Working and / or travelling on uneven ground and / or abrassive material will influence the lifetime of the components and attract additional cost for the undercarriage components. In general travel action has to be kept to the lowest level that is possible. Minimize travelling with turning through a narrow turning circle and long distance travel. To minimize the travel ratio, professional mine planning with longfront winning sections is preferred. If digging operations at various spots are necessary, a proper short term and long term plan of winning oper ations has to be employed to guarantee long term use of the excavator at one place before moving to another location.

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However, if frequent machine movement is necessary, the following set of procedures defined by LIEBHERR to minimize possible machine damage, downtime and wear have to be taken into consideration.

General In order to move the machine forwards : with the excavator in standard forward position, depress travel pedals all the way forward with the toes. Direction of travel is in the direction of idlers.


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Operating manual

Transport

In order to move the machine backwards : with the excavator in standard forward position, depress travel pedals all the way down with the heels. Direction of travel is in direction of the drive sprockets.

Moving the machine duri ng loading operations Moving the machine during loading operations means adjustment of excavator digging and / or truck loading position of some meters.

Important procedures – Before moving the machine, empty the bucket and close up the attachment to a position as close as possible to the excavator undercarriage. – The practice of placing the attachment on the ground and lifting the machine, then counter turning the undercarriage, is not allowed, because it could cause premature structural damage to the machine. – If there is a build up of material around the tracks where the machine will not turn, you must move the machine several meters forwards and / or backwards and attempt to turn again. – If mine safety regulations allow, the operator can use the swing function to assist in turning the tracks, i.e. if turning to the right, swing upper deck to the lef t and vice versa.

Walking the machine over distance

Fig. 3-83

Hazard area r

Walking the machine distances means any movement of the machine of more than 100 m or for a time period longer than 3 minutes, whatever comes first. In addition to above mentioned guidelines, when moving the machine during loading operations, the following procedures apply : – It is required to have somebody standby with a heat gun, to monitor the temperature of the drive components, including the track and carrier rollers. Danger! The person which is checking the temperature of the different rollers must always be out of the hazard area r of the machine during its movement. For the checking of the temperature, the excavator should stop moving. And only when the excavator is stopped, the person could go in the hazard area r to check the temperature of the different rollers. The machine could only start moving again when the driver has seen the operator out of the hazard area r .

– If temperature of any moving part is growing up about 20°C above ambiant tem-

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Operating manual


perature, interrupt travel and only commence again after parts have sufficiently cooled. – To prevent overheating during travelling or to speed up cooling procedure it is advisable to have a water truck standby, t o hose the heating components during travelling or cooling break. – Move with idler and attachment forwards. Whenever possible, a nd not to contravene with mine safety regulations, swing whilst travelling to equally load track rollers. However, always ensure that clear forward vision is maintained.

Travelling t he machine down gr ades or upgrades In addition to above mentioned guidelines, when moving the machine during loading operations or when walking the machine distances, the following procedures apply : – When travelling down grades greater than ten percent, it would be better to walk the machine down with the track motor first, i.e. the machine is moved backwards. – When travelling up an incline, the final drives must be at the rear of the excavator. – When walking down from a bench, firstly prepare a ramp. Respect the angle value indicated in the "Technical data" section of this manual (machine must be able to walk up unaided). When moving down the ramp never allow the machine to fall down on the attachment. When walking up the ra mp never use attachment to assist the movement by pushing with the hydraulic power of the bucket, stick or boom.

Travelling the machine first tim e The slide bearing (friction bearing) of the track rollers needs some time for runningin. If the bearing becomes hot at an early stage of machine life, this may cause lubrication problems during further life. Therefore when travelling the machine the first time aside from all above mentioned guidelines it is strongly recommended to move carefully and at reduced speed. Note! Warranty may become void if failure to recognize and comply with the recommended travel operating procedures, as outlined in this document, is noted.

3.6.2

Excavator lifting and lashing operations Danger! For safety reasons, always consider the precautions given in this section.

Lifting precautions 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

Lift element: – always checking and respecting the lifting configuration indicated on the corresponding transport drawing, – only with the provided lifting appliances, – with adequate and approved lifting devices of other kind (cables, chains, slings) if necessary, – only after mounting the lifting appliances in accordance with the regulations, – only at the declared threads or lugs shown on the assembly drawing,


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Transport

– with the best possible equal load distribution, – only being sure that the lifted element has been already dismounted, – only after having drained tanks (hydraulic, fuel…), – if no specific value is indicated on the corresponding transport drawing, always respecting the angles given on the figure bellow: •  < 60° •  < 30°

Fig. 3-84

Lifting angles

Lashing precautions

Fig. 3-85

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Lashing angles

A

Diagonally lashing

B

Cross-diagonally lashing

1

Load

4

Transversal axis

2

Lashing chain

5

Longitudinal axis

3

Vertical axis

6

Loading plane

Lash element:

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Operating manual


– always using necessary and appropriate devices or tools (e.g. elevating platform) in order to ensure safe lashing, – always checking and respecting the lashing configuration indicated on the corresponding transport drawing, – if no specific value is indicated on the corresponding transport drawing, always respecting the angles given on the figure above: • 0°    50° • 25°  x  50° – always ensuring a sufficient coefficient of friction (0,2 or higher) between load and supporting surface so as to avoid element to slip (e.g. using wooden parts, nonslip mats...).

Transport drawings The following drawings indicate the different lashing and lifting points on the elements of the excavator. Weight (with and without transport tooling and packaging), overall dimensions as well as gravity center are also given. The aim of these drawings is to ensure safe operatio n during transport, handling and storage. Note! The lashing and lifting points are indicated on the concerned elements of the excavator by specifics labels (see § "Signs on the machine"). To be easily recognized, lifting points are painted in yellow (in red if excavator is yellow) as well.

Danger! The lifting points given on a transport drawing for an element are designed to lift this element only and nothing else.  Never lift an assembly of several elements by the lifting points of only one of the-

se elements.

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Transport

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4 Malfunctions Warning messages and fault m essages:

– Various faults are displayed on screen in the form of indicator lights or symbols (see chapter “Control and operating elements”). – Warning functions can also be supported acoustically (buzzer). Identifying and rectifying faults and errors:

– Faults can very often be traced back to incorrect operating or maintenance of the machine. For each fault, therefore, read the relevant chapter in the operating in struc tions carefully once more. – Analyse the cause of the fault and rectify it immediately. – Describe the fault and all accompanying circumstances a s precisely as possible if you contact LIEBHERR customer service. Precise information makes it possible to find and rectify the cause of the fault quickly. Additionally, therefore, precise information on the type and serial number of the machine is also required. – Do not carry out any work which you have not been trained to do.

Fig. 4-1

LIEBHERR service

If the cause of the fault cannot be recognised or recti fied using t he error c odes and fault ch arts, please consult LIEBHERR customer s ervice. 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L


MJFCIFSS

4-1

Malfunctions

Operating manual

Error code charts

4.1 Error code charts Danger! When switching over to emergency operation, the speed can no longer be changed using the arrow keys on the monitoring screen. The servo control, parking brake and swing gear brake can no longer be activated.  Please also note the section “Emergency operations” in the chapter “Control and

operation” in this regard.

4.1.1

Sensors

Error code

Effect

E 004

Coolant level B3 not being monitored.

E 005

Cause

E 006 E 010 E 011

E 014

Hydraulic oil level B14 not being monitored.

Accidental ground Accidental + Broken wire

Hydraulic oil temperature B67 not being monitored.

E 015 E 454 E 455

E 458 E 465 E 466 E 468 E 469 E 471 E 472 E 474 E 475 E 477 E 478 E 480 E 481

Accidental ground Accidental + Broken wire

Swing speed B53 not being monitored

E 455 E 456

Accidental +

Check coolant level, consult LIEBHERR customer service.

Broken wire

E 012 E 013

Accidental ground

Measure / remedy

Accidental + Broken wire

Check hydraulic oil level, consult LIEBHERR customer service. Check hydraulic oil for contamination, consult LIEBHERR customer service. Consult LIEBHERR customer service.

Accidental ground Fuel level transmitter B1 not being monitored

Accidental ground

Pump 1 leak oil temperature B64_1 not being monitored

Broken wire


Broken wire


Broken wire


Broken wire

Swing pump 1 leak oil temp. B64_7/1 not being monitored

Broken wire

Swing pump 2 leak oil temp. B64_7/2 not being monitored

Broken wire

Broken wire Accidental + Accidental + Accidental + Accidental + Accidental + Accidental +

Consult LIEBHERR customer service. Consult LIEBHERR customer service. Consult LIEBHERR customer service. Consult LIEBHERR customer service. Consult LIEBHERR customer service. Consult LIEBHERR customer service. Consult LIEBHERR customer service.

E 542

Gradient sensor passing over from threshold or parting of a cable

Consult LIEBHERR customer service.

E 599

Default test sensor attenuation


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Operating manual

Malfunctions Error code charts

4.1.2

Regulating circuit

Error code

Effect

E 022

Diesel engine speed B12 not being monitoring, Diesel engine speed cannot be adjusted using keyboard, reduced hydraulic power

Accidental ground

E 027

Solenoid valve for power control Y4 LR1 not being monitored

Cable defect


E 030

Output ventilator oil Y10.2 not being monitored

Cable defect


E 033

Output ventilator water Y10.1 not being monitored

Cable defect


E 036

Output Y3.1 EL1 not being monitored

Cable defect


E 039


Cable defect


E 042


Cable defect


E 023 E 024

4.1.3

Cause

Accidental plus

Measure / remedy


Broken wire

Keyb oar d

Error code

Effect

Cause

Measure / remedy

E 302

Coding plug missed in keyboard

No coding plug


E 303

No CAN 1 connection between control unit S2 and circuit board BST

Error detected also if BST is not operative : no power supply, ...)


E 305

No CAN 2 connection between control unit S2 and circuit board ESP01

Error detected also if ESP01 is not operative


E 312

No CAN 1 connection between control unit S2 and E1036 (connection box pump transmitters)

No CAN bus connection


E 313

No CAN 1 connection between control unit S2 and A1020 (FSG plate)



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MJFCIFSS

4-3

Malfunctions

Operating manual

Error code charts

4.1.4

Display

Error code

Effect

Cause

Measure / remedy

E 308

No CAN 2 connection between control unit S2 and display or no function of the control unit



4.1.5

Co di ng er ro r

Error code

Effect

Cause

Measure / remedy

E 319

Coding BST not compatible with coding control unit S2

Coding error


E 321

Unknown excavator type from BBT

Coding error


E 322

Unknown hardware coding from BST

Coding error


4.1.6

Connection box pump transmitters

Error code

Effect

E 311

No CAN 1 connection on E1036 (connection box pump transmitters)


E 320

No CAN 1 connection between E1036 (connection box pump transmitters) and translater J1939


4.1.7

Cause

Measure / remedy

Joysticks

Error code

Effect

Cause

Measure / remedy

E 411

Problem on A1020 - X96/3 / Swing control

Zero point not allready started


E 413 E 414

Broken wire, Current >21mA or <3mA Problem on A1020 - X96/4 / Stick control

E 416 E 417 E 419



Broken wire, Current >21mA or <3mA Problem on A1020 - X98/3 / Tilt control



Broken wire, Current >21mA or <3mA

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Operating manual


Error code

Effect

Cause

Measure / remedy

E 420

Problem on A1020 - X98/4 / Boom control



E 422 E 423

Broken wire, Current >21mA or <3mA Problem on A1020 - X100/3 / Travel left control

E 425 E 426

Problem on A1020 - X101/3 / Travel right control



Broken wire, Current >21mA or <3mA Problem on A1020 - X102/3 / Trap open control

E 431 E 432



E 428 E 429




Broken wire, Current >21mA or <3mA Problem on A1020 - X102/4 / Trap close control

E 434




4.1.8

Error due to warning symbols in SY field These error codes will not be displayed in the EC field of the operator’s menu. They can only be read off the S-Exxx menu list.

Error code

Effect

Cause

E 459

Injector solenoid driver circuit

Voltage below normal or open circuit

E 460

Symbol appears

Exhaust gas temp. deviation

E 461

Exhaust gas sensor

Voltage below normal or open circuit

E 462

Exhaust gas temp. deviation

Voltage above normal or shorted to high source

E 463

Intake manifold temperature / Symbol appears

Abnormal rate of change

E 495 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

Measure / remedy

See symbol description

Diesel engine is started while coolant temperature too low.

Do not start the Diesel engine as long as the corresponding symbol is on. Install optional preheating system if necessary.

E 501

Symbol appears

Oil pressure low


E 502

Symbol appears

Coolant level low


E 503

Symbol appears

Coolant overheating (moderate or high)


E 504

Symbol appears

Hydraulic oil level low


E 505

Symbol appears

Hydraulic oil overheating



MJFCIFSS

4-5

Malfunctions

Operating manual

Error code charts

Error code

Effect

Cause

Measure / remedy

E 506

Symbol appears

Splitterbox oil temperature too high


E 540

Symbol appears

Coolant pressure low


E 543

Symbol appears

Lifetime sealing oil level low


E 544

Symbol appears

External swing teeth greasing


E 545

Symbol appears

Grease level low


E 562

Symbol appears

Oil level splitterbox low


E 564

Symbol appears

Oil level splittebox high


E 566

Symbol appears

Pump 1 clogged


E 567

Symbol appears

Pump 2 clogged


E 568

Symbol appears

Pump 3 clogged


E 569

Symbol appears

Pump 4 clogged


E 572

Symbol appears

Swing pump 1 clogged


E 573

Symbol appears

Swing pump 2 clogged


E 578

Symbol appears

Overheat pump 1


E 579

Symbol appears

Overheat pump 2


E 580

Symbol appears

Overheat pump 3


E 581

Symbol appears

Overheat pump 4


E 584

Symbol appears

Overheat swing pump 1


E 585

Symbol appears

Overheat swing pump 2


E 590

Symbol appears

Hydraulic tank pressure low


E 591

Symbol appears

Splitterbox oil pressure low


E 592

Symbol appears

Centinel oil level


E 593

Symbol appears

Fuel temperature


E 594

Symbol appears

Fuel pressure


E 595

Symbol appears

Blowby pressure


E 596

Symbol appears

Engine oil level


E 597

Symbol appears

Manifold temperature


E 598

Symbol appears

Oil change required


D 115

Engine magnetic speed / Symbol appears

Position lost both of two signals

D 214

Symbol appears

Engine oil overheating

D 234

Engine crankshaft speed / position to high / Symbol appears

Most severe level

D 342

Electronic calibration code incompatibility / Symbol appears

Out of calibration

D 418

Symbol appears

Water in fuel


D 421

Symbol appears

Engine oil temperature high


D 441

Symbol appears

Battery voltage low


D 442

Symbol appears

Battery voltage high


D 449

Symbol appears

Rail overpressure



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Operating manual


Error code

Effect

Cause

D 599

Auxiliary commanded dual output shutdown / Symbol appears

Special instructions

D 689

Engine crankshaft speed/ position / Symbol appears

Data erratic, intermittent or incorrect

1257

At least one intake manifold temperature / Symbol appears

Abnormal rate of change

1362

Symbol appears

Engine oil filter diff. pressure

1517

At least one module has a most severe fault / Symbol appears

Condition exists

1518

At least one module has a moderately severe fault / Symbol appears

Condition exists

1519

At least one module has a least severe fault / Symbol appears

Condition exists

1852

Symbol appears

Water in fuel high level


2963

Symbol appears

Coolant overheating (low)


4.1.9

Measure / remedy


Heating/air conditioning system Note! The following error codes concerning the heating and air conditioning system are displayed directly on the front panel of its control unit.

2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

Error code

Affected elements

Description / possible causes

Possible effects / measures

F0

Room temperature sensor

Short circuit or disconnection of cable, connector or control unit. Defective sensor.

Control function no longer operational.

F1

Exhaust air temperature sensor



F2

Exhaust air temperature sensor (head area)



F3

Outside temperature sensor



F4

High-/Low pressure switch

Failure on condenser fan, evaporator blower, expansion valve, compressor or refrigerant circuit.



MJFCIFSS

4-7

Malfunctions

Operating manual

Faults and remedies

4.2 Faults and remedies 4.2.1

Diesel engine and fuel system

Fault / error

Diesel engine does not start

Cause

Solution

Fuel tank almost or completely empty

Fill tank and vent fuel system

Shut off valve closed

Open the shut off valve

Fuel filter dirty

Clean or change filter and vent fuel system, drain fuel / clean tank

Outside temperature below 0°C

For operation under specific climatic conditions, see operating instructions

Starter motor not drawing through

Check line connections, overhaul starter motor

Batteries have no power

Charge / replace

Fuel tank empty (low pressure in tank)

Fill tank and vent fuel system

Fuel filter dirty

Clean or change filter and vent fuel system (tank)

Particularly in winter: too viscous engine oil used

Use engine oil suitable for the outside temperature

Dry-air filter dirty

Clean or change main filter element

Air in fuel system

Bleed fuel system

Ventilation in fuel tank obstructed

Clean

Fuel line bent

Check line and repair if required

Diesel engine emitting grey or black smoke


Clean or change filter

Diesel engine continually emitting white smoke (steam)

Water in combustion chamber

Consult customer service

Diesel engine does not reach full speed

Speed adjustment not set to maximum value

Set speed adjustment to maximum value

Injection system is set incorrectly



Clean or replace filter

Bad fuel supply

Clean or change fuel filter, check lines, drain water from tank

Too little coolant

Fill coolant, check for leaks

Water pump defective

Repair

Thermostats do not work

Change thermostats

Coolant contaminated

Clean coolant

Oil level too low

Correct oil level

Oil pressure display faulty

Change oil pressure switch

Engine starts but stops immediately after or runs irregularly

Diesel engine becomes too hot

Diesel engine has insufficient oil pressure Note! Switch off diesel engine immediately

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MJFCIFSS

R9400 / 11000047

2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

Operating manual

Malfunctions Faults and remedies

Fault / error

Cause

Diesel engine consumes too much oil

Solution

External leak on diesel engine

Oil in coolant or coolant in oil


Unusual noise / sounddevelopment on exhaust side

4.2.2

Retighten screws, replace seals if required

Exhaust system leaking

Check exhaust system / repair

Hydraulic system

Fault / error

Cause

Solution

Unusual noise / sounddevelopment at hydraulic pumps Note! Switch off diesel engine immediately

Shutoff valve on hydraulic tank closed

Open the shutoff valve

Hydraulic pumps taking in air

Check oil level in hydraulic tank, check intake lines for leaks

Hydraulic oil temperature too high

Coolant contaminated

Clean coolant

Fan or fan control defective

Rectify error / consult customer service

Hydraulic oil level too low

Oil loss

Repair leaks, exchange hoses, refill oil via return-line filter

Cannot drive

Push the safety lever up

Push the safety lever down

Swing gear not functioning

No servo control

Push the safety lever down Switch on servo control

Swing gear brake activated

Push the safety lever down Release swing gear brake

No working movement

No servo control

Push the safety lever down Switch on servo control

4.2.3


No pump high pressure present


Tr an sm is si on

Fault / error

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No servo pressure present

Cause

Solution

Oil flowing out on track rollers, support rollers or leading wheel

Seal defective

Replace seal

Insufficient crawler tracking on leading wheel

Leading wheel tracking on track rol- Adjust the leading wheel tracking ler mounting has too much play play

Chain jumps off or over

Chain tension too low / crawler wheel worn

Adjust chain tension

Correctly tensioned crawler losing tension quickly during chain

Chain tensioning cylinder defective

Check chain tensioning cylinder, change if required or seal (only authorized specialist personnel)

Track roller or support roller sticking

Running gear extremely dirty

Clean running gear


MJFCIFSS

4-9

Malfunctions

Operating manual

Faults and remedies

4.2.4

Electrical system

Fault / error

Cause

Battery charge indicator light does not goes out

Solution

Drive belt for alternator loose or torn

Tension or replace drive belt

Alternator defective

Replace alternator

Batteries defective

Replace batteries

Battery connections dirty / oxidised

Clean battery connections

Cable loose or damaged

Connect or replace cable

indicator light or display instrument not functioning or functioning incorrectly

Bulb burnt out, display instrument defective

Replace defective part

Some or all functions on instrument panel drop out

Plug connector separated or damaged, earth lead interrupted, short circuit fuse defective

Mount plug connector correctly or change, rectify short circuit, replace fuse or activate overload cut-outs

Servo control cannot be activated using switch

Excavator electrics faulty

Switch on emergency function using switch S73 in the right control panel Caution: Servo circuit and brake circuit can only be switched off using the safety lever. Keypad not functioning. Consult customer service.

Batteries do not charge or charge poorly

Swing gear brake cannot be released using switch

4.2.5

Heating/air-conditioning system

Fault / error

Cause

Heating not giving out warm air

Heating fan does not operate Only low air flow in cab

4.2.6

Solution

Shutoff valves for coolant line on diesel engine closed

Open shutoff valve

Engine not at operating temperature

Bring engine to operating temperature

No power supply

Check fuse and wiring / repair

Fan motor defective

Change fan motor

Outside air filter / recirculated air filter dirty

Clean air intake opening, replace outside air filter

Air vent closed

Open air vent

Work equipment

Fault / error

Cause

Solution

Cylinder stretches when loaded

Piston seal in cylinder defective

Overhaul cylinder

Bearing clearance too high on equipment

Bearing points worn out

Replace bearing parts

Bucket does not move

Valve block on tilting cylinder incorrectly switched

Switch over valve block

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MJFCIFSS

R9400 / 11000047

2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

Operating manual

Malfunctions Fuses and relays

4.3 Fuses and relays

Danger! Incorrect or bypassed fuses do not offer the machine's operator or the electrical system the required degree of protection.  Only use original fuses.  Never bypass electrical fuses.  If required, order replacement fuses from LIEBHERR.

4.3.1

Power electrical box E1003 The power electrical box E1003 is located under the cabin in the cab elevation.

2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

Fig. 4-2

Power electrical box E1003

K11

Relay current charging

K20_2

Relay attachment floodlight

K16_1

Startrelay E1003

K20_3

Relay fuel tank floodlight

K16_2

Startrelay E1003

K20_4

Relay hydraulic tank floodlight

K19_1

Relay Kl15

K20_5

Relay counterweight floodlight


MJFCIFSS

4 - 11

Malfunctions

Operating manual

Fuses and relays

K19_2

Relay Kl15

K20_6

Relay counterweight floodlight

K19_3

Relay Kl15

K20_7

Relay reserve

K19_4

Relay Kl15

K110

Relay for M10

K20_1

Relay attachment floodlight

K112

Relay for M11

Fig. 4-3

Fuses in power electrical box E1003

F12_1

Fuse / attachment floodlight

F131

Reserve

F12_2

Fuse / attachment floodlight

F137

Fuse / Quantum

F12_3

Fuse / fuel tank floodlight

F138

Fuse / service circuit supply

F12_4

Fuse / hydraulic tank floodlight F139

Fuse / M10 supply

F12_5

Fuse / counterweight floodlight F140

Fuse / board

F12_6

Fuse / counterweight floodlight F141

Fuse / E14

F20_1

Fuse / supply cabin Kl15

F142

Fuse / lighting

F20_2

Fuse / supply E1005 Kl15

F143

Fuse / lighting

F20_3

Fuse / charging current

F144

Fuse / ladder / trap door

F20_4

Fuse / Kl30 floodlight

F145

Reserve

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MJFCIFSS

R9400 / 11000047

2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

Operating manual

Malfunctions Fuses and relays

4.3.2

F20_5

Fuse / Kl30 counterwght flood. F147

Fuse / M11 supply

F20_6

Fuse / engine

F152

Fuse / Quantum

F37

Fuse / ether

F164

Fuse / E1003

F119

Fuse / S1 / Kl30

F166

Reserve

F120

Fuse / air conditionning

F167

Fuse / elevation pressure fan

F121

Fuse / air conditionning

F169

Fuse / charging

F122

Fuse / option. windshield wiper F170

F123

Fuse / supply A1020

Reserve

Cabin electrical box E1005 The cabin electrical box E1005 is located in the cabin, behind the operator’s seat.

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Fig. 4-4

Cabin electrical box E1005

F29

Fuse / reserve cameras

K22_1

Relay / reserve

F30

Fuse / attenu. plate supply res. K22_2

Relay / reserve

F31

Fuse / A1020 boom / shovel tilt K23

Relay second air conditionned

F32

Fuse / A1020 stick / swing

Relay / travel alarm

F33

Fuse / A1020 travel / trap door K99

K98

Relay / supply A1020


MJFCIFSS

4 - 13

Malfunctions

Operating manual

Fuses and relays

4.3.3

F34

Fuse / A1020 FSG

K139

Relay / fire alarm

F35

Fuse / A1020 controller FSG

K183

Relay / reserve

F124

Fuse / S7, A1001

K193

Relay / reserve

F125

Fuse / A1019, U16

KT10

Relay timer emergency stop

F126

Fuse / A1001

KT17

Relay timer / reserve

F127

Fuse / greasing

KT51

Relay timer / reserve

F128

Fuse / board

F129

Fuse / cabin

F130

Fuse / A1001

F148

Fuse / A1019

F161

Fuse / A1036

Heating / air-conditioning electrical box E1006 Heating / air-conditioning electrical box E1006 is located in the ceiling of the cab.

Fig. 4-5

Heating / air-conditioning electrical box E1006

F131

Fuse / evaporator engine 1

K23A

Relay / second air conditioner

F132


K121

Relay / switching A/C

F133


K273

Relay / heater

F134

Fuse / heater motor

KT52

Relay timer / air conditioner

F135

Fuse / motor dryer 2

F136

Fuse / motor dryer 2

F190

Fuse / air conditioning

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R9400 / 11000047

2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

5 Maintenance 5.1 Servicing the machine safely General safety inst ructi ons – Maintenance and repair work may only be carried out by specially trained personnel. – Observe statutory timetables or intervals given in the operating instructions for repeat tests / inspections. It is imperative that a suitably equipped workshop is available in order to carry out maintenance work. – The inspection and maintenance schedule given at the end of these operating instructions defines precisely who is required / permitted to carry out what work. Jobs listed as daily / weekly work may be carried out by the machine's driver or maintenance personnel when they have received appropriate instruction. The remaining work may only be carried out by specialist personnel with appropriate training. – Replacement parts must correspond to the technical requirements determined by the manufacturer. Original replacement parts are always guaranteed to meet t hese criteria. – Always wear safe work clothes when carrying out maintenance work. Avoid the wearing of rings, wrist watches, ties, scarves, open jackets, baggy clothing etc... There is a risk of injury from, for example, getting caught up or being drawn in. Protective goggles, safety helmets, safety shoes and gloves, reflective vests and ear protection etc. are required for specific jobs. – Do not remain in direct proximity of the diesel engine while the diesel engine is running. Persons with pacemakers should not approach within 20 cm of the running diesel engine. Do not touch voltage-carrying parts on the electrical connection of the individual solenoid injection pumps (Unit Pumps UP) while the diesel engine is running. – Do not permit unauthorised persons to approach the machine during maintenance work. – Cordon off a wide maintenance area if required. – Inform operational personnel before starting to carry out any special work and repair work. Designate persons in charge of supervision. – In the absence of any other information in the operating instructions, carry out all maintenance work on the machine on level, firm ground with the working equipment set aside and the engine switched off. – For some machines, the only one position which enables a secured access to every maintenance locations on the uppercarriage, is when the uppercarriage is aligned with the undercarriage so that the sprockets locate at the back-end. The ladder situated on the undercarriage only corresponds with the uppercarriage’s access when the excavator is in this configuration.

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– Pull out the ignition key and shut off the main battery switch. – Always tighten any loose screw connections during maintenance and repair work. – The mounting bolts of the main components, of the hydraulic hoses and of the counterweight must be replaced after every removal. – If safety devices have to be dismantled during set-up, maintenance and repair work, they must be immediately reinstalled and checked at the end of the work.


MJFCIFSS

5-1

Maintenance

Operating manual

Servicing the machine safely

– When carrying out repair work, particularly when working under the machine, hang a “Do not start” warning sign in a clearly visible position on the control panel. Pull out the start key and shut off the main battery switch. – Operate combustion motors and fuel operated heaters only in well ventilated areas. Before operating these units, check ventilation. – In addition, always follow applicable local regulations.

Cleaning – Clean oil, fuel or care products off the machine before starting maintenance or repair work and pay particular attention to connections and screw fittings. Do not use aggressive cleaning products and use lint-free cleaning cloths. – Do not use aggressive cleaning products or steam jet devices to clean the machine for the first two months after initial set-up of the machine (or after repainting). – Do not use combustible liquids to clean the machine. – Before cleaning the machine with water or steam jets (high pressure cleaner) or other cleaning materials: • lubricate all bearing points, bolt connections and the rim bearing to prevent water or steam entering the bearing points. • cover or glue shut all openings into which for safety or functional reasons water or steam may not be permitted to enter. Electric motors, electrical components, control boxes, plug connections and air filters are particularly at risk. – Ensure that the fire warning systems and fire extinguishers of the engine compartment’s temperature sensor do not come into contact with hot cleaning products during cleaning work. The fire extinguisher could start. – If you use a high pressure cleaner with steam or hot water to clean the machine, observe following recommendations : • the distance between the nozzle and the surface to be cleaned must be no lower than 20 inches • the water temperature should not exceed 60°c (140°F) • limit the water pressure to 80 bar maximum (11500 PSI) • if you employ cleaning fluid, only use neutral cleaning agents such as customary car shampoos diluted to 2 or 3 percent maximum – After cleaning: • remove all covers completely. • check all fuel, engine oil and hydraulic lines for leakage, loosened connections, chafing and damage. • rectify any defects found immediately. • lubricate all bearing points, bolt connections and the rim bearing to displace any water or cleaning products that may have entered.

Field of view – Mirrors and cameras, which were possibly removed for the transport, must be inevitably reinstalled and correctly adjusted before the initial set-up of the machine. – Regularly check that the interior and exterior mirrors as well as the cameras are correctly adjusted. – Control the surroundings, and particularly the nearness area of the machine, during operation or when travelling. – Mirrors are installed on the machine: • on the left to check the left side of the machine. • on the front to check the front side of the machine.

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MJFCIFSS

R9400 / 11000047

2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

Operating manual

Maintenance Servicing the machine safely

• on the right to check the right side of the machine. • above the counterweight to check the rear side of the machine. – On some machines, some mirrors may be replaced with cameras. – At each extension, construction or change on the machine, the sight conditions must be maintained. These conditions must otherwise be checked according to ISO 5006. – Mirrors must be cleaned at least at daily intervals. – Damaged mirrors and cameras must be immediately replaced. – The site has to be organised so that the dangers due to a restricted field of view are minimized, particularly for machines with an operating weight which is superior to 40 tons.

Crack t esting – Even when the machine is operated carefully, there is a possibility of individual cases of overloading occurring, which could lead to cracks or loose connections. The machine should therefore be checked regularly for cracks, loose co nnections or other visible damage to maintain operational safety. – In order to be able to check for cracks, it is essential that the machine is kept clean and cleaned regularly. – The tests should be carried out in accordance with the monitoring and maintenance plan: • every 250 operating hours by the machine owner’s maintenance personnel. • every 500 operating hours by authorised specialist personnel. – It is advisable to carry out these tests: supported, on firm, horizontal substrate, with the equipment in longitudinal and cross direction for variable loads. Current accident prevention regulations must be adhered to. – Especially check the supporting components, in particular : • framed construction undercarriage with axle and gearbox storage, support outriger, lower slewing ring support with tower and slewing ring. • framed construction uppercarriage with bearing for boom and hoist cylinder, upper slewing ring support, cab suspension, mounting fo r slewing gear and counter weight. • framed construction components of attachments, e.g. boom, stick, quick change adapter, digging tool and grapple. • hydraulic cylinders, axles, steering, pins and pin connections, ascents, ladders and mounting elements. – The crack test should be carried out visually. If a crack is suspected, the dye penetration test should be carried out as a crack test on areas which do not have good visibility, such as the ring bearing support, in order to increase testing safety. – Any damage found must be rectified immediately. Welding work on load -bearing parts of the earth-moving machinery, loading devices and transport devices may only be carried out by trained specialist personnel and only in accordance with the accepted rules of welding engineering. In case of doubt, contact the LIEBHERR customer support service to discuss suitable remedies.

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Welding, drilling, firing and grinding work – Any welding on structural parts (as undercarriage, uppercarriage, equipment parts,…) may only be done the manufacturer, or authorized official dealer. If this rule is neglected, the warranty is voided.


MJFCIFSS

5-3

Maintenance

Operating manual


– Only carry out welding, drilling, firing and grinding work on the machine with express authorization. Clean dust and combustible materials off the machine and its surrounding areas before welding, drilling, firing or grinding. Ensure adequate ventilation. Risk of fire or explosion. – Before welding repairs on other parts, always disconnect the bat tery. Always remove the negative terminal first and reconnect it last. – Nevertheless if welding repair should be done on components which may contain inflammable gases (welded counterweight, hydraulic tank, fuel tank, …), these components must be previously and sufficiently ventilated with pressurized air to avoid all fire or explosion hazard – Before welding, connect the ground cable as close as possible to the welding point, so the welding current will not run through the swing ring, joints, gears, bushings, rubber parts and seals

Process m aterials – When working with oils, greases and other chemical substances, observe the appropriate current safety regulations for the product. – Ensure that process materials and replacement parts are disposed of in a safe and environmentally acceptable manner. – Take care when handling hot process materials (Risk of burning and scalding).

Repair work – Do not attempt to lift heavy parts. Use devices which are suitable for this purpose and which have sufficient load capacity. When replacing single parts and larger subassemblies, carefully secure them on lifting devices them so that they do not present a risk. Only use suitable and correctly functioning lifting devices and load take-up devices with adequate load capacity. Do not stand or work under swinging loads. – Do not use lifting devices which are damaged or do not have sufficient load carrying capacity. Wear work gloves when working with wire cables. – Authorize only experienced people to attach load and to give indications to the crane operator. This people must be in the operator’s sight or in radio contact with him. – When working above body height, use safe climbing devices and working platforms which are appropriate for the job. Do not use machine parts as climbing devices if they are not designed for this purpose. When working at height, wear a harness to prevent falling. Ensure that all grips, steps, rails, platforms and ladders are free of dirt, snow and ice. – Pneumatic cylinders do not have to be used as handles. Open doors and covers carefully, so that pneumatic cylinders do not hit their stops, because this could cause mechanical damages. – Make sure the equipment on which you will operate is securely supported before working (e.g. replacing teeth). Prevent metal touching metal when doing this. – For safety reasons, never open and remove a track chain unless having previously totally released the pretension of the chain tensioning unit. – Never lay under the machine if it is raised with work equipment and has not been securely supported with appropriate supports.

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MJFCIFSS

R9400 / 11000047

2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

Operating manual

Maintenance Servicing the machine safely

– Always jack the machine up in such a way that any weight displacement does not jeopardize stability and prevent metal touching metal while doing this. – Work on the suspension, brake and steering systems may only be carried out by trained specialist personnel. – If the machine has to be repaired on a slope, secure the crawler with chocks and connect the upper structure to the chassis using stop bolts. – Only personnel with special training and experience may work on hydraulic equipment. – When searching for leakage, wear protective gloves. A fine jet of liquid under pressure can penetrate the skin. – Do not unscrew any lines or connections before you have set aside the equipment, switched off the engine and depressurized the hydraulic system. After switching off the engine, with the start key in contact position and with the safety lever down into its lowest position, you must operate all pilot control devices (joystick and pedals) in all directions in order to reduce the actuating and dynamic pressures in the work circuits. You must then reduce the internal tank pressure as described in these operating instructions.

Electri cal system – Check the electrical system regularly. Have all faults, such as loose connections, blown fuses and lamps and clogged or abraded cables rectified by personnel. – Only use original fuses with approved current strength. – For machines with electrical neutral and high tension leads: • switch the machine off immediately in the event of malfunctions in the power supply. – Work on the machine’s electrical equipment may only be carried out by skilled electrical personnel or by trained personnel under the supervision of an electrician in accordance with electrical regulations. – When working on live parts, ensure that a second person is available t o operate the emergency-off or the main switch and overvoltage release. Cordon off the working area with a red and white safety chain and a warning sign. Only use insulated tools. – When working on neutral and high tension subassemblies, after releasing the voltage, briefly disconnect the supply cable at earth and electronic devices such as capacitors using an earthing rod. – First test the released parts to make sure that they are off circuit, earth them and then disconnect them briefly. Insulate adjacent live parts. – Disconnect the battery before working on the electrical system or carrying out any electric arc welding on the machine. First disconnect the negative, then the positive pole. When reconnecting, proceed in the reverse order. 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

Hydraulic accumulator – All work on the hydraulic accumulators must be carried out by trained specialist personnel. – Inexpert assembly and handling of hydraulic accumulators can cause serious accidents. – Do not operate damaged hydraulic accumulators.


MJFCIFSS

5-5

Maintenance

Operating manual


– Before working on a hydraulic accumulator, you must reduce the p ressure in the hydraulic system (hydraulic system including hydraulic tank), as descr ibed in these operating instructions. – Do not carry out welding or soldering or do any mechanical work on the hydraulic accumulator. The hydraulic accumulator can be damaged by heat penetration and can be made to rupture by mechanical working. RISK OF EXPLOSION! – Only charge the hydraulic accumulator with nitrogen. There is a RISK OF EXPLOSION if oxygen or air is used. – The accumulator body can become hot during operation; there is a risk of burning. – New hydraulic accumulators must be charged with the pressure required for the purpose of use before installation. – The operating data (minimum and maximum pressure) are marked permanently on hydraulic accumulators. Ensure that this marking remains visible.

Hydraulic lin es and hos es. – It is forbidden to carry out repair work on hydraulic lines and hoses! – All lines, hoses and bolt connections must be checked regularly for extern ally visible damage and any possible damage must be immediately checked for leakage. – Never check for leaks with your bare hands, use a sheet of paper or something else. – Any damaged parts must be removed immediately! Spurting oil can lead to injury and burns. – Even with correct storage and perm itted load, lines and hoses are subject to the natural aging process. This restricts their duration of use. • Incorrect storage, mechanical damage and unauthorized load are the most common causes of failure. • In relation to duration of use, current norms, regulations and guidelines pertaining to lines and hoses at place of use must be adhered to. • Use at the limit range of permissible load can shorten duration of use (e.g. high temperatures, frequent movement cycles, extremely high pulse frequencies, multiple shift usage). – Lines and hoses should be replaced if the following are found during inspection: • Damage to the outer sheath as far as the liner (e.g. chafing, cuts and cracks); • Brittleness of the outer sheath (fracture formation in hose material); • Deformations which do not correspond to the natural form of the line or hose, whether in a unpressurized or pressurized state or on bends e.g. sheath separation, blistering; • Unsealed areas; • Non-adherence to requirements during installation; • Damage or deformations to the hose fittings which reduce the tightness of the fittings or the hose / fitting connection; • Hoses working themselves out of the fittings; • Corrosion of the fittings which reduces function and tightness; – When replacing lines and hoses, use only original replacement parts. – Install and mount lines and hoses correctly. Do not mix up the connections.

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MJFCIFSS

R9400 / 11000047

2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

Operating manual

Maintenance Maintenance access doors

– The following is to be noted when replacing lines and hoses: • Always ensure that the lines and hoses are installed free of torsion. For highpressure hoses, the screws from the half-clamps or full flange must always be attached to both hose ends and should only be tightened afterwards. • When tightening the flange on high-pressure lines and hoses with bent fittings, the side with the bent fitting must always be tightened first and then the side with the straight fitting tightened afterwards. • Any mounting clamps which are located in the centre of the hose may only be attached and tightened subsequently. • Check daily to ensure that all clamps, covers and protective devices are properly fastened. Doing this will prevent vibration and damage during operation. • Install the lines and hoses in such a way that they cannot chafe on other lines, hoses or parts. • A minimum distance from other parts of approx. half the exterior diameter of the hose is recommended. The distance should not, however, be less than 10 to 15 mm. • When replacing the lines or hoses on moving parts (e.g. from the boom to the stay), check before initial start-up that there are no chafing areas in the entire area of movement.

5.2 Maintenance access doors The machine has access doors for maintenance. The locks integrated in the handles must be unlocked before starting to drive. Caution! Access doors can close accidentally and trap the operator or maintenance personnel.  When you have opened the access doors, latch them using the retainer.

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MJFCIFSS

5-7

Maintenance

Operating manual

Maintenance access doors

Fig. 5-1

Access doors

1

Counterweight access

5

Fuel tank and cab elevation access

2

Left catwalk access

6

Right catwalk access

3

PowerPack access

7

Counterweight access

4

Centralized lubrication system access

8

Pumps and splitterbox access

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MJFCIFSS

R9400 / 11000047

2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

Operating manual

Maintenance Lubricants and operating fluids

5.3 Lubricants and operating fluids 5.3.1

General information on changing lubricants and operating fluids Note The quantities given in the lubrication and operating mater ial chart and on the lubrication chart in the cab are only guide values.  After each oil change or refill, check the level in the relevant unit.

Note! Adhering to regulations for lubrication, level checks and operating material changes guarantees a high degree of reliability and a long service life for the machine. It is particularly important to adhere to the oil change intervals and use the spe cified type of lubricant.  Observe the following when using and checking lubricants and operating fluids:

– see "Lubricants and operating fluids" – see "Inspection and maintenance schedule"

Note! Cleanliness is of the utmost importance when changing oil.  Clean all filler plugs, filler covers and drain plugs and their surroundings before

opening.  For preference, drain off oil when it is at operating temperature.  Ensure that old oils are collected and disposed of in an environmentally accep-

table manner using the removable oil filter cartridges.

Danger! When checking and changing lubrication and operating materials, ensure that the following precautions are adhered to:  Unless otherwise indicated, carry out all work on the machine on level, solid

ground and with the engine switched off.  Whenever you reach into the engine compartment, always secure the cover and

side doors against accidentally falling back or closing.  Only refuel the machine when the engine is switched off, do not smoke and

avoid naked flame. 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

 Turn the main battery switch to position 0 (off) and remove the ignition key.


MJFCIFSS

5-9

Maintenance

Operating manual

Lubricants and operating fluids

5.3.2

Lubricating chart

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Fig. 5-2

Lubricating chart

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MJFCIFSS

R9400 / 11000047

Operating manual


Symbol

Display

Quantity*

Diesel engine Reserve system Engine coolant Hydraulic system Swing gear Travel gear Lifetime sealing interspace Splitterbox Fuel Grease / Swing ring teeth Grease Coupling Windshield washer Check oil level Oil change First oil change Oil analysis

Tab. 5-1

Lubricating chart key

*The given quantities are only guidelines. Check fluid level after each change or refilling.

5.3.3

Service trap To simplify the oil change and the refilling procedure, the drain of the following major components on the uppercarriage are centrally connected to a service trap:

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• • • • • • • •

The lube oil for the Diesel engine The optional reserve system or Centinel The splitterbox The two swing gears The fuel tank The hydraulic oil tank The tank for windshield washer fluid The grease tank for general lubrication


MJFCIFSS

5 - 11

Maintenance

Operating manual


• The grease tank for swing ring teeth lubrication Component

Adapter WIGGINS

Flow max.

Swing gear

OSP2

50 l/min

Splitterbox

C-1807

50 l/min

Engine oil

OSP2

50 l/min

Oil reserve

OSP2

50 l/min

Hydraulic oil

6000B12

100-200 l/min

Fuel

ZZ9A 1

500 l/min

Windshield washer

EC280B8

25 l/min

Principal grease

OSP2

15-30 l/min

Teeth grease

6000B12

15-30 l/min

Tab. 5-2

Service trap couplings

Fig. 5-3

Service trap 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L

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MJFCIFSS

R9400 / 11000047

Operating manual


5.3.4

Lubricant chart

Designation

Medium

Diesel engine

Engine oil

Symbol

Classification

Quantity*

210 l. See the Operation and Maintenance Manual fo r CUMMINS engine. 300 l.

Reserve system

Hydraulic tank

See section "Lubricating and ope- 2200 l. in hydraulic tank rating material specifications" . 4200 l. in whole system

Swing gear

Transmission oil

See section "Lubricating and ope- 2 x 39 l. rating material specifications" .

Travel gear

Transmission oil

See section "Lubricating and ope- 2 x 80 l. rating material specifications" .

Lifetime sealing interspace

Engine oil

Use same oil as used for hydraulic tank.

2 x 8 l.

Use same oil as used for hydraulic tank.

4 x 0,4 l.

Travel brake

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Viscosity

Splitterbox

Transmission oil

API-GL-5 SAE 90 MIL-L 2105 B, C or SAE 80W-90 D

65 l. in splitterbox 90 l. in lub. pump

Elastic coupling

Lube oil for elastic coupling

Mercedes Benz 228.1

1,35 l.

Swing ring roller bearing races and general lubrication points

Lubricating grease

Multipurpose grease Consistency 2 200 l. KP2k or EP2 (extre- NL GI N°2 Grame pressure N°2 de grade)

Swing ring teeth

Lubricating grease

Special grease 80 l. See section "Lubricating and operating material specifications".

Track roller

SAE15W-40

ITT

ITT L203

18 x 3,8 l.

Berco

90% Agip Rotra LSX 10% Agip Rocol ASO R

18 x 2,7 kg.


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Maintenance

Operating manual


Designation

Carrier roller

Idler Wheel

Medium

Symbol

Classification

Viscosity

Quantity*

ITT

ITT L203

4 x 1.0 l.

Berco


4 x 2,04 kg

LEC

PANOLIN EP Gear Synth ISO 220

4 x 2,35 l.

ITT

ITT L227

2 x 4,83 l.

Berco


2 x 3,04 kg

LEC

BP Energear HYPO SAE 80W-90

2 x 4l

Hinges, joints, locks

Engine oil

-

-

-

-

Rubber seal on doors and trim panels

Silicon spray or talc

-

-

-

Tab. 5-3

Lubricant chart


5.3.5

Operating material chart

Designation

Medium

Fuel tank

See the Operation and Maintenance Manual for CUMMINS engi ne.

6908 l.

Engine coolant

See the Operation and Maintenance Manual for CUMMINS engi ne.

320 l.

Windshield washer system

Commercially available windshield washer fluid or denatured alcohol

Refrigerating agent for air conditioner

R 134 a

-

7 kg

Refrigeror oil in air conditioner compressor

PLANETELF PAG SP 20

-

0,207 l.

Tab. 5-4

Symbol

Quantity*

- 75 l.

Operating material chart


5.3.6

Service trap For safety reasons and ease of maintenance, oil for the connected components should only be drained and refilled via the quick-change couplings in the service trap.

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Operating manual


However, these components are also equipped with oil drain valves, see description for oil change procedure of these components.

To lower and raise the servic e trap

Fig. 5-4

Control box E1022_2 and disable lock button S122 on control board

When the service trap is lowered, the service plate is accessible from the ground level. The service trap can be moved up and down via the four push buttons on the con trol box E1022_2 mounted on the access ladder. The service trap can also be actuated with the engine shutted down. It should only be moved out if the uppercarriage and the undercarriage are aligned. To lower the service trap from its uppermost po sition  First push the switch S161 to unlock the trap.  Then push the switch S162 to move the trap downward.

To retract the trap  First push the switch S159 until the red indicator light H69 goes out.  Then push the switch S160 to lock the trap until the lock pin has reached its stop

position.

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The lighting of the red indicator light H70 indicates that the locking pin of the trap is not in end (locked) position. The lighting of the red indicator light H69 indicates that the trap is not in upper end position. The locking of the trap via switch S160 is possible only when light H69 is out.


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Maintenance

Operating manual


Caution! For safety reasons, the excavator can only be operated if the service trap is locked in its uppermost position. Otherwise the red indicator light H70 goes on. This means that the swing and travel movements remain locked.

However, this safety measure can be bypassed for as long as the button S122 on the right front instrument panel is depressed.

5.3.7

Location of oil sample points To make the oil sampling easier, some components of the excavator have been fitted either with an oil sample extraction valve (Diesel engine, splitterbox, hydraulic circuit), or with a special drain valve allowing good accessibility and sampling conditions (both travel gears).

Fig. 5-5 5

Oil sample point

Cap

6

Flow adjustment valve

To make an oil sample:  Remove cap 5.  Attach a sampling hose, e.g., a high-pressure hose for pressure gauge.  Turn the valve 6 to adjust and close off the oil flow.

Note! The location of these sample points is indicated in the description for oil change for the concerned components further in this chapter.

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Operating manual

Maintenance Lubricating and operating material specifications

5.4 Lubricating and operating material specifications 5.4.1

Lubrication oil for the diesel engine Standard or with the Centinel system. See the Operatio n and Maint enance Manual for CUMMINS engine.

5.4.2

Fuel See the Operatio n and Maint enance Manual for CUMMINS engine.

5.4.3

Hydraulic oil specifications for LIEBHERR Mining excavators Hydraulic oils must meet the requirement outlined below (depending on temperature range). Non-compliance with these requirements shall void all warranty and liability by LIEBHERR. Maximum water content of hydraulic oil : <0,1%. Caution! According to the oil type used for the hydraulic system, the fans speed regulation must be set specifically ("STANDARD ", "COLD" or "EXTRA-COLD").

– If the excavator is delivered without arctic kit, it is set to "STANDARD " at delivery. – If the excavator is delivered with an arctic kit, it is set to "COLD" at delivery. Before first start of the excavator or if an oil type change is done afterwards, the fans speed regulation setting must be checked and corrected if necessary.  Contact LIEBHERR Customer Service. 2 1 0 2 / 6 0 : n o i t i d E / n e / C E L


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Maintenance

Operating manual

Lubricating and operating material specifications

LIEBHERR oils for hydraulic syst em Requirements

Fig. 5-6

LIEBHERR oils for hydraulic system

A Ambient air temperature B

Operating range

C

Extra-cold start range if excavator fitted with operating Liebherr arctic kit (with warm-up instruction)

Fans sp eed regulation s ettings LIEBHERR oil

fans speed regulation setting

Liebherr Hydraulic Plus

"STANDARD "

Liebherr Hydraulic Basic 68

"STANDARD "

Liebherr Hydraulic Basic 100

"STANDARD "

Liebherr Hydraulic HVI

"COLD"

Liebherr Hydraulic Plus Arctic

"EXTRA-COLD"

Engine oils for hydraulic system Requirements

Fig. 5-7

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Engine oils for hydraulic system

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Operating range

C


Caution! Minimum ambient air temperature for extra-cold start depends on oil type and brand and equals to oil pourpoint temperature +5 degrees K.

Recommended and approved are engine oils, which conform to the following specifications: – Single viscosity oils: API - CD / ACEA - E1 Mercedes-Benz specifications Nr. 226.0 and 227.0 – Multi viscosity oils:

API - CD, CE, CF / ACEA - E2, E3, E4 Mercedes-Benz specifications Nr. 227.5, 228.1, 228.3 and 228.5

Fans sp eed regulation setti ngs

Engine oil


SAE10W30

"STANDARD "

SAE10W40

"STANDARD "

SAE20W-20 (ISO VG68)

"STANDARD "

SAE15W40

"STANDARD "

SAE30 (ISO VG100)

"STANDARD "

SAE 10W (ISO VG46)

"EXTRA-COLD" or "COLD"

Hydraulic oils for hydraulic sys tem Requirements

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Fig. 5-8

Hydraulic oil for hydraulic system


Operating range


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Maintenance

Operating manual


C


Caution! Minimum ambient air temperature for extra-cold start dep ends on oil type and brand and equals to oil pourpoint temperature +5 degrees K.

Hydraulic oils must conform to the following specifications: DIN 51524-2 (HLP) / ISO 11158 (HM) DIN 51524-3 (HVLP) / ISO 11158 (HV) DIN 51524-2 with detergent-/dispergent additives: HLP-D DIN 51524-3 with detergent/-dispergent additives: HVLP-D Shear stability

KRL/C < 15% according to DIN 51350-6, CEC L 45-A-99

Air release properties

LAV < 10 min at 50°C according to DIN ISO 9120

Fans sp eed regulation s ettings

Hydraulic oil


ISO VG68

"STANDARD "

ISO VG100

"STANDARD "

ISO VG46

"COLD"

ISO VG32

"EXTRA-COLD"

Warm-up pr ocedure The black bar C indicates that the ambient temperatures are maximum 20 °C below the operating range B . In the event of a cold start at an ambient temperature included in range C, the following warm-up instruction applies to the hydraulic oil:  1. Start the diesel engine and run it at appro x. 1/2 rated speed. Carefully activate

the working hydraulic circuits. Operate a hydraulic cylinder (Stick for example) and move them to the stop quickly and many times. After approx. 5 minutes, start the travel hydraulic circuits. Warm-up duration: approx 10 minutes For temperature below the limits A :  2. Preheat hydraulic oil in the tank before starting the engine.

Biodegradables hydraulic oil s The use of biodegradables hydraulic oils must in any case be discussed with LIEBHER MINING EQUIPMENT COLMAR SAS.  Do not mix biodegradable hydraulic oils from different suppliers and never mix

with mineral oils.  Do not use vegetable oils as they do not possess the necessary thermal stability.

Depending on the temperature range, LIEBHERR recommends its poly-alpha-olefin (PAO, HEPR) oils, that are biodegradable according to CEC-L-33-A-93:

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Liebherr Hydraulic Plus or Liebherr Hydraulic Plus Arctic

If these oils are not available locally or if furth er specifications are required, use one of the following oils (before choosing an oil, contact our Customer Service): Fully satur ated synthetic ester-based oils , HEES

Depending on the temperature range, the viscosity grade of the HESS oil must conform to the above specifications hor hydraulic oils. Caution! LIEBHERR recommends to limit the use of HEES oils to areas where HEES oils are mandatory by local regulations. Lifetime of components made out of rubber material such as hoses, seals, compensators might be reduced while using HEES oils! When mixing ester-based biodegradable hydraulic oils with mineral oils, there is a risk of agressive chemical reactions, which might damage the hydraulic equipment.

Hydraulic oil selection f or cold climate conditions When a LIEBHERR Mining excavator works under cold climates conditions, in any case, the appropriate arctic kit must be installed. Oil must match the above prescription for engine oils or hydraulic oils. Oil’s pourpoint temperature must be at least 5 K below the minimal air ambient temperature. Oil’s flash point temperature > 160°C (recommended > 200°C). The operating range of the arctic oil depends on the ambient air temperature and must be checked as follow: – If the maximal ambient air temperature stays below +20°C, the oil viscosity at +50°C (oil temperature) must be over 16 cst. In this case, the fans speed regulation "EXTRA-COLD" must be selected. – If the maximal ambient air temperature stays below +30°C, the oil viscosity at +60°C (oil temperature) must be over 16 cst. In this case, the fans speed regulation "EXTRA-COLD" or "COLD" must be selected. – If the maximal ambient air temperature stays below +40°C, the oil viscosity at +70°C (oil temperature) must be over 16 cst. In this case, the fans speed regulation "COLD" must be selected.  Contact LIEBHERR Customer Service for additionnal questio ns about oil selec-

tion.

Oil mixing In principle, oil mixing between two different oil types must be avoided. Mixing two different oil types leads to an unknown lubricant with resultant unknown physical properties (viscosity, pourpoint, flash point, ageing behaviour, lubricity, reaction with additives...).

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 However, if mixing is absolutely necessary, respect the following maximum

mixing proportions: – Mixing LIEBHERR oils with hydraulic oils, or LIEBHERR oils with mineral oils, or hydraulic oils with mineral oils, or two different mineral oils together, or two different hydraulic oils together: max. 10%

– Mixing HEES oils with hydraulic oils or mineral oils or LIEBHERR oils:


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Maintenance

Operating manual


max. 2%

Hydraulic oil monitoring Note! Environmentally acceptable hydraulic fluids should generally be checked at regular intervals by oil analysis. Oil analysis is recommended for mineral oils.  Machines in normal use: at least every 500 operating hours.

Hydraulic oil c hange intervals Oil changes in pre-set int ervals Note! Oil change in pre-set intervals are only permitted fo r mineral oils. When using environmentally friendly hydraulic fluids, oil sample analysis reports must be used to determine the time of the oil change, see "Optimised oil change intervals determined through oil sample analysis reports".

Fig. 5-9

Changing oil

Optimised oil c hange intervals determined throug h oil sample analysis reports Use this procedure to take oil samples in pre-set intervals. The intervals may be extended between two oil changes as long as the properties of the oil are still satisfactory. The time when the oil must be changed is determined by the lab report. LIEBHERR recommends to submit the oil samples to "WEAR-CHECK" for oil analysis. A kit for 6 complete analysis at WEAR-CHECK is available : Id. No. 7018368 (the kit contains the sample containers, documentation, shipping container and oil sample hose). A hand pump is required to take the oil sample, and should be ordered seperately (Id. No. 8145666).

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Fig. 5-10

Taking an oil sample

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R9400 / 11000047

operating manual 9400 Liebherr

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